ABB SensyMaster FMT230 Installation and operation manual

—
ABB MEASUREMENT & ANALYTICS | COMMISSIONING INSTRUCTION
SensyMaster FMT230, FMT250
Thermal mass flowmeter
Measurement made easy
Additional Information
Additional documentation on SensyMaster
FMT230, FMT250 is available free of charge for
downloading at www.abb.com/flow.
Alternatively simply scan this code:

2 SENSYMASTER FMT230, FMT250 THERMAL MASS FLOWMETER | CI/FMT230/250-EN REV. A
Short product description
Thermal mass flowmeter on the mass flow measurement of
gases and gas mixtures in closed pipelines.
Device firmware version:
— 01.00.07 (Modbus)
Additional Information
Additional documentation on SensyMaster FMT230, FMT250 is
available free of charge for downloading at www.abb.com/flow.
Alternatively simply scan this code:
Manufacturer
ABB Automation Products GmbH
Measurement & Analytics
Dransfelder Str. 2
37079 Göttingen
Germany
Tel: [phone]
Fax: [phone]
Customer service center
Tel: [phone]
Mail: automation.s[email protected]

SENSYMASTER FMT230, FMT250 THERMAL MASS FLOWMETER | CI/FMT230/250-EN REV. A 3
Change from one to two columns
Contents
1Safety.............................................................................. 4
1.1 General information and instructions ..............4
1.2Warnings.................................................................4
1.3Intended use ..........................................................4
1.4Improper use .........................................................4
1.5Notes on data security.........................................5
2Product identification................................................... 5
2.1 Name plate.............................................................5
3Transport and storage .................................................. 6
3.1Inspection ..............................................................6
3.2Transport................................................................6
3.3Storing the device.................................................6
3.3.1Ambient conditions..............................................6
3.4Returning devices .................................................6
4Installation ..................................................................... 7
4.1Installation conditions......................................... 7
4.1.1Installation location and assembly.................... 7
4.1.2Inlet and outlet sections......................................8
4.1.3Installation at high ambient temperatures......8
4.1.4Sensor insulation ..................................................8
4.2Environmental conditions...................................9
4.2.1Ambient temperature ..........................................9
4.2.2NEMA rating...........................................................9
4.3Process conditions ...............................................9
4.3.1Measuring medium temperature.......................9
4.3.2Material loads for process connections .........10
4.4Assembly of the pipe component....................10
4.4.1Wafer type design (FMT091) and partial
measuring section (FMT092).............................11
4.4.2Weld-on adapter ................................................. 12
4.4.3Integrated hot tap fitting.................................. 15
4.5Installing the sensor........................................... 16
4.5.1Wafer type design and welding adapter ........ 16
4.5.2Installation / Disassembly in connection with
the changing device ........................................... 17
4.6Opening and closing the housing.................... 18
4.7Electrical connections........................................ 19
4.7.1Installing the connecting cables ...................... 19
4.7.2Electrical connection.......................................... 19
4.7.3Electrical data for inputs and outputs............ 19
4.7.4Modbus protocol ................................................20
4.7.5Connection on the device.................................. 22
5Commissioning and operation ................................... 23
5.1Write-protection switch, service LED and local
operating interface ............................................ 23
5.2Checks prior to commissioning ....................... 23
5.3Switching on the power supply........................ 23
5.3.1Inspection after switching on the power supply
................................................................................ 23
5.4Parameterization of the device........................ 24
5.4.1Parameterization via the Modbus interface .. 24
5.4.2Parameterization via the local operating
interface ............................................................... 25
5.5Operating instructions ...................................... 25
6Maintenance ................................................................. 26
6.1Safety instructions ............................................. 26
7Specification ................................................................ 26
8Additional documents ................................................. 26
9Appendix....................................................................... 27
9.1Return form.......................................................... 27

