FCI ST80 Series Installation, Operation & Maintenance Manual
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FCI ST80 Series Installation, Operation & Maintenance Manual

Thermal mass flow meter
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06EN003490 Rev. B

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  • Page 1 06EN003490 Rev. B...
  • Page 2 (and does not include manufacture or processing uses). Any other use is strictly prohibited without the prior written consent of FCI. © Copyright 2019 by Fluid Components International LLC. All rights reserved. FCI is a registered trademark of Fluid Components International LLC. Information subject to change without notice.

  • Page 3: Table Of Contents

    ST80/ST80L Flow Meter 06EN003490 Rev. B Table of Contents Table of Contents ......................................iii List of Figures ......................................List of Tables ......................................vii Typographical Conventions ..................................viii GENERAL ......................................Product Description ................................... Theory of Operation ..................................Safety Instructions ..................................... Order Verification ....................................Technical Specifications ..................................
  • Page 4 06EN003490 Rev. B ST80/ST80L Flow Meter TROUBLESHOOTING ..................................Non-Maintenance Observations ..............................General Function Check ................................. Troubleshooting the Flow Element ..............................Verification of the Electronics ................................Constant Power Configuration Troubleshooting ..........................Defective Parts ....................................Customer Service .................................... Reference: Error/Status Register Information ..........................APPENDIX A DRAWINGS ..................................

  • Page 5: List Of Figures

    ST80/ST80L Flow Meter 06EN003490 Rev. B List of Figures Figure 1 – Example Compression Fitting Process Connection ......................... Figure 2 – Compression Fitting Installation, Dimensions .......................... Figure 3 – Example Flange Mount Installation ............................Figure 4 – Example NPT Pipe Thread Mount Installation ......................... Figure 5 –...
  • Page 6 06EN003490 Rev. B ST80/ST80L Flow Meter Figure 40 – NAMUR Fault ..................................Figure 41 – NAMUR Output Level Selection (4-20 mA User Tab) ......................Figure 42 – Example idR Check Results Display ........................... Figure 43 – Example Internal Delta R Scheduled Screen (After Clicking "Run test now...") ..............Figure 44 –...
  • Page 7 ST80/ST80L Flow Meter 06EN003490 Rev. B List of Tables Table 1 – Compression Fitting Material ..............................Table 2 – Interconnecting Cable Minimum Conductor Size ........................Table 3 – Modbus Select Jumpers ................................. Table 4 – Modbus Line Configuration Jumpers ............................Table 5 –...

  • Page 8: Typographical Conventions

    06EN003490 Rev. B ST80/ST80L Flow Meter 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.

  • Page 9: General

    ● 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.
  • Page 10 GENERAL ST80/ST80L Flow Meter 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...

  • Page 11: Technical Specifications

    2" 2250* 155* ■ Temperature Compensation * 1½" and 2" Sch 80 available by special order only; contact FCI. Standard: ±30 °F [±16 °C] ¾" pipe also available by special order. Optional: ±100 °F [±55 °C] Fluid Components International LLC...
  • Page 12 GENERAL ST80/ST80L Flow Meter ■ Operating Temperature (Process) ■ Remote Transmitter Configurations ST80 Insertion Style (FPC, FP, and S sensor head types) Transmitter may be mounted remotely from flow element using interconnecting cable (up to 1000 ft [300 m]). Remote configura- Process Connection Transmitter Temp.
  • Page 13 ST80L (in-line). ■ Sun Shield Shades main transmitter, electronics, and display from direct sunlight; 316L stainless steel. FCI P/N 023241-01 Integral transmitter FCI P/N 023237-01 Remote transmitter ■ Ball Valves/Cable Glands ■ Certification and Testing Documentation CMTR, NACE, PMI, 0...
  • Page 14 GENERAL ST80/ST80L Flow Meter This Page Intentionally Left Blank Fluid Components International LLC...

  • Page 15: Installation

    The proper flow meter location in the process piping configuration is critical to the instrument’s ability to measure the process variables accurately. FCI recommends 20 nominal pipe diameters upstream and 10 pipe diameters downstream of the instrument installation point for most applications.

  • Page 16: Figure 2 - Compression Fitting Installation, Dimensions

    Compression Fitting FCI single point insertion flow meters are calibrated at the centerline of the process pipe. The flow element is properly mounted when the tip of the flow element is located 0.50 inches (13 mm) past the pipe centerline. See Figure 2 below.

  • Page 17: Figure 3 - Example Flange Mount Installation

    ST80/ST80L Flow Meter INSTALLATION Flange Mount The flange mount flow element is shown in Figure 3 below. Attach the process mating flange with care. Correctly orient the flow element's reference flat to ensure the instrument's calibrated accuracy. ● Verify the process media flow matches the flow direction arrow on the flow element. ●...

  • Page 18: Figure 5 - Retractable Packing Gland Installation

    A retractable low and medium pressure packing gland, with 1¼" MNPT threads or ANSI/DIN flange, and graphite or Teflon packing, is a process connection option. FCI single point flow meters are calibrated at the centerline of the process pipe. The flow element is properly mounted when the tip of the flow element is located .50 inches (13 mm) past the pipe centerline.

  • Page 19: Figure 6 - Packing Gland Locking Collar

    ST80/ST80L Flow Meter INSTALLATION Mark the insertion pipe at the calculated insertion depth. Ball Valve Applications Only: If a ball valve is required, install the ball valve to the process mounting coupling. Close the ball valve to prevent the process media from leaking out when installing the packing gland with the process line pressurized. Fully retract the insertion probe into the cavity of the packing gland and install the packing gland into the process mounting coupling or ball valve as described in the previous sections: Flange Mount...

  • Page 20: St80L In-Line Process Connection

    Use power wiring with a minimum 90 °C rating. ESD Precautions Caution: FCI flow meters contain static-sensitive devices. To avoid damage to the instrument observe the ESD precautions listed below before opening the instrument for wiring. ● Use a wrist band or heel strap with a 1 MΩ resistor connected to ground.

