Fluid Components International FS10A User Manual
FS10 Series
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.
© Copyright 2011 by Fluid Components International LLC. All rights reserved. FCI is a registered trademark of Fluid Components International LLC. Information subject to change without notice.
Notice of Proprietary Rights
Fluid Components International LLC
FS10 Series 06EN003394 Rev. D
Table of Contents
Technical Specification ................................................................................................................................................................................3
1 INSTRUMENT DESCRIPTION AND IDENTIFICATION .........................................................................................................................4
2 INSTRUMENT INSTALLATION ................................................................................................................................................................4
Special Conditions for Safe Use: .....................................................................................................................................................................................4
Mounting Orientation .......................................................................................................................................................................................................5
3 INSTRUMENT WIRING .............................................................................................................................................................................6
Recommended Minimum Wire Gauge ............................................................................................................................................................................6
Grounding .........................................................................................................................................................................................................................6
Input Power, 24 Vdc ..........................................................................................................................................................................................................6
4 POWER UP, FUNCTIONAL VERIFICTAION AND ADJUSTMENT ........................................................................................................6
Switching Inductive Loads................................................................................................................................................................................................9
5 SET-UP AND OPERATION ......................................................................................................................................................................13
FS10 Function Overview .................................................................................................................................................................................................13
FS10 Field Quick Setup Procedure..................................................................................................................................................................................14
FS10 Button Controls ......................................................................................................................................................................................................15
Normal set-up and operation using the button interface ..............................................................................................................................................16
Bank Selection of Stored Parameters (Function 4) .....................................................................................................................................................16
Flow Switch Operation ...................................................................................................................................................................................................17
Minimum Flow Setting (Function 6) ............................................................................................................................................................................17
Maximum Flow Setting (Function 7) ...........................................................................................................................................................................17
Static/Dynamic Mode Option (Function 5) ..................................................................................................................................................................17
Trip Point Adjust (Function 1 or 2) ...............................................................................................................................................................................17
There are two ways to set the trip point using the buttons. .....................................................................................................................................17
Additional Switch Settings.............................................................................................................................................................................................17
Failsafe Position (Function 3) ......................................................................................................................................................................................17
Hysteresis (Function 8 and 9) ......................................................................................................................................................................................17
Time Delay (Function 10 or 11) ....................................................................................................................................................................................18
Alarm Simulation (Function 12) ...................................................................................................................................................................................18
Keypad Lockout (Function 13)......................................................................................................................................................................................18
Filter Setting (Function 14) ..........................................................................................................................................................................................18
Save to Bank (Function 15) ..........................................................................................................................................................................................18
Output and Display Parameters......................................................................................................................................................................................19
PC Interface and Command Line Interface Configurations ...........................................................................................................................................22
FS10 Communication Options .....................................................................................................................................................................................22
Password Protection....................................................................................................................................................................................................22
Flow Rate Indication on PC Interface ..........................................................................................................................................................................22
Power Supply Interface Kit..........................................................................................................................................................................................22
PC Interface Software .................................................................................................................................................................................................23
PC Interface Software .................................................................................................................................................................................................25
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06EN003394 Rev. D FS10 Series
FS10 Serial Interface ......................................................................................................................................................................................................26
Command Line Interface Commands..............................................................................................................................................................................28
6 MAINTENANCE AND TROUBLESHOOTING .......................................................................................................................................32
Maintenance ...............................................................................................................................................................................................................32
Troubleshooting ...........................................................................................................................................................................................................32
APPENDIX A APPROVALS ........................................................................................................................................................................34
APPENDIX B AUXILIARY DRAWINGS ....................................................................................................................................................38
PC Interface Kits .............................................................................................................................................................................................................41
022083-02 Power Supply/Interface Box Kit ...................................................................................................................................................................42
022083-01 Power Supply/Interface Box.........................................................................................................................................................................42
PC Interface Components ...............................................................................................................................................................................................43
Board Connectors - OEM ................................................................................................................................................................................................44
DB9 Connection Schematic ............................................................................................................................................................................................45
APPENDIX C CUSTOMER SERVICE ......................................................................................................................................................... 46
Customer Service/ Technical Support .........................................................................................................................................................................46
Warranty Repairs or Returns .......................................................................................................................................................................................46
Non-Warranty Repairs or Returns ...............................................................................................................................................................................46
Extended Warranty ......................................................................................................................................................................................................47
Return to Stock Equipment..........................................................................................................................................................................................47
Field Service Procedures .............................................................................................................................................................................................47
Field Service Rates ......................................................................................................................................................................................................47
Return Authorization Request ...................................................................................................................................................................................48
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FS10 Series
Technical Specification
Instrument
Media Compatibility
All gases and liquids compatible with 316L stainless steel and
hastelloy C22.