4 SENSYMASTER FMT230, FMT250 THERMAL MASS FLOWMETER | CI/FMT230/250-EN REV. A
1Safety
1.1 General information and instructions
These instructions are an important part of the product and
must be retained for future reference.
Installation, commissioning, and maintenance of the product
may only be performed by trained specialist personnel who have
been authorized by the plant operator accordingly. The
specialist personnel must have read and understood the manual
and must comply with its instructions.
For additional information or if specific problems occur that are
not discussed in these instructions, contact the manufacturer.
The content of these instructions is neither part of nor an
amendment to any previous or existing agreement, promise or
legal relationship.
Modifications and repairs to the product may only be
performed if expressly permitted by these instructions.
Information and symbols on the product must be observed.
These may not be removed and must be fully legible at all times.
The operating company must strictly observe the applicable
national regulations relating to the installation, function
testing, repair and maintenance of electrical products.
1.2 Warnings
The warnings in these instructions are structured as follows:
DANGER
The signal word "DANGER" indicates an imminent danger.
Failure to observe this information will result in death or
severe injury.
WARNING
The signal word "WARNING" indicates an imminent danger.
Failure to observe this information may result in death or
severe injury.
CAUTION
The signal word "CAUTION" indicates an imminent danger.
Failure to observe this information may result in minor or
moderate injury.
NOTICE
The signal word "NOTICE" indicates useful or important
information about the product.
The signal word "NOTICE" is not a signal word indicating a
danger to personnel. The signal word "NOTICE" can also refer
to material damage.
1.3 Intended use
This device can be used in the following applications:
— As a plug-in sensor flanged into the pipe component in
pipelines with nominal diameters DN 25 ... DN 200 (1 ... 8 in.).
— Through a welding adapter directly in pipelines of nominal
diameter DN 100 (4 in.) and above, as well as for non-
circular cross-sections.
This device is intended for the following uses:
— for direct mass flow measurement of gases and gas
mixtures in closed pipelines.
— for indirect measurement of standard volume flows
(through standard density and mass current).
— For measuring the temperature of the measuring medium.
The device has been designed for use exclusively within the
technical limit values indicated on the identification plate and in
the data sheets.
When using media for measurement the following points must
be observed:
— Measuring media may only be used if, based on the state of
the art or the operating experience of the user, it can be
assured that the chemical and physical properties
necessary for safe operation of the materials of flowmeter
sensor components coming into contact with these will not
be adversely affected during the operating period.
— Media containing chloride in particular can cause corrosion
damage to stainless steels which, although not visible
externally, can damage wetted parts beyond repair and lead
to the measuring medium escaping. It is the operator's
responsibility to check the suitability of these materials for
the respective application.
— Measuring media with unknown properties or abrasive
measuring media may only be used if the operator can
perform regular and suitable tests to ensure the safe
condition of the meter.
1.4 Improper use
The following are considered to be instances of improper use of
the device:
— For operating as a flexible adapter in piping, e.g. for
compensating pipe offsets, pipe vibrations, pipe
expansions, etc.
— For use as a climbing aid, e.g. for mounting purposes
— For use as a support for external loads, e.g. as a support for
piping, etc.
— Material application, e.g. by painting over the housing,
name plate or welding/soldering on parts.
— Material removal, e.g. by spot drilling the housing.

SENSYMASTER FMT230, FMT250 THERMAL MASS FLOWMETER | CI/FMT230/250-EN REV. A 5
1.5 Notes on data security
This product is designed to be connected to and to
communicate information and data via a network interface.
It is operator’s sole responsibility to provide and continuously
ensure a secure connection between the product and your
network or any other network (as the case may be).
Operator shall establish and maintain any appropriate measures
(such as but not limited to the installation of firewalls,
application of authentication measures, encryption of data,
installation of anti-virus programs, etc.) to protect the product,
the network, its system and the interface against any kind of
security breaches, unauthorized access, interference, intrusion,
leakage and / or theft of data or information.
ABB Automation Products GmbH and its affiliates are not liable
for damages and / or losses related to such security breaches,
any unauthorized access, interference, intrusion, leakage and /
or theft of data or information.
2Product identification
2.1 Name plate
Fig. 1: Name plate (example)
1Type designation 2CE mark 3Measuring element design
4Sensor installation length 5Wetted material 6IP / NEMA
protection type 7Sensor process connection 8Ambient
temperature / model number range (Tamb. / Tmed.) 9Power supply
j“Read operating instruction” symbol k“Hot surface” symbol
lManufacturer address mManufacture date (month / year)
nUpdate field device firmware oDevice firmware revision
pOrder code qSerial number