  • Page 21: Figure 8 - Integral Electronics Installation (Compression Fitting Shown)

    Lock Nut Torque Specification: 30-35 ft-lbs (40-47 N-m) Provide integral electronics with additional support/bracing in applications where excessive vibration is present. A mounting bracket is available from FCI to support the electronics when additional support is required. See Figure 8 below.

  • Page 22: Figure 9 - Remote Installation, Mounting Bracket On Wall

    INSTALLATION ST80/ST80L Flow Meter Remote Electronics A mounting bracket is supplied when the transmitter is ordered for remote mounting. The bracket mounting details are shown in Figure 9 below. Refer to the outline installation drawings in Appendix A for additional mounting details. The electronics can be easily mounted on a wall or pipe.

  • Page 23: Figure 10 - Remote Installation, Mounting Bracket On 1" - 1½" Pipe

    Figure 10 – Remote Installation, Mounting Bracket on 1" – 1½" Pipe 2x 3/16"-16 ST100A SERIES U BOLTS, SST TRANSMITTER 2x M4 SCREWS (FCI PROVIDED) 2" Pipe 4x 3/16" HEX NUT ALUMINUM BRACKET (FCI PROVIDED) Figure 11 – Remote Installation, Mounting Bracket on 2" Pipe...

  • Page 24: Figure 12 - Remote Installation, Optional Stainless Steel Bracket On 2" Pipe

    ST80/ST80L Flow Meter (9.25) ST100A SERIES 2" PIPE (4.25) TRANSMITTER 2x ¼"-20 U BOLTS, SST 4x ¼" HEX NUT 2x M4 SCREWS (FCI PROVIDED) C01247-2-1 Figure 12 – Remote Installation, Optional Stainless Steel Bracket on 2" Pipe Fluid Components International LLC...

  • Page 25: Instrument Wiring

    Figure 13 – Recommended Wiring Routing, Base Electronics Enclosure Table 2 below shows the smallest copper wire (maximum AWG number) that can be used for the listed cabling. Contact FCI concerning greater distances than those listed in the chart. Refer to...

  • Page 26: Figure 14 - St80/St80L I/O Connector Locations

    INSTALLATION ST80/ST80L Flow Meter Accessing the I/O Connectors Warning: Turn instrument power OFF before wiring the instrument. Caution: Use caution inserting wires into electronics housing. The metal ends can damage circuit boards. Remote Units: Avoid pulling, or inadvertently tugging, the remote cable when wiring the instrument. The sensor connector/circuit board can be easily damaged by excess pulling of the remote cable.

  • Page 27: Figure 15 - St80/St80L Electronics Enclosure Label

    ST80/ST80L Flow Meter INSTALLATION Electronics Enclosure Label Affixed to the inside of the blind lid is a label that identifies the ST80/ST80L’s jacks and connectors (with terminal assignment). See Figure below. Use this label as a guide when wiring the instrument. Note that the PCB silkscreen also provides connector identification. B (+) FIELDBUS_A RETURN...

  • Page 28: Figure 17 - Input Power Wiring

    Then insert the stripped power wire ends into the appropriate P1 connector terminals. The ferrite core clamp (supplied with the instrument as ferrite kit FCI p/n 023638-02) protects the instrument against the adverse effects of EMI/RFI electrical noise. POWER WIRING...

  • Page 29: Figure 19 - Flow Element Connections, Tb1

    ST80/ST80L Flow Meter INSTALLATION Power overload protection is provided by a clip-mounted SMT fuse. Refer to Power Fuse Replacement, page (MAINTENANCE section) for fuse replacement details. Flow Element Connections Note: The flow element in all integral units is pre-wired at the factory. The information in this section applies to remote configuration units only.

  • Page 30: Figure 20 - Hart And Ch. 1 & Ch. 2 4-20 Ma Connections, J25

    INSTALLATION ST80/ST80L Flow Meter HART Connections Referencing Figure 14 connect the installation HART wiring to the J25 Phoenix connector. Similar to flow element connector TB1 the J25 connector is a detachable plug that plugs into the header socket on the board. Use the appropriate J25 connector terminals depending on your application as shown in Figure 20 below.

  • Page 31: Figure 21 - Single Connection And Multidrop Hart Setups

    ST80/ST80L Flow Meter INSTALLATION Network P.S. Internal Loop Power External Loop Power 24 VDC HART HART– HART+ HART HART Master LOAD J25-1 J25-1 HART ST80/ST80L ST80/ST80L Master LOAD HART HART – J25-2 J25-2 – J25-4 (a) HART Single Connection Network P.S. 24 VDC HART HART–...

  • Page 32: Figure 22 - Modbus/Profibus/Fieldbus Connections, J8

    INSTALLATION ST80/ST80L Flow Meter Modbus Connections Referencing Figure 14 connect the Modbus device/network to Phoenix connector J8 on the main board. Note that the J8 connector is also used for F Fieldbus and PROFIBUS wiring (only one interface can be active at a time). See Figure 22 below.

  • Page 33: Figure 24 - Fieldbus/Profibus Wiring

    ST80/ST80L Flow Meter INSTALLATION Modbus Configuration Refer to Figure 16 on page 19. To set J8 for Modbus operation install a 2 mm jumper shunt onto the J12 and J13 jumper pins as shown in Table 3 below. Table 3 – Modbus Select Jumpers Install Jumper Shunt over Pins ...

  • Page 34: Post Installation Check

    INSTALLATION ST80/ST80L Flow Meter Fieldbus/PROFIBUS Configuration OUNDATION Refer to Figure 16 on page 19. To set J8 for FF/PROFIBUS operation install a 2 mm jumper shunt onto the J12 and J13 jumper pins as shown in Table 5 below. Table 5 – F Fieldbus/PROFIBUS Select Jumpers OUNDATION Install Jumper Shunt over Pins ...

  • Page 35: Operation

    ST80/ST80L Flow Meter OPERATION OPERATION Basic Commissioning and Start-Up Verify the wiring and then apply power to the instrument. LCD-equipped instruments briefly show a welcome screen indicating the instrument model and core version followed by the normal operation process screen. The normal process screen shows: percentage of flow bar, icons (if present), process flow rate, totalized flow (optional), temperature in customer units, pressure (optional) in customer units, calibration group and group name.