Process Connection
1/4” NPT; compatible with 1/4”, 3/8” and 1/2” tube tee,
1/4” tube tee with 1/8” injection tube adapters and SP76 adapter
(FCI part number 019897-01)
Flow Sensitivity/Range:
Air / Gas Liquids
CC / Min SCFH CC / Min GPH
Min Max Min Max Min Max Min Max
1/8” tube adapter with
0.0625” ID injection tube
1/8” tube adapter with
0.0940” ID injection tube
1/4” tube tee 50 20,000 0.10 40 4.00 100.00 0.07 1.70
SP76 adapter 50 20,000 0.10 40 4.00 100.00 0.07 1.70
3/8” tube tee
1/2” tube tee
10 2,000 0.02 5 0.70 18.00 0.01 0.30
25 5,000 0.05 10 1.50 40.00 0.03 0.60
180
50,000 0.40 100
375
100,000 0.80 200
14.00
350.00 0.20 5.50
30.00
750.00 0.50 12.00
Repeatability:
± 0.5% of reading
Temperature Coefficient
For temperatures > ± 30 °F [± 16 °C]
Gas: Maximum ± 0.025% of reading/°F up to 500 °F
[± 0.05% of reading/°C up to 260 °C]
Liquid: Maximum ± 0.2% of reading/°F up to 250 °F
[± 0.367% of reading/°C up to 121 °C]
Turndown Ratio: 5:1 to 100:1
Agency Approvals
FM, FMc: Nonincendive, Class I Division 2 Groups A, B, C, D;
Class II, Division 2 Groups E, F, G; Class III,
T4@Ta=71°C Type 4X
ATEX, IEC: Nonincendive for gas and dust, Zone 2
II 3 G Ex nA IIC T4 Gc
II 3 D Ex tc IIIC T 81°C Dc
IP64
CE Mark
Transmitter/Electronics
Enclosure
NEMA 4X [IP64], anodized aluminum
Operating Temperature
-40 °F to 160 °F [-40 °C to 71 °C]
Output Signals
Standard:
(1) Relay (SPDT, 1A @ 24 Vdc); [1A @ 24 Vdc / 120 Vac, FM and
FMc only] or (1) Open Collector N-Channel MOSFET (100 mA);
(1) 4-20 mA * (500 Ω max. load). User scalable, general purpose,
un-calibrated output proportional to flow rate for trend monitoring.
(1) RS232C Serial I/O
(For linearized, calibrated analog outputs see FCI thermal mass
flow meter products)
* Fault indication per NAMUR NE43 guidelines, user selectable
high (> 21.0 mA) or low (< 3.6 mA)
Other Digital Comms: Contact FCI
Display
10 LED array, red; sequential lighting proportional to flow trend and
flashes at setpoint
User Interface
Two top-mounted push buttons to program switch/trip point, zero and
span setting, relay hysteresis and time delay; button operation may
be user disabled to prevent unwanted changes; all set-up functions
also programmable via RS232C port
Input Power
24 Vdc (21.5 Vdc to 30 Vdc); maximum 2.5 watts
Remote Configuration
Transmitter/electronics may be remote-mounted from flow element
using interconnecting cable; remote flow element available with
potted cable in 6’, 15’ or 30’ [2m, 5m or 10m] length and M12 connection plug at electronics; optional extended temperature service to
500 °F [260 °C] with selection of PTFE jacketed cable.