6 SENSYMASTER FMT230, FMT250 THERMAL MASS FLOWMETER | CI/FMT230/250-EN REV. A
3Transport and storage
3.1 Inspection
Check the devices immediately after unpacking for possible
damage that may have occurred from improper transport.
Details of any damage that has occurred in transit must be
recorded on the transport documents.
All claims for damages must be submitted to the shipper
without delay and before installation.
3.2 Transport
DANGER
Life-threatening danger due to suspended loads.
In the case of suspended loads, a danger of the load falling
exists.
Remaining under suspended loads is prohibited.
WARNING
Risk of injury due to device slipping.
The device's center of gravity may be higher than the harness
suspension points.
— Make sure that the device does not slip or turn during
transport.
— Support the device laterally during transport.
3.3 Storing the device
Bear the following points in mind when storing devices:
— Store the device in its original packaging in a dry and dust-
free location.
— Observe the permitted ambient conditions for transport
and storage.
— Avoid storing the device in direct sunlight.
— In principle, the devices may be stored for an unlimited
period. However, the warranty conditions stipulated in the
order confirmation of the supplier apply.
Observe the following instructions:
— Do not expose the device to humidity during transport.
Pack the device accordingly.
— Pack the device so that it is protected against vibrations
during transport, e.g., by using air-cushioned packaging.
If the original packaging material is no longer available, wrap
the device in bubble wrap or corrugated cardboard and place it
in a box of sufficient size lined with a shock-absorbing material
(e.g., foam rubber). The thickness of the padding should be
appropriate for the device weight and type of shipment. The
box must be labeled as “fragile”.
For overseas shipment, always add a desiccant (e.g., silica gel)
and hermetically seal the device plus desiccant in a layer of
polythene that is 0.2 mm thick. Use an amount of desiccant that
is appropriate for the packing volume and the expected
transport time (at least for three months). You should also line
the box with a layer of union paper.
3.3.1 Ambient conditions
Storage temperature range
-25 ... 85 °C (-13 ... 185 °F)
Relative humidity
Maximum 85 % RH, annual average ≤65 % RH
3.4 Returning devices
Use the original packaging or a secure transport container of an
appropriate type if you need to return the device for repair or
recalibration purposes. Fill out the return form (see the
Appendix) and include this with the device.
According to the EU Directive governing hazardous materials,
the owner of hazardous waste is responsible for its disposal or
must observe the following regulations for shipping purposes:
All devices delivered to ABB must be free from any hazardous
materials (acids, alkalis, solvents, etc.).
Please contact Customer Center Service acc. to page 2 for
nearest service location.

SENSYMASTER FMT230, FMT250 THERMAL MASS FLOWMETER | CI/FMT230/250-EN REV. A 7
4Installation
DANGER
Danger to life due to piping under pressure!
Sensors which may eject during installation or removal in
piping remaining under pressure may pose a danger to life.
— Install or remove a sensor only if the piping is
depressurized.
— As an alternative, use a pipe component with an
integrated replacement device.
WARNING
Risk of injury due to process conditions.
The process conditions, e.g. high pressures and temperatures,
toxic and aggressive measuring media, can give rise to
hazards when working on the device.
— Before working on the device, ensure that the process
conditions do not pose any safety risks.
— If necessary, wear suitable personal protective equipment
when working on the device.
— Depressurize and empty the device / piping, allow to cool
and purge if necessary.
4.1 Installation conditions
4.1.1 Installation location and assembly
Note the following points when selecting the installation
location and when mounting the sensor:
— The ambient conditions (IP rating, ambient temperature
range Tamb) of the device must be adhered to at the
installation location.
— Sensors and transmitters must not be exposed to direct
sunlight.If necessary, provide a suitable means of sun
protection on site. The limit values for the ambient
temperature Tamb must be observed.
— On flange devices, ensure that the counterflanges of the
piping are aligned plane parallel. Only install flange devices
with suitable gaskets.
— Prevent the sensor from coming into contact with other
objects.
— The device is designed for industrial applications.
No special EMC protective measures are required if the
electromagnetic fields and interference at the installation
location of the device comply with "Best Practice"
guidelines (in accordance with the standards referred to in
the declaration of conformity).
Maintain a suitable distance from electromagnetic fields
and interference that extend beyond the usual dimensions.
Gaskets
Users are responsible for selecting and mounting suitable
gaskets (material, shape).
Note the following points when selecting and mounting
gaskets:
— Only gaskets made from a material that is compatible with
the measuring medium and measuring medium
temperature may be used
— Gaskets must not extend into the flow area, since possible
turbulence may influence the accuracy of the device.