  • Page 36: Figure 26 - Hmi Display Ir Sensor Functions

    OPERATION ST80/ST80L Flow Meter HMI Display Menu Navigation Use the four IR sensors to navigate the HMI Service menu. Touch the top/bottom sensor to scroll up ()/down () through the menu selections. Touch the right sensor to select (). Touch the left sensor to go back () to the previous menu. Some setup parameters are password protected—when prompted enter the HMI user password: E#C.

  • Page 37: Figure 27 - Basic Setup Options, Hmi

    ST80/ST80L Flow Meter OPERATION Basic Setup Options, HMI Figure 27 below summarizes the basic setup options using the optional HMI. Enter the HMI user password as required when changing a setup parameter. Note: The setup options described in this section (except Language) can also be changed via the configuration software. Refer to Basic Setup Options, Configuration Software on page 31.

  • Page 38: Figure 29 - Display Setup Options

    OPERATION ST80/ST80L Flow Meter Instrument setup includes the following parameters: Flow – Sets flow parameters including flow type and flow timebase. Table 7 below summarizes the Flow parameters. The default is • Vel Flow, SFPS (Standard Feet Per Second). Temperature (Temp) – Sets the temperature scale in use: Degrees C (Celsius) or Degrees F (Fahrenheit). The default is Degrees F. •...

  • Page 39: Verify Engineering Units

    ST80/ST80L Flow Meter OPERATION ST80/ST80L Configuration Software The ST80/ST80L comes with a configurator utility (Windows) that provides comprehensive programming of the instrument’s settings via a PC connection to the instrument’s USB service port (refer to Service Port Connection, USB , page 26). Configure the ST80/ST80L to your application using the ST80/ST80L configuration software.

  • Page 40: St80/St80L Configuration Software Application (User Password: 2772)

    OPERATION ST80/ST80L Flow Meter Logging, Alarm, and Fault Icons Figure 31 – Example Log, Alarm, and Logging Icons on the Optional Display ST80/ST80L Configuration Software Application (User Password: 2772) The ST80/ST80L configuration software application provides full access to instrument programming. However, this requires opening the electronics enclosure and attaching a PC to the instrument’s USB service port.

  • Page 41: Real Time Clock

    ST80/ST80L Flow Meter OPERATION Figure 33 – Example Process Data Screen With the configuration software running on the attached PC the user has access to all configurable features of the ST80/ST80L instrument. When prompted, enter the User Level Password (2772) to make parameter changes. For more detailed instructions on the configuration software, refer to the ST80/ST80L Configuration Software manual 06EN003491.

  • Page 42: Totalizer Setup

    OPERATION ST80/ST80L Flow Meter Click Get from Device. This displays the current date and the ST80/ST80L system time. If needed, set the correct date using the field's calendar date picker and time using the field's spinner buttons. Click Send to Device to save the changes to the instrument. Totalizer Setup The flow totalizer function accumulates the instrument total flow, much like the odometer on an automobile.

  • Page 43: Configuring For Ast™ Or Constant Power Measurement Methods

    ST80/ST80L Flow Meter OPERATION Configuring for AST™ or Constant Power Measurement Methods The default factory sensor heater configuration is AST™ (Adaptive Sensing Technology) in which the instrument automatically transitions between constant Delta T operation (heater power to maintain Delta T proportional to flow) and constant power operation (constant heater power and sensor Delta T proportional to flow) to measure the flow rate.

  • Page 44: Flow Filtering

    OPERATION ST80/ST80L Flow Meter Flow Filtering Use the configuration software to adjust flow filtering (Advanced Setup/Flow FIltering) as required for your application. Refer to the ST80/ST80L Configuration Software manual 06EN003491 for software details. The Flow Filtering setup screen is shown in Figure 38 below.

  • Page 45: Namur Setup

    ST80/ST80L Flow Meter OPERATION 65.000 64.800 64.600 64.400 64.200 64.000 Damping = 0.25 Damping = 1.00 63.800 Damping = 3.00 Damping = 5.00 63.600 Data Logger Samples (Every 250 mS or 240/Minute) C01406-1-1 Figure 39 – Chart: Flow Output Over Time with Various Flow Damping Values Flow Input Moving Average (Boxcar) Filter Use the Flow Input Moving Average Filter field to smooth out the input flow signal using a moving average (boxcar) filter.

  • Page 46: Figure 41 - Namur Output Level Selection (4-20 Ma User Tab)

    OPERATION ST80/ST80L Flow Meter Note: The NAMUR settings field in the 4-20 mA User tab will only show when the output is set for Flow or HART Flow. If Temperature output is selected the NAMUR settings will not show up. NAMUR only works on Flow outputs. In the window's NAMUR field, define the NAMUR output level by clicking either Set NAMUR @ 3.6 mA or Set NAMUR @ 21.0 mA.

  • Page 47: Internal Delta-R Resistor (Idr) Check

    The Internal Delta-R Resistor (idR) Check is a routine designed to assess the ST80/ST80L internal normalization. The normalization process fine tunes the instrument’ s ability to accurately measure resistance. Proper normalization also allows FCI electronics to be interchangeable for replacements, spares or repaired boards. If the unit’ s normalization shifts, the accuracy of the meter may be compromised.

  • Page 48: Figure 43 - Example Internal Delta R Scheduled Screen (After Clicking "Run Test Now

    OPERATION ST80/ST80L Flow Meter Figure 43 – Example Internal Delta R Scheduled Screen (After Clicking "Run test now...") The result for a scheduled idR check is logged in FRAM. Click Get Test Log from Device in the idRTest Logs tab to view the idR test log as shown in the example in Figure 44 below.

  • Page 49: Figure 45 - Internal Delta-R Resistor Check (Idr) Hmi Display Sequence

    ST80/ST80L Flow Meter OPERATION Figure 45 – Internal Delta-R Resistor Check (idR) HMI Display Sequence Fluid Components International LLC...