Flow Element
Materials of Construction (Wetted parts) 316L stainless steel with
Hastelloy C-22 thermowells; optional, all Hastelloy-C22 probe
assembly
Operating Temperature
Standard: -40 °F to 250 °F [-40 °C to 121 °C]
Optional: -40 °F to 500 °F [-40 °C to 260 °C]; remote configuration
only
Operating Pressure
Tube tee fitting: 500 psig [34 bar (g)]
SP76 adapter: Per SP76 manifold specifications up to 500 psig
[34 bar (g)] maximum
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FS10 Series
1 INSTRUMENT DESCRIPTION AND IDENTIFICATION
The FS10A is a universal flow monitor and switch specifically designed for gas and liquid process analyzer sampling systems. The FS10A is a fast
responding, highly repeatable sensor which installs easily into a standard tube tee fitting or SP76 (NeSSI) modular manifold.
2 INSTRUMENT INSTALLATION
The FS10 is marked with a flow direction arrow or “A” etched onto the sensor element. It is located on the flattened area of the sensor body
close to the housing or on the assembled tee. In 1/4 and 3/8 inch tube tees, the “A” should be mounted upstream of the flow to maximize sensitivity
at low flow rates (flow into the “A”). Larger line sizes should follow the flow arrow direction. Refer to Table 1 for optimum results. Where the flow
tube is not included with the sensor assembly, the orientation mark must be parallel to flow (±3°). For liquid vertical flows in particular, FCI
recommends the sensor element be installed where flow is in the up direction. In vertical low flow gas applications, flow in the
down direction is recommended.
As a level device, the orientation mark can be perpendicular or parallel to the liquid level. The sensor element may be installed top mount 90° to
the liquid surface. The sensor element can be at any angle as long as the flow direction follows the flow arrow. Liquid applications where the flow
element is positioned other than horizontally, FCI recommends the flow go in the up direction.
CAUTION: To minimize the possibility of damage, leave the protective covers over the sensing area until the time of installation. Take
extra precaution with the sensing elements and surface when installing.
For NPT process connections, apply the appropriate sealant compatible with the process media to the male threads. Tighten until the orientation
mark is positioned correctly. Check for leaks.
Special Conditions for Safe Use:
a. Provisions shall be made to prevent the rated voltage being exceeded by transient disturbances of more than 40%.
b. For applications in explosive atmospheres caused by air/dust mixtures, cable and conduit entries used shall provide a degree of ingress
protection of at least IP 54 according to EN 60529.
c. When the temperature under rated conditions exceeds 158 °F [70 °C] at the cable or conduit entry point, or 176 °F [80 °C] at the branching
point of the conductors, the temperature specification of the selected cable shall be in compliance with the actual
measured temperature.
d. Cable gland assemblies are factory tightened – do not adjust; M12 connectors assembled finger-tight. Mencom MDC-8MR-PG9 or equal
M12 connector is used on FS10A.
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Mounting Orientation
Flow Direction
“A” (Active) mark
Upstream
Sensors parallel
Left to Right Flow Example in 1/4 and 3/8 inch tube tees
For optimum sensitivity in low flow applications, probes should
be installed with the “A” (Active) sensor positioned upstream.
Horizontal lines: gas or liquid.
Vertical lines: gas - flow must be down
liquid - flow must be up
Flow Direction Arrow
Sensors perpendicular
Right to Left Flow Example in 1/2 inch or greater tube or
pipe tee
Probes mounted into 1/2 inch or greater tees are installed with
the sensors positioned perpendicular to the flow path in the
tee. “A” (Active) should be facing up in side mount horizontal
configurations. These sensors may also be marked with a flow
direction arrow.