8 SENSYMASTER FMT230, FMT250 THERMAL MASS FLOWMETER | CI/FMT230/250-EN REV. A
4.1.2 Inlet and outlet sections
The figures below show the recommended inlet and outlet
sections for various installations.
Fig. 2: Inlet and outlet sections
Installation Inlet section Outlet section
A
Pipe extension min. 15 x DN min. 5 x DN
B
Pipe reduction min. 15 x DN
C
90° Pipe elbow min. 20 x DN
D 2 x 90° Pipe elbow in
one level
min. 25 x DN
E 2 x 90° Pipe elbow in
two levels
min. 40 x DN
F
Turn-off device min. 50 x DN
To achieve the specified measuring accuracy, the indicated inlet
and outlet sections are required.
In case of combinations of several inlet-side errors, e.g. valve
and reduction, a longer inlet section must always be taken into
account.
In case of confined spaces at the installation place, the outlet
section can be reduced to 3 x DN. However, reducing the
specified inlet section will reduce the achievable level of
accuracy.
A high repeatability of the measured value is maintained.
In case of insufficient inlet and outlet sections, a special
calibration may be possible. To do this, a detailed alignment is
necessary for individual cases.
The specified inlet and outlet sections must be doubled for
gases with a very low density (hydrogen, helium).
4.1.3 Installation at high ambient temperatures
G10858
ra
Fig. 3: Mounting position at high ambient temperatures
Under high but permissible ambient temperatures, avoid
additional thermal stress from heat convection or radiation,
since these sources of heat may exceed the permissible
ambient temperature on the equipment surface.
If the device needs to be installed directly on a hot, horizontal
piping, we recommend installing it on the side. In such cases,
you should avoid installing it in the 12 o'clock position,
otherwise the warm air that rises up will cause additional
heating of the electronics.
4.1.4 Sensor insulation
G12338
1
Fig. 4: Insulation of the sensor
1Insulation
The sensor may be insulated as shown in Fig. 4.
G12064
AB
CD
≥15 x DN ≥5 x DN ≥15 x DN ≥5 x DN
≥20 x DN ≥5 x DN ≥25 x DN ≥5 x DN
≥40 x DN ≥5 x DN ≥50 x DN ≥5 x DN
EF
<7° <7°

SENSYMASTER FMT230, FMT250 THERMAL MASS FLOWMETER | CI/FMT230/250-EN REV. A 9
4.2 Environmental conditions
4.2.1 Ambient temperature
— Standard: -20 … 70 °C (-4 … 158 °F)
— Extended TA9: -40 ... 70 °C (-40 ... 158 °F)
— Extended TA6: -50 ... 70 °C (-58 ... 158 °F)
Relative humidity
Maximum 85 % RH, annual average ≤65 % RH
IP rating
In accordance with EN 60529: IP 65 / IP 67
4.2.2 NEMA rating
NEMA 4X
4.3 Process conditions
4.3.1 Measuring medium temperature
Devices with ceramic element and flange connection
— Standard: -25 … 150 °C (-13 … 302 °F)
— Extended (optional, only FMTx50):
-25 ... 300 °C (-13 ... 572 °F)
The approved measuring medium temperature Tmedium also
depends on the selected sensor process connection and the
design of the pipe components.
The following temperature specifications apply:
Sensor connection Tmedium
Threaded connection DIN 11851 -40 ... 140 °C (-40 ... 284 °F)
Clamp ring fitting -25 ... 140 °C (-13 ... 284 °F)
Pipe components with ball valve Maximum 150 °C (302 °F)
Integrated hot tap fitting See the chapter titled ‘Integrated
hot tap fitting’ on page 10
Maximum operating pressure
Standard for devices with flange connection, Pmedium:
4 MPa, 40 bar (580 psi)
The approved operating pressure Pmedium also depends on the
selected sensor process connection and the design of the pipe
components.
The following temperature specifications apply:
Sensor connection Pmedium
Threaded connection DIN 11851 1.6 MPa, 16 bar (232 psi)
Clamp ring fitting 2 MPa, 20 bar (290 psi)
Integrated hot tap fitting See the chapter titled ‘Integrated
hot tap fitting’ on page 10
Pressure drop
G10796
10 50 100 500 1000 5000 10000
10
5
0,5
0,1
1
DN 50 DN 80 DN100
DN 150
DN 25
[mbar]
[kg/h]
A
B
Fig. 5: Pressure loss in logarithmic representation
APressure loss BMass flow