  • Page 50: Using Digital Outputs

    OPERATION ST80/ST80L Flow Meter Analog Output Response to idR Check During the idR sequence the analog outputs respond as listed below. Readings are taken with a 250 Ω load across Analog Output 1, 2 or 3. NAMUR Enabled LOW 2.325 Vdc = 23.16 sfps = baseline (example: actual flow output varies from 1-5 volts) 0.900 Vdc = idR In Progress 1.000 Vdc = momentary state 2.326 Vdc = after 3 seconds.

  • Page 51: Table 9 - St80/St80L Hart Process Variables

    Search by Manufacturer (Fluid Components International LLC) to find the instrument’s files under the product name: FCI ST80/ST100A Series. The posted DD files are contained in a zip archive with FCI’s manufacturer ID and product device type hex values embedded in the filename (e.g., hart.0000a6.a677.zip).

  • Page 52: Figure 47 - Field Communicator Easy Upgrade Utility, Import Dd

    Service Data Operation Shown below is example service information as provided by the Emerson 475 HART communicator with FCI’ s DD files loaded. The same information seen by the 475 is shown in the DCS (Distributed Control System) when the ST80/ST80L HART DD files are loaded. The screens shown below are a subset of the total 475 HART communicator information for the ST80/ST80L.
  • Page 53 ST80/ST80L Flow Meter OPERATION ST80/ST80L Device Setup The Device Setup function is a gateway to ST80/ST80L device information, process data and setup, both basic and advanced. Additional options include K Factor display/adjust and totalizer reset. ST80/ST80L Basic Setup The Basic Setup function includes the ability to review and change the engineering units of the process variables, review and change the plenum or pipe size, enable or disable the Totalizer, review and change device information, reset the...
  • Page 54 OPERATION ST80/ST80L Flow Meter Factory Reset WARNING – The Factory Reset command reloads the con- figuration and calibration parameters that were loaded into the instrument during the original calibration and setup. Any changes made to the calibration parameters configuration will be lost when the Factory Reset command is executed.

  • Page 55: Hart Command List Reference

    Unsigned-16 Configuration Change Counter Bits Extended Field Device Status 17–18 Enum Manufacturer ID Code: 166 /00A6 (FCI) 19–20 Enum Private Label Distributor Code Enum Device Profile = 1 “HART Process Automation Device” Response Codes Table 16, page 62, for response code list.
  • Page 56 OPERATION ST80/ST80L Flow Meter Command 2: Read Primary Variable Loop Current and Percent of Range Byte Format Description Request Data Bytes None Response Data Bytes 0–3 Float Primary Variable Loop Current (mA) 4–7 Float Primary Variable Percent of Range (%) Response Codes Table 16, page 62, for response code list.
  • Page 57 ST80/ST80L Flow Meter OPERATION Command 9: Read Device Variables with Status Byte Format Description Request Data Bytes Unsigned-8 Slot 0: Device Variable Code Unsigned-8 Slot 1: Device Variable Code Unsigned-8 Slot 2: Device Variable Code Unsigned-8 Slot 3: Device Variable Code Unsigned-8 Slot 4: Device Variable Code Unsigned-8...
  • Page 58 Unsigned-16 Configuration Change Counter Bits Extended Field Device Status 17–18 Enum Manufacturer ID Code: 166 /00A6 (FCI) 19–20 Enum Private Label Distributor Code Enum Device Profile = 1 “HART Process Automation Device” Response Codes Table 16, page 62, for response code list.
  • Page 59 ST80/ST80L Flow Meter OPERATION Command 15: Read Device Information Byte Format Description Request Data Bytes None Response Data Bytes Enum Flow Alarm Selection Code Enum Flow Transfer Function Code (not supported) Enum Flow Upper and Lower Range Value Units Code 3–6 Float Flow Upper Range Value...
  • Page 60 Unsigned-16 Configuration Change Counter Bits Extended Field Device Status 17–18 Enum Manufacturer ID Code: 166 /00A6 (FCI) 19–20 Enum Private Label Distributor Code Enum Device Profile = 1 “HART Process Automation Device” Response Codes Table 16, page 62, for response code list.
  • Page 61 ST80/ST80L Flow Meter OPERATION Command 48: Read Additional Device Status Byte Format Description Request Data Bytes 0–5 Bits Device-Specific Status (only first 6 bytes used, see page additional info) Bits Extended Device Status. Normally “0”; set to “1” (0x01) if maintenance is required.

  • Page 62: Table 12 - Hart Common Practice Commands

    OPERATION ST80/ST80L Flow Meter ST80/ST80L HART Common Practice Commands The ST80/ST80L supports Common Practice commands 35, 40, 42, 44, 45, 46, 50 and 51. Table 12 below summarizes the instrument’s HART Common Practice command set and the data associated with each command. Table 12 –...
  • Page 63 ST80/ST80L Flow Meter OPERATION Command 46: Trim DAC Gain – Measured Current Chan #1 (in mA) Byte Format Description Request Data Bytes 0–3 Float Ext. Measured Current Ch. #1 Level (20 mA GainDAC) Response Data Bytes 0–3 Float Actual Measured Current Ch. #1 Level (20 mA GainDAC) Response Codes Table 16, page 62, for response code list.