Diagram 1
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FS10 Series
3 INSTRUMENT WIRING
Only qualified personnel are to wire or test this instrument. The operator assumes all responsibilities for safe practices while wiring or troubleshooting. One of the following wiring instruction and diagrams illustrate the requirements for power input, alarm and analog outputs and safety instructions for the unit being installed.
ALERT: The Instrument contains electrostatic discharge (ESD) sensitive devices. Use standard ESD precautions when handling the
instrument.
Recommended Minimum Wire Gauge
The following wire gauge chart specifies the correct wire for the distance to the power source or loads. Note that the open collector option is limited
to 50 ft. It is also recommended that the open collector cable is shielded and that it is not run in the same conduit with the power source or the relay
load.
I/O Wiring Gauge vs. Distance
Maximum Diameter (guage)
Connection
Input Power (24 Vdc nominal) 24 24 22 22 20 18
Relay Output (1 amp contacts) 18 16 14 12 10 X
10 ′ 50 ′ 100 ′ 250 ′ 500 ′ 1000 ′
(3 m) (15 m) (30 m) (76 m) (152 m) (305 m)
Open Collector Output 24 22 X X X X
4-20 mA Output 24 24 22 22 20 18
Table 1
Grounding
The switch must be properly grounded for safety and operational reasons.
The circuit board is tied to the enclosure case internally and both are tied to the probe assembly. If the installation pipe or vessel is not properly
grounded, connection to earth ground may be connected at the output connector, i.e. M12 or cable pigtail. Use the recommended wire gauge specified for the input power and distance listed in the chart above. Do not connect the earth ground to DC ground (terminals marked “GND”,
“COM” or “-”).
Input Power, 24 Vdc
FCI recommends installing an input power disconnect and a fuse near the instrument to interrupt power during installation, maintenance, calibration, alarm selection and troubleshooting procedures. Conduit should also be installed according to the local electrical codes or hazardous location
requirements.
Attach the power leads according to the Input/Output connection schematic on the following page. If the unit has an M12 interface, verify that the
mating connector pin numbers match the designations of the wiring diagram. If the unit is supplied with a cable pigtail, the flying leads should be
connected via an approved terminal block or connector in an electrically safe and approved conduit box.
Attach the wires to the relay and other functions as needed. The relay contact conditions are shown in the alarm state (de-energized). The relay’s maximum rating is 1 amp 24Vdc, 120 Vac (FM only), 24 Vdc (ATEX), resistive loads.
Refer to the next section for the set point and alarm state settings.
4 POWER UP, FUNCTIONAL VERIFICTAION AND ADJUSTMENT
Before Applying power to the instrument, it is recommended that a third party inspect the installation workmanship. Make sure wires are not pinched
or frayed. Check for matching serial numbers on the sensing element and the control circuit. Verify that the power and alarm circuits are properly
connected. Review the instrument configuration and its application.
Units supplied with LED’s will have at least one LED on or slowly blinking to indicate power on. Apply power and look for the power indicator light.
After power is established let the instrument warm up for 5 minutes. Refer to set-up on following pages. The switch must be properly grounded for
safety and operational reasons.
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(OEM)
Switching Inductive Loads
If the FS10A relay contacts are to be used to energize or de-energize an external relay, diode suppression must be used across the external relay coil.
Use the guidelines in the following example to select the proper diode.
A Tyco Electronics relay K10P-11D15-24 is used as a slave relay. The DC coil voltage is specified at 24 Vdc and the specification indicates a coil
resistance of 650Ω. The DC coil current is calculated by dividing the Rated coil power by the Rated Voltage Vdc or dividing the Rated Voltage Vdc by
the Coil resistance. In this case the current through the coil will be around 37mA (24/650). Refer to the K10P-11D15-24 data sheet.