10 SENSYMASTER FMT230, FMT250 THERMAL MASS FLOWMETER | CI/FMT230/250-EN REV. A
4.3.2 Material loads for process connections
DIN and ASME flanges
G12340
TS [°C /°F]
20 50 100 150 200 250 280 300 [°C]
40
20
0
PN 40
580
290
0
68 122 212 302 392 482 536 572 [°F]
PS [psi]PS [bar]
PN 16
PN 10
Fig. 6: DIN flange process connection
G12341
TS [°C / °F]
20 50 100 150 200 250 280 300 [°C]
PS [bar]
60
40
20
0
CL 300
CL 150
870
580
290
0
68 122 212 302 392 482 536 572 [°F]
PS [psi]
Fig. 7: ASME flange process connection
The maximum approved operating pressure for CL 300 is
limited to 40 bar (580 psi).
Integrated hot tap fitting
G10815
0
2
4
6
8
10
12
14
16
18
0 (32) 50 (122) 100 (212) 150 (302) 200 (392) 250 (482)
T [°C] (°F)
0
29
58
87
116
145
174
203
232
261
p [psi]
p [bar]
Fig. 8: Maximum pressure / temperature values for integrated hot
tap fitting
4.4 Assembly of the pipe component
When installing the pipe components, observe the following
points:
— During installation, it is important to ensure that the flow
direction corresponds to the attached label.
— When welding the welding adapter, remember to observe
the relevant welding instructions. The amount of heat
introduced must be kept to an absolute minimum to
prevent warping of the mounting flange's sealing surface.
— In the case of flanged connections, flat gaskets must be
installed, which should be in perfect condition and resistant
to the measuring media.
— Before installing pipe components or sensors, check all
components and gaskets for damage.
— Pipe components must not be installed under tension,
otherwise the pipeline may exert impermissible forces on
the device.
— When assembling the flanged connections, use screws that
offer the required strength and dimensions.
— The screws must be tightened evenly and to the required
torque.
— Once the pipe components have been installed, the
insertion connection must be sealed by means of a blind
flange plus gasket or by closing a shut-off device (if
present).

SENSYMASTER FMT230, FMT250 THERMAL MASS FLOWMETER | CI/FMT230/250-EN REV. A 11
4.4.1 Wafer type design (FMT091) and partial measuring
section (FMT092)
G10793
1 2 3 4 6
7
5
8
Fig. 9: Installing a pipe component (example, wafer type design)
1Flange screw 2Washer 3Flange 4Flange gasket 5Pipe
component 6Sensor connection flange 7Centering pin, outflow
side 8Nut
Installation of the FMT091 pipe component (wafer type
design) and FMT092 (partial measuring section).
1. Position the pipe component coplanar and centered
between the piping. The flow direction must correspond to
the arrow indicated on the pipe component. The centering
pin on the pipe component must be located on the outflow
side (behind the measuring point).
2. Install gaskets between the sealing surfaces.
NOTICE
For achieve the best measurement results, make sure the
gaskets fit concentrically with the pipe component.
— The inside diameter of the pipe and flange must precisely
match in the wafer type design. Any differences in levels
or edges, or untidy weld seams, will reduce the measuring
accuracy.
— To guarantee that the flow profile is not distorted, the
gaskets must not protrude into the piping.
3. Use the appropriate screws for the holes.
4. Slightly grease the threaded nuts.
5. Tighten the nuts in a crosswise manner as shown in the
figure. First tighten the nuts to approx. 50 % of the
maximum torque, then to 80 %, and finally a third time to
the maximum torque.
NOTICE
Torques for screws depend on temperature, pressure, screw
and gasket materials. The relevant applicable regulations must
be taken into consideration.
G11726
1
2
7
8
5
3
4
6
1
2
3
4
Fig. 10: Tightening sequence for the flange screws