  • Page 64: Table 13 - St80/St80L Hart Device Specific Command Groupings

    OPERATION ST80/ST80L Flow Meter ST80/ST80L HART Device Specific Commands The ST80/ST80L Manufacturer Specific or Device Specific commands start at command 137. Use the device specific commands to setup and configure the ST80/ST80L instrument via HART. The ST80/ST80L device specific commands are grouped in functional categories as summarized in Table 13 below.
  • Page 65 ST80/ST80L Flow Meter OPERATION Command 145: Read Customer Engineering Units Byte Format Description Request Data Bytes None — — Response Data Bytes Unsigned-8 Units Code for Flow Unsigned-8 Units Code for Temperature Unsigned-8 Units Code for Totalizer Unsigned-8 Units Code for Pressure Response Codes Table 16, page 62, for response code list.
  • Page 66 OPERATION ST80/ST80L Flow Meter Command 151: Read Calibration Flow Limits Byte Format Description Request Data Bytes None — — Response Data Bytes 0–3 Float Flow Lower Limit Value 4–7 Float Flow Upper Limit Value Response Codes Table 16, page 62, for response code list. Command 154: Read Calibration Temperature Limits Byte Format...
  • Page 67 ST80/ST80L Flow Meter OPERATION Command 163: Write (4-20 mA) Output Channel #2 Parameters Byte Format Description Request Data Bytes 0–1 Unsigned-16 D/A Setting for 4 mA Out (OUTZ2) 2–3 Unsigned-16 D/A Setting for 4 mA Out (OUTF2) Unsigned-8 Channel #2 Out Variable Response Data Bytes 0–1 Unsigned-16...
  • Page 68 OPERATION ST80/ST80L Flow Meter Command 179: Write/Set Calibration Group Byte Format Description Request Data Bytes Unsigned-8 Write/Set Calibration Group Response Data Bytes Unsigned-8 Write/Set Calibration Group Response Codes Table 16, page 62, for response code list. Command 180: Read Calibration Group Byte Format Description...
  • Page 69 ST80/ST80L Flow Meter OPERATION Command 187: Read KFactor3 Byte Format Description Request Data Bytes 0–3 Float Read KFactor3 Response Data Bytes 0–3 Float Read KFactor3 Response Codes Table 16, page 62, for response code list. Command 188: Read KFactor4 Byte Format Description Request Data Bytes...

  • Page 70: Table 15 - Command Status Bytes, Bit Assignments

    OPERATION ST80/ST80L Flow Meter Table 15 – Command Status Bytes, Bit Assignments Error/Status Description Byte Communication Error Response Code (No Comm Error) Reserved – Bit cleared to zero. Buffer Overflow – The message was too long for the received buffer of the device. Reserved –...

  • Page 71: Table 17 - Command 48, Additional Device Status Bytes Bit Assignments

    ST80/ST80L Flow Meter OPERATION Command 48, Additional Device Status Bytes Table 17 below summarizes the Command 48 Additional Device Status bytes. This is a 6-byte field. The remaining status bytes are reserved for future use. A status bit is cleared (0) for no error. A status bit is set (1) when an error (or condition) is detected. Table 17 –...

  • Page 72: Table 18 - Hart Engineering Units Codes

    OPERATION ST80/ST80L Flow Meter HART Engineering Units Codes Table 18 below summarizes the HART codes used to represent the instrument’s engineering units. Table 18 – HART Engineering Units Codes Units Type HART Code Unit Description HART Code Unit Description Temperature degrees Celsius degrees Fahrenheit Standard Cubic Feet per Second (SCFS)

  • Page 73: Modbus Operation

    ST80/ST80L Flow Meter OPERATION Modbus Operation The ST80/ST80L offers Modbus as one of its digital communication protocol, but unlike the other digital communication protocols Modbus only offers set up and configuration for the totalizer variable. Refer to Modbus Connections on page for Modbus wiring info.

  • Page 74: Figure 49 - St80/St80L Configuration Software Modbus Tab, Serial Interface Configuration

    OPERATION ST80/ST80L Flow Meter Figure 49 – ST80/ST80L Configuration Software Modbus Tab, Serial Interface Configuration ST80/ST80L Modbus Commands With the Modbus protocol the instrument data is read and written via multiple register access. The following public function numbers are defined for communication with the ST80/ST80L: 03 and 04. Table 19 –...

  • Page 75: Table 20 - St80/St80L Modbus Process Data

    ST80/ST80L Flow Meter OPERATION in the Modbus standard integer register form. And lastly registers 4111, 4112, 4113, and 4114 offer the flow totalizer as a single precision floating point value in the Modbus standard register form. Because the Totalizer values can become a very large number, the single precision floating point presents the data as two register groups.

  • Page 76: Figure 50 - Modscan32, Data Definition

    OPERATION ST80/ST80L Flow Meter ST80/ST80L Modbus Service Registers The ST80/ST80L Modbus supports service registers Totalizer Reset and Totalizer Start/Stop. ● Reset Command for Totalizer – Use the Function 03 holding command via 4117 integer register to manually reset the ST80/ST80L totalizer count.

  • Page 77: Figure 51 - Modscan32, Serial Interface And Transmission Mode Configuration

    ST80/ST80L Flow Meter OPERATION Once data is defined, select Connect from the Connection pull-down menu. Below window is displayed. Set the serial parameters and protocol as required for your application. Figure 51 – ModScan32, Serial Interface and Transmission Mode Configuration After entering the appropriate connection details the ModScan32 master then attaches itself to the Modbus device (ST80/ST80L) as shown in Figure 52...

  • Page 78: Figure 53 - Modscan32 Connected To Modbus Device With Registers 4113 And 4114 On Display (Rollover Count)

    OPERATION ST80/ST80L Flow Meter Checking the Totalizer 2 (Upper Count/Rollover Count) Value ● Repeat step 1 above, but specifying register #4113 (and #4114) instead. ● Repeat step 2 above (no need to change serial configuration if already configured). ● Figure 53 below for a “Rollover count”...

  • Page 79: Figure 55 - Modscan32 Connected To Modbus Device With Register 4117 On Display (Totalizer Reset)

    ST80/ST80L Flow Meter OPERATION Resetting the Totalizer Count ● Repeat step 1 above, but specifying register #4117 instead (Length = 1). ● Repeat step 2 above (no need to change serial configuration if already configured). ● Double click on the register number (see pointer in Figure 55 below).

  • Page 80: Table 22 - St80/St80L Modbus Engineering Unit Codes

    OPERATION ST80/ST80L Flow Meter Modbus Engineering Unit Codes Table Table 22 below summarizes the Modbus codes used to represent the instrument’s engineering units. Table 22 – ST80/ST80L Modbus Engineering Unit Codes Modbus Modbus Units Type Unit Description Unit Description Code Code Temperature degrees Celsius...

  • Page 81: Table 23 - St80/St80L Modbus Exception Codes

    ST80/ST80L Flow Meter OPERATION Modbus Exception Codes Table Table 23 below summarizes the possible Modbus exception codes for the ST80/ST80L. Table 23 – ST80/ST80L Modbus Exception Codes Code Exception Description Illegal Data Address The Data address received in the query is not an allowable address for the master/slave Illegal Data Value A value contained in the query data field is not an...
  • Page 82 OPERATION ST80/ST80L Flow Meter This Page Intentionally Left Blank Fluid Components International LLC...