It is recommended the Diode Reverse Voltage (Vr) rating be twice or greater the voltage across the relay and the diode forward current (IF) rating be
greater than the relay current. Diodes 1N914 or 1N4148 meet these limits for this case.
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FS10 Series
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FS10 Flow Element Options
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FS10 Remote Enclosure and Connector Options
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5 SET-UP AND OPERATION
FS10 Function Overview
The FS10 flow monitor may come configured for use as a flow or temperature meter. The output of the switch configuration is a SPDT relay contact or
binary collector to ground [N-channel MOSFET] output (sync). A 4-20 mA output signal is also active as a signal reference. In the transmitter configuration, either the flow or temperature functions may be assigned to the 4-20 mA output. The table below shows the possible output configurations,
including the status of the LED bar display.
Output Configuration [Field Selectable with PC Interface Kit]
Configuration 4-20 ma Output Relay on/off Output LEDs
1
(default)
Corresponds to Flow
measurement
Controls Relay switch on/off
from Flow
Reflects Flow. Flashing LED
indicates Relay Limit.
4 Corresponds to Temp
measurement
5 Corresponds to Temp
measurement
Controls Relay switch on/off
from Flow
Controls Relay switch on/off
from Flow
Reflects Temperature. No
Relay Limit indication.
Reflects Flow. Flashing LED
indicates Relay Limit.
Table 2
• Flow measurement will be mapped using CUST_FLOW_MIN and CUST_FLOW_MAX in the 4-20 mA output configuration.
• Temperature measurement will be mapped using CUST_TEMP_MIN and CUST_TEMP_MAX in the output configuration and reflected
in the 4-20 mA output when configuration 4 or 5 is selected. The default temperature range mapped to the 4-20 mA
output is 0 °F to 250 °F [-17.8 °C to 121 °C]. Rescaling temperature output may be performed with the PC interface program.
The output configuration setting is normally factory set but may be changed in the field if required. Caution should be used when making any
configuration changes, as the monitor may not have been properly calibrated to accommodate the new setting. Only the RS232 interface may
be used to make a change in output configuration.
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FS10 Series
FS10 Field Quick Setup Procedure
Quick Setup Mode *
This feature permits field setting the critical zero and span parameters of the FS10A with a single push of the button and throttling the process flow
over the desired range to capture the low and high ends. All defaults applicable to a low flow indication/alarm application apply along with a
trip-point default setting at 30% of span.
To activate the Quick Setup Mode (QSM), simply press and hold for at least 10 seconds:
“ – “ button, for process fluids that are gases or very low flow liquid hydrocarbons
“ + “ button, for process fluids that are liquids or high velocity gases (+50% sensor excitation).
The first three and last three LEDs will alternately flash to acknowledge entry into the Quick Setup Mode. The FS10A is now cued to remember the
lowest and highest flow signal it sees while in this mode. Pressing either button momentarily exits into the normal operating mode and saves the
detected limits as the zero and span. LED’s 1 and 10 and corresponding trip point LED will alternately flash (3 sec), indicating zero and span have
been properly set.
A minimum span setting of 0.05% is required to save new parameters. If minimum span is not reached during QSM, the first two, middle two and
last two LEDs will flash; indicating an error (3 sec) and resume last operation without saving new parameters.
Recommendations
Gas applications
The high flow limit or span setting is normally the most difficult to stabilize in a gas application, therefore simulating the desired high flow rate at
normal process conditions and allowing it to stabilize before entering into the QSM is recommended. Using in-line valves or other throttling means,
establish the desired full scale flow rate and allow system to stabilize. Now enter into the QSM (FS10 immediately captures this high flow signal)
and then slowly throttle the flow down until the zero flow setting is reached (i.e. valve closed, no flow). Allow to stabilize, then momentarily press
either button to save parameters and return to normal operating mode with the new scaled operating range established.