12 SENSYMASTER FMT230, FMT250 THERMAL MASS FLOWMETER | CI/FMT230/250-EN REV. A
4.4.2 Weld-on adapter
Consider the following points when installing the welding dater
in the piping:
— After welding, the welding adapter must have a length of L
(see chapter ‘Mounting dimensions – welding adapter with
flange and with and without ball valve’ on page 13 and
‘Assembly dimension - welding adapter with threaded
connection in accordance with DIN 11851’ on page 14 ).

DhL  2/1
L Length of the welding adapter
h Installation length of the sensor
D Outside diameter of the pipeline
— Shorten the length of the welding adapter as needed
before welding it on. After welding, the welding adapter
may protrude into the piping no more than 10 mm
(0.39 inch).
— Observe thickness of pipeline wall and degree of
shrinkage when welding!
— The distance h from the upper edge of the adapter
flange to the pipe central axis must be within a
tolerance of ± 2 mm (0.08 inch).
— Maintain a right angle to the pipe axis (max. tolerance 2°).
— The adapter centering pin must be aligned with the pipe
axis in the flow direction (outflow side, behind the
measuring point).
— Once welding is complete, there must be free clearance of
at least 28 mm (1.10 inch) to install the sensor; drill to create
clearance as needed.
Additional instructions for welding adapter with ball valve
DANGER
Danger to life due to improper installation!
During welding, the gaskets in the ball valve may overheat.
This can lead to the measuring medium escaping in an
uncontrolled manner. This can result in severe injuries or
death.
Remove the ball valve before welding.
Versions featuring a ball valve enable the flowmeter sensor to
be installed and disassembled at low gauge pressures in the
pipeline with minimal gas leakage.
The design with ball valve is installed as described above, but
the following indications must be observed in addition:
— To install the sensor, the ball valve must be opened
completely. Then, the flowmeter sensor can be installed
along with the appropriate gasket and screwed into place.
— Before disassembling the sensor, make sure that the
pipeline has been depressurized. Then, you can release the
screws on the flange, remove the flowmeter sensor and
close the ball valve.
NOTICE
Damage to the sensor.
Closing the ball valve before you remove the sensor can
seriously damage the protective cage or the sensor elements.
Do not close the ball valve until the flowmeter sensor has been
removed.
Change from tw o to one column

SENSYMASTER FMT230, FMT250 THERMAL MASS FLOWMETER | CI/FMT230/250-EN REV. A 13
Mounting dimensions – welding adapter with flange and with and without ball valve
Without ball valve
G10802
min. 28 (1.10)
h
L
Ø 33,7 (1.33)
450 (17.72)
Ø d
Ø D
1
2
1 3
4
With ball valve
G10803
h
L
Ø D
2
Ø 48,3 (1,90)
450 (17,72)
4
1 3
min. 28 (1,10)
Ø d
1
Fig. 11: Welding adapter with flange - all dimensions given in mm (inch).
1Centering pin 2Nut for O-ring 3connection flange DN 25 (1”) 4flow direction
h – sensor length Ø D – outer pipe diameter (min. / max.)
Without ball valve With ball valve
263 (10.35) 100 ... 350 (3.94 ... 13.78) 100 ... 150 (3.94 ... 5.91)
425 (16.73) > 350 ... 700 (> 13.78 ... 27.56) > 150 ... 500 (> 5.91 ... 19.69)
775 (30.51) > 700 ... 1400 (> 27.56 ... 55.12)1) > 500 ... 1150 (> 19.69 ... 45.28)1)
1) The limitation of the maximum pipe diameter only applies for installations with a measuring element in the middle of the pipe. In case of larger or non-
round cross-sections, a non-centered position of the measuring element in the piping is considered in the calibration.