  • Page 83: Maintenance

    Use operation experience to establish the frequency of each type of maintenance. Calibration To ensure compliance with EPA 40 CFR Part 98, Subparts A and HH, FCI recommends checking the calibration of the ST80/ST80L flow meter every 24 months and recalibrating the instrument if required.

  • Page 84: Power Fuse Replacement

    Replace with the appropriate Schurter UMZ 250 fuse as listed in Table 25 below. Reinstall the blind lid. Table 25 – Power Fuse Summary FCI Assembly P/Ns Description Mfgr. P/N FCI P/N 025806-01 (AC-DC Power Supply) SMT fuse (in clip), Schurter UMZ 250, 3404.2419.11...

  • Page 85: Lithium Battery Replacement

    A 3-volt lithium coin cell battery powers the ST80/ST80L real time clock (RTC). Typical service life of the battery is two years. Replace the battery every two years with the CR2450N coin cell battery listed in Table 26 below. Table 26 – Lithium Coin Cell Battery Summary FCI Assembly P/Ns Description Mfgr. P/N FCI P/N 3V Lithium battery type CR2450N, 025740-01 (Main Board) 540 mAh, temperature range: -40 °C...

  • Page 86: Figure 58 - Instrument Disassembly For Lithium Coin Cell Battery (Cr2450N) Replacement

    MAINTENANCE ST80/ST80L Flow Meter ELECTRONICS/CAGE ASSEMBLY 2X M4 SOCKET HEAD CAP SCREW ELECTRONICS ASSEMBLY (MAIN BOARD ON TOP) GROUND CR2450N WIRE LITHIUM COIN B ATTERY BATTERY HOLDER HMI JUMPER CABLE CONNECTOR, CAGE MAIN BOARD HMI JUMPER CABLE 3X DRIVE SCREW, 18-8 SST FFC CABLE CONNECTOR (MAIN BOARD SOLDER SIDE) HMI JUMPER...

  • Page 87: Troubleshooting

    ST80/ST80L Flow Meter TROUBLESHOOTING TROUBLESHOOTING Warning: Instrument testing/troubleshooting limited to qualified personnel only. The operator assumes all responsibilities for safe practices while troubleshooting. Caution: The flow transmitter contains electrostatic discharge (ESD) sensitive devices. Use standard ESD precautions when handling the flow transmitter. See Precautions, page for details.

  • Page 88: General Function Check

    Connect the flow meter via USB to a computer or laptop running the ST80/ST80L configuration software supplied with the instrument. Refer to the ST80/ST80L Configuration Software manual 06EN003491 for details. Confirm the setup of the flow meter by reviewing the setup windows in the configurator. Contact your local representative or FCI for instructions if a setup discrepancy exists.

  • Page 89: Troubleshooting The Flow Element

    ST80/ST80L Flow Meter TROUBLESHOOTING Troubleshooting the Flow Element Check the Resistance of the Flow Element Turn flow transmitter power OFF. Remove the TB1 connector plug from the sensor wiring pin socket (pull plug straight out). Measure the resistance between the terminals of the pulled connector plug and compare with the values shown in Table 27 below.

  • Page 90: Figure 59 - Example Heater Values Tab (Diagnostics)

    TROUBLESHOOTING ST80/ST80L Flow Meter If the instrument has been off for some time, the resistance of the active RTD will be the same as the reference RTD. For Remote Units – If the measured resistances correspond to Table 28, but not to Table 27, then the sensor interconnect cable is probably defective.

  • Page 91: Verification Of The Electronics

    ON (no blink, continuous) System controller halted (hang). Cycle the power to see if the instrument recovers from a possible system controller hang. Contact FCI Technical Support for assistance if the system status LED is still not blinking. SYSTEM STATUS LED,...

  • Page 92: Table 31 - Instrument Power Supply Voltages

    TROUBLESHOOTING ST80/ST80L Flow Meter Transmitter Power Supply Use the ST80/ST80L configuration software to check the power supply voltages. Refer to ST80/ST80L Configuration Software manual 06EN003491 for details. Select the Factory branch from the menu tree on the window's left side. Select the SIL Adj tab. The screen shows power supply voltage readings for +24 VDC and +5 VDC.

  • Page 93: Constant Power Configuration Troubleshooting

    ST80/ST80L Flow Meter TROUBLESHOOTING Constant Power Configuration Troubleshooting Equipment List ● 250 Ω 0.01% resistor ● 2 digital multimeters (DMM) ● Delta R Calibration Data Sheet (serial number specific by instrument and group) ● FES-200 flow element simulator ● FES-200 interface cable for ST80/ST80L (022610-xx) Alternative to FES-200: ●...

  • Page 94: Figure 62 - Connecting Fes-200 To St80/St80L Transmitter

    If you are troubleshooting the flow meter and the readings are good, the flow transmitter is good and the problem may involve the flow element or interconnecting cable. If the readings are off, a flow element calibration may be required or the flow transmitter needs to be set up. Contact FCI Customer Service. FES-200...

  • Page 95: Defective Parts

    FCI, freight prepaid, for disposition. Customer Service In the event of problems or inquiries regarding the instrument, contact an authorized FCI field agent for the region or country. Refer to the FCI website: http://www.fluidcomponents.com/...

  • Page 96: Reference: Error/Status Register Information

    TROUBLESHOOTING ST80/ST80L Flow Meter Reference: Error/Status Register Information Summarized below are various registers that provide the instrument with error/status information. This information is normally presented in the configuration software’s Fault Log tab. Digital busses (such as HART) can also access this information via a read operation using the appropriate register address.

  • Page 97: Table 33 - Devices (Sensor X) Status Codes #1 Register

    Class 0 (LSB) CORE: If any of these errors occur: I2C error, UART error, Mutex error, watchdog reset. Fatal FCI Reserved (bit not used) Non-Fatal FCI Reserved (bit not used) Non-Fatal CORE unable to update process data (PD_NO_FE_DATA). Unable to obtain/use data from any Active FEs.