Liquid applications
To optimize the performance of the FS10A in liquids, it is critical to establish a stable zero setting under a packed line (full) condition. It is
recommended the FS10A be operating and allowed to come to equilibrium with a downstream valve closed and the line completely filled with the
process fluid and no flow. At this point, enter into the QSM (FS10 immediately captures this low flow signal), and then slowly open the downstream
valve to allow flow up to the maximum span desired. Momentarily press either button to save parameters and return to normal operating mode with
the new scaled operating range established.
In some cases the high liquid flow signal will saturate before reaching the high flow that is simulated, but the FS10A will save the highest value it is
capable of sensing in that application and use it as the high end limit.
Trip point
By factory default, the trip-point is set to 30% of the established span when using the Quick Setup Mode. This may be changed in the field using
the standard button commands (refer to Functions 1 and 2 under Normal set-up and operation using the button interface in the operating manual).
Alternatively, the QSM factory trip-point default of 30% of span may be changed in the field using the PC interface program before entering into the
QSM. Selecting the factory setup option at order will also permit designating an alternative customer desired default value at the factory. Note, this
value is always a % of the established span and alters any previous trip point that may have been attained on a previous setup.
Note, the 4-20mA output and relay trip will continue to operate at the previously set range while in the Quick Setup Mode
Summary
1. Activate QSM: Press “-“ button (gas) or “+” button (liquid) minimum 10 seconds (LEDs will acknowledge entry into QSM).
2. Throttle flow valve to simulate zero and full scale flow.
3. Press either button momentarily to save parameter values and exit into normal operating mode.
* FS10A with Firmware version 4.0 or greater
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FS10 Button Controls
It is recommended the unit be powered-up for 10-15 minutes before making changes to any of the flow settings.
General Control Description
The FS10 control “functions” can be accessed through the two buttons by:
1. Entering “function selection”
2. Selecting the desired function to adjust
3. Adjusting the function control
4. Exiting to normal operation
1. To Enter “Function Selection” mode:
a. Press and hold both buttons down for 3 seconds
b. When “function selection” is entered, all the LEDs will flash “on”, then
c. The first function (LED # 1) will be illuminated
2. “Function Selection” mode:
Once the unit is in “function selection” mode, the buttons take on new controls:
• The “-“ and “+” buttons will step (increment down or up respectively) through the different functions. The current function number will
be indicated on the LED blinking at the slow rate.
• Holding either the “+” or “-“ for 3 seconds will “select” the current function to be adjusted.
3. When a Function has been selected for adjustment:
After selecting the desired function by pushing and holding either the “-” or “+” button for 3 seconds the LEDs will flash at a faster rate. The
pattern of the LEDs will either reflect the current value of the parameter being adjusted, or the “ready to capture” pattern for parameters to be
captured (see specific function descriptions for details).
The buttons will either increment or decrement the function parameter, or capture a value for the corresponding parameter.
4. To exit out of the current function, push and hold both buttons down for 3 seconds. The LEDs will indicate that you are once again in “function
election” mode, and the current mode will have incremented to the next function. To exit completely (into operational mode), press the two
buttons simultaneously for 3 seconds once again.
Note: Function #4 (load a bank) and function #15 (save to a bank), requires holding either button for 3 seconds to load or save.
Holding both buttons will exit either function without performing the operation.
Button Operation
1 Enter “function selection” Push and hold both buttons simultaneously 3 seconds
2 Select desired “function” Push “+” or “-“ to step through (LEDs indicate function #)
3a. Enter “function adjust” Push and hold either “-“ or “+” button 3 seconds
3b. Adjust within function Follow instructions for particular function entry
4a. Exit “function adjust” Push and hold either “-” or “+” button 3 seconds (now in “function selection”
operation)
select operation]
4b. Exit “function selection” Push and hold both buttons simultaneously 3 seconds (now in normal operation)
[NOTE: Function #4 or #15 requires holding both buttons to exit into function
Table 3
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