14 SENSYMASTER FMT230, FMT250 THERMAL MASS FLOWMETER | CI/FMT230/250-EN REV. A
Assembly dimension - welding adapter with threaded connection in accordance with DIN 11851
Ø d
min. 28 (1.10)
D
h
Rd52 x 1/6”
L
G11022
Ø 34 (1,34)
117 (4.6)
3
2
1
Fig. 12: Dimensions in mm (inch)
1Union nut 2Flow direction 3Centering pin
Change from one to two columns

SENSYMASTER FMT230, FMT250 THERMAL MASS FLOWMETER | CI/FMT230/250-EN REV. A 15
4.4.3 Integrated hot tap fitting
Wafer type design
Installation of the wafer type design is performed as explained
in chapter ‘Assembly of the pipe component’ on page 10 .
Welding design
DANGER
Danger to life due to improper installation!
Do not shorten hot tap fitting components or interfere with
the design. This can lead to the measuring medium escaping
in an uncontrolled manner. This can result in severe injuries or
death.
The welding version of the integrated changing device is
available in two installation lengths:
— for nominal diameters DN 100 ... DN 125 (4 ... 5") and
— for nominal diameters DN 150 ... DN 300 (6 ... 12")
NOTICE
— The sensor length his 425 mm (16.73 inch) respectively.
— The installation depth Ydepends on the pipe diameter
and must be calculated individually.
G10852
X
h
Ø50
Y
28
48
(2)
(1,1)
(1,9)
1
2
3
Fig. 13: Integrated changing device in measurement position,
dimensions in mm (inch)
1Sensor 2Centering pin 3Flow direction
Calculation of the outside length X and installation depth Y

2/ DhX 

)1.1(282/ inchmmDY 
X Outside length of the integrated changing device
Y Installation depth of the integrated changing device
h Sensor length
D Outside diameter of the pipeline
Example
— Sensor length h = 425 mm (16.73 inch)
— Pipe with external diameter of 210 mm (8.27 inch)
— The changing device is in measurement position
X = 425 mm - (210 mm / 2) = 320 mm
Y = (210 mm / 2) - 28 mm = 77 mm
Consider the following points when installing the welding
version in the piping:
— Maintain a right angle to the pipe axis (max. tolerance 2°).
— The adapter centering pin must be aligned with the pipe
axis in the flow direction (outflow side, behind the
measuring point).
NOTICE
Damage to components
If the welded joints become hot, warping of the sealing
surfaces and / or damage to the O-rings can occur.
Pause occasionally to allow the fitting to cool.
NOTICE
Impact on measuring accuracy
Deviations from the stated dimension and position tolerances
have an impact on measuring accuracy.

16 SENSYMASTER FMT230, FMT250 THERMAL MASS FLOWMETER | CI/FMT230/250-EN REV. A
4.5 Installing the sensor
When installing the sensor, observe the following points:
— Installation in the pipe component or welding adapter is
only possible if the sensor data matches the measuring
point specifications.
— The sensor may be sealed only by using the O-ring supplied
in the scope of delivery. The O-ring must be placed in the
designated groove on the sensor connection flange.
— The measuring elements may not be damaged when
inserting the sensor into the pipe component.
— If you are using an integrated changing device, you must
check that the changing device is in the disassembly
position before releasing the mounting screws.
4.5.1 Wafer type design and welding adapter
Fig. 14: Installing a sensor (example)
1Sensor 2Flange screws 3O-Ring 4Sensor connection flange
5Centering pin 6Washers and nuts
Installing the sensor:
1. Place the supplied O-ring in the groove of the sensor
connection flange.
2. Carefully slide the sensor into the pipe component. Observe
correct alignment to the centering pin in the process
3. Fasten the sensor to the sensor connection flange using
screws. Tighten the flange screws simultaneously by
applying the required torque (torque for supplied screws,
non-lubricated, without use of spring washers: 87 Nm).