  • Page 98: Table 35 - Devices (Sensor X) Status Codes #3 Register

    Table 35 – Devices (Sensor x) Status Codes #3 Register Fault Status Description Class 0 (LSB) (Any) FE reports AD5754_DAC_FAULT Fatal FCI RESERVED (bit not used) Non-Fatal (Any) FE reports CURR_SENSORS_ADC_FAULT Non-Fatal (Any) FE reports HTRS_PRESSNS_ADC_FAULT Non-Fatal (Any) FE reports HTRS_FAULTS_ADC_FAULT...

  • Page 99: Appendix Adrawings

    Table 36 – ST80/ST80L Drawings in Appendix A Dwg. No. Dwg. Type Page No. Description 026357 System Cert. System Certification, ST80 Series, ATEX, IECEx 026155 Wiring Diagram, Remote, ST80 Series Wiring Diagram 026763 Wiring Diagram Wiring Diagram, Integral, ST80 Series 004871 Outline Instl.
  • Page 100 APPENDIX A – DRAWINGS ST80/ST80L Flow Meter This Page Intentionally Left Blank Fluid Components International LLC...
  • Page 101 ST80/ST80L Flow Meter APPENDIX A – DRAWINGS Fluid Components International LLC...
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  • Page 130 APPENDIX A – DRAWINGS ST80/ST80L Flow Meter Fluid Components International LLC...

  • Page 131: Appendix Badditional Information

    ST80/ST80L Flow Meter APPENDIX B – ADDITIONAL INFORMATION APPENDIX B ADDITIONAL INFORMATION This appendix contains the following information: ● Parameters Report from the ST80/ST80L Configuration Application (Sample) ● HMI Menu Outline ● ST80/ST80L Configuration Software Menu Outline (v3.2.0.x) ● Instructions: Installing Sun Shield on ST80/ST80L Integral Enclosure ●...

  • Page 132: Parameters Report From The St80/St80L Configuration Application (Sample)

    APPENDIX B – ADDITIONAL INFORMATION ST80/ST80L Flow Meter Parameters Report from the ST80/ST80L Configuration Application (Sample) Destination Parameter Name Parameter Value CORE Date and Time: 7/11/2018 10:15:25 AM CORE Unit Serial Number: CORE Cust Number: CORE Cust Name: CORE Core Version: 1.00L CORE HMI Version:...
  • Page 133 ST80/ST80L Flow Meter APPENDIX B – ADDITIONAL INFORMATION Destination Parameter Name Parameter Value CORE GROUP 1 20 mA DAC1: 50000 CORE GROUP 1 Namur1(0=Off, 1=On): CORE GROUP 1 Namur DAC1: CORE GROUP 1 Analog Out 2: CORE GROUP 1 CH2 4 mA: CORE GROUP 1 4 mA DAC2: 10000...
  • Page 134 APPENDIX B – ADDITIONAL INFORMATION ST80/ST80L Flow Meter Destination Parameter Name Parameter Value FE 1 GROUP 1 DPoly(2,2): 200.970275 FE 1 GROUP 1 DPoly(2,3): -60305.54 FE 1 GROUP 1 DPoly(2,4): 7980455.9326 FE 1 GROUP 1 DPoly(2,5): -3938943.862 FE 1 GROUP 1 0=Spline 1=DPoly: FE 1 GROUP 1 Number of Splines:...
  • Page 135 ST80/ST80L Flow Meter APPENDIX B – ADDITIONAL INFORMATION Destination Parameter Name Parameter Value FE 1 GROUP 1 Spline Y25: FE 1 GROUP 1 Spline Y26: FE 1 GROUP 1 Spline Z1: 14.59323796 FE 1 GROUP 1 Spline Z2: 20.31745992 FE 1 GROUP 1 Spline Z3: 5.377977595 FE 1 GROUP 1...
  • Page 136 APPENDIX B – ADDITIONAL INFORMATION ST80/ST80L Flow Meter Destination Parameter Name Parameter Value FE 1 CAL GAS 0 KCal3: -6.644107E-08 FE 1 CAL GAS 0 KCal4: 3.001559E-11 FE 1 CAL GAS 0 KCal5: 0.025728284 FE 1 CAL GAS 0 CpCal1: 1.035435 FE 1 CAL GAS 0 CpCal2:...

  • Page 137: Hmi Menu Outline

    ST80/ST80L Flow Meter APPENDIX B – ADDITIONAL INFORMATION HMI Menu Outline ● ○ Boot Screen Set-up ● ■ Process Data Screen Instrument □ ◘ Percentage of Flow Group ‘X’ [current active group] □ – Flow: [eng units] Flowrate □ – Temp: [Deg F or Deg C] Totalizer □...

  • Page 138: St80/St80L Configuration Software Menu Outline (V3.2.0.X)

    APPENDIX B – ADDITIONAL INFORMATION ST80/ST80L Flow Meter ST80/ST80L Configuration Software Menu Outline (v3.2.0.x) ST80/ST80L Configuration Application ■ FE 1 ■ ST80/ST80L ● P ROCESS ● P ROCESS USTOMER NITS ■ Parameter Reports ■ FLOW (display) ● G ROUP SCROLLABLE WINDOW ■...

  • Page 139: Instructions: Installing Sun Shield On St80/St80L Integral Enclosure

    ST80/ST80L Flow Meter APPENDIX B – ADDITIONAL INFORMATION Instructions: Installing Sun Shield on ST80/ST80L Integral Enclosure STEP 1 STEP 2 C01104-2-1 C01103-1-1 Remove top of sun shield assembly. Remove existing tag screws. STEP 3 STEP 4 C01104-3-1 C01104-4-1 Attach enclosure to lower portion of sun shield using supplied screws & washers. Secure tag using supplied hex standoffs.

  • Page 140: Instructions: Installing Sun Shield On St80/St80L Remote Enclosure

    APPENDIX B – ADDITIONAL INFORMATION ST80/ST80L Flow Meter Instructions: Installing Sun Shield on ST80/ST80L Remote Enclosure STEP 1 STEP 2 C01103-2-1 C01103-1-1 Remove existing tag screws. Remove top of sun shield assembl y. STEP 3 STEP 4 C01103-4-1 C01103-3-1 Attach enclosure and lower portion of sun shield to remote bracket using Secure tag using supplied hex standoffs.