SENSYMASTER FMT230, FMT250 THERMAL MASS FLOWMETER | CI/FMT230/250-EN REV. A 17
4.5.2 Installation / Disassembly in connection with the
changing device
DANGER
Danger to life due to piping under pressure!
If the changing device is in the measurement position during
disassembly of the sensor, this may pose a danger to life due
to the possibility of the sensor being ejected.
Disassemble the sensor only if the changing device is in the
disassemble position.
DANGER
Danger to life due to leaking measuring medium!
If the changing device is in the measurement position during
disassembly of the sensor or gaskets in the changing device
are damaged, leaking measuring medium may pose a danger
to life.
— Make sure that the changing device is in the disassemble
position.
— If measuring medium should start to leak in spite of this,
immediately stop disassembly of the sensor and tighten
the fastening screws.
— Drain and rinse the piping before disassembling the
sensor, check and repair the changing device.
CAUTION
Risk of injury due to leaking measuring medium!
When you disassemble the transmitter, small quantities of
measuring medium may leak due to the nature of the design.
Make sure that sufficient ventilation is ensured during
disassembly of the sensor.
NOTICE
Damage to the changing device
Using tools or other devices to operate the lock nut can
damage the hot tap fitting.
Only ever operate the lock nut manually.
Fig. 15: Sensor process connection
1O-Ring 2Connection flange 3Centering pin 4Screws to
secure the guiding pipe 5union nut
Fig. 16: Sensor Installation / Disassembly
AIntegrated changing device in disassemble position Bintegrated
changing device in measurement position
1Sensor 2Protection cap 3Union nut in disassemble position
4Union nut in measurement position 5Special screws for
protection cap

18 SENSYMASTER FMT230, FMT250 THERMAL MASS FLOWMETER | CI/FMT230/250-EN REV. A
Installation of the sensor during operation
NOTICE
The changing device must be in the disassemble position
before disassembling the sensor, the sensor process
connection is sealed.
Installing the sensor:
1. Place the supplied O-ring in the groove of the sensor
connection flange.
2. Carefully slide the sensor into the changing device. Observe
correct alignment to the centering pin in the process.
3. Fasten the sensor to the sensor connection flange using
screws. Use the supplied M12 screws, as well as two
extended special screws for this.
4. Place the protection caps onto the special screws and
tighten using two nuts.
5. Twist the transmitter with the union nut into the measuring
position. The lower edge of the union nut indicates the
position of the sensor. Only when the measuring position is
reached 50 - OPEN - MESSEN (the lower limit stop of the
union nut) will the sensor be in the middle of the piping and
precise values can be provided.
6. Carry out the electrical connection
Disassembly of the sensor during operation
Disassembly of the sensor:
1. Twist the transmitter with the union nut into the
disassemble position. The lower edge of the union nut
indicates the position of the sensor. Only when the
disassemble position is reached 0 - CLOSE - ZU (the upper
limit stop of the union nut) will the sensor be in the
disassemble position and the changing device is sealed off
from the process.
2. Disconnect electrical connections.
3. Remove protection caps.
4. Remove flange screws.
5. Carefully pull the sensor out of the changing device (do not
tip to the side).
4.6 Opening and closing the housing
WARNING
Risk of injury due to live parts!
When the housing is open, contact protection is not provided
and EMC protection is limited.
Before opening the housing, switch off the power supply.
Fig. 17: Cover safety device (example)
To open the housing, release the cover safety device by
screwing in the Allen screw 1.
After closing the housing, lock the housing cover by unscrewing
the Allen screw 1.
NOTICE
Potential adverse effect on the IP rating
— Make sure that the cover of the power supply terminals is
mounted correctly.
— Check the O-ring gasket for damage and replace it if
necessary before closing the housing cover.
— Check that the O-ring gasket is properly seated when
closing the housing cover.

SENSYMASTER FMT230, FMT250 THERMAL MASS FLOWMETER | CI/FMT230/250-EN REV. A 19
4.7 Electrical connections
WARNING
Risk of injury due to live parts.
Improper