  • Page 141: Appendix Cglossary

    Definitions Active RTD The flow element part that senses the fluid flow rate. Adaptive Sensing An FCI exclusive flow measurement technique that combines both constant Technology (AST) Delta T and constant power measuring techniques in a single device. Resistance Differential The difference in resistance between the active and reference RTDs.
  • Page 142 APPENDIX C – GLOSSARY ST80/ST80L Flow Meter This Page Intentionally Left Blank Fluid Components International LLC...

  • Page 143: Appendix Dapproval Information

    ST80/ST80L Flow Meter APPENDIX D – APPROVAL INFORMATION APPENDIX D APPROVAL INFORMATION EU Information Fluid Components International LLC...

  • Page 144: Figure 64 - Tag, Unit Certification, Fm (Canada/Us), St80/St80L

    APPENDIX D – APPROVAL INFORMATION ST80/ST80L Flow Meter Equipment Tags Figure 64 – Tag, Unit Certification, FM (Canada/US), ST80/ST80L Fluid Components International LLC...

  • Page 145: Figure 65 -Tag, Unit Certification, Atex, Iecex, St80/St80L Integral Configuration

    ST80/ST80L Flow Meter APPENDIX D – APPROVAL INFORMATION Figure 65 – Tag, Unit Certification, ATEX, IECEx, ST80/ST80L Integral Configuration Fluid Components International LLC...

  • Page 146: Figure 66 -Tags, Unit Certification, Atex, Iecex, St80/St80L Remote Configuration

    APPENDIX D – APPROVAL INFORMATION ST80/ST80L Flow Meter Figure 66 –Tags, Unit Certification, ATEX, IECEx, ST80/ST80L Remote Configuration Fluid Components International LLC...

  • Page 147: Safety Instructions

    ST80/ST80L Flow Meter APPENDIX D – APPROVAL INFORMATION Safety Instructions Safety Instructions for the use of the ST80/ST80L flow meter in Hazardous Areas Approval FM18ATEX64X / IECEx FMG 18.0025X for: II 2 G for Gas protection Ex db IIC T6…T1; IP66/IP67 II 2 D for Dust protection Ex tb IIIC T85ºC…T450ºC;...
  • Page 148 APPENDIX D – APPROVAL INFORMATION ST80/ST80L Flow Meter Deutsch - Sicherheitshinweise Diese Sicherheitshinweise gelten für die Fluid Components, ST80/ST80L flow meter gemäß der EG-Baumusterprüfbescheinigung Nr. FM18ATEX64X / IECEx FMG 18.0025X (Bescheinigungsnummer auf dem Typschild) der Kategorie II 2 GD. 1) Die Errichtung von Ex-Anlagen muss grundsätzlich durch Fachpersonal vorgenommen werden. 2) Der ST80/ST80L muß...
  • Page 149 F B L Français - Consignes de sécurité Ces consignes de sécurité sont valables pour le modèle série ST80/ST80L de la société Fluid Components (FCI) conforme au certificat d’épreuves de type FM18ATEX64X / IECEx FMG 18.0025X (numéro du certificat sur l’étiquette signalétique) conçu pour les applications dans lesquelles un matériel de la catégorie II2GD est nécessaire.
  • Page 150 NL B Nederlands - Veiligheidsinstructies Deze veiligheidsinstructies gelden voor de flow meter uit de ST80/ST80L-serie van Fluid Components (FCI) overeenkomstig het EG- typegoedkeuringscertificaat met nummer FM18ATEX64X / IECEx FMG 18.0025X (nummer van het certificaat op het typeplaatje) voor gebruik in een explosieve atmosfeer volgens Categorie II 2GD.
  • Page 151 ST80/ST80L Flow Meter APPENDIX D – APPROVAL INFORMATION Svenska - Säkerhetsanvisningar Säkerhetsanvisningarna gäller för Fluid Componenets flödesmätare, typ ST80/ST80L, enligt EG-typgodkännandeintyg nr FM18ATEX64X / IECEx FMG 18.0025X (intygsnumret återfinns på typskylten) för användning i explosiv gasblandning i kategori II 2 GD. 1) Installation av Ex-klassade instrument måste alltid utföras av fackpersonal.
  • Page 152 APPENDIX D – APPROVAL INFORMATION ST80/ST80L Flow Meter This Page Intentionally Left Blank Fluid Components International LLC...

  • Page 153: Appendix Ecustomer Service

    Attn: Customer Service Department By Phone Contact the area FCI regional representative. If a field representative is unable to be contacted or if a situation is unable to be resolved, contact the FCI Customer Service Department toll free at 1 (800) 854-1993.
  • Page 154 Contact an FCI field representative to request field service. A field service technician is dispatched to the site from either the FCI factory or one of the FCI representative offices. After the work is com- plete, the technician completes a preliminary field service report at the customer site and leaves a copy with the customer.
  • Page 155 ST80/ST80L Flow Meter APPENDIX E – CUSTOMER SERVICE Fluid Components International LLC...
  • Page 156 APPENDIX E – CUSTOMER SERVICE ST80/ST80L Flow Meter Fluid Components International LLC...
  • Page 157 ST80/ST80L Flow Meter APPENDIX E – CUSTOMER SERVICE WARRANTIES Goods furnished by the Seller are to be within the limits and of the sizes published by the Seller and subject to the Seller’s standard tolerances for variations. All items made by the Seller are inspected before shipment, and should any of said items prove defective due to faults in manufacture or performance under Seller approved applications, or fail to meet the written specifications accepted by the Seller, they will be replaced or repaired by Seller at no charge to Buyer provided return or notice of rejection of such material is made within a reasonable period but in no event longer than one (1) year from date of shipment to Buyer, and provided further, that an...
  • Page 158 (and does not include manufacture or processing uses). Any other use is strictly prohibited without the prior written consent of FCI. © Copyright 2019 by Fluid Components International LLC. All rights reserved. FCI is a registered trademark of Fluid Components International LLC. Information subject to change without notice.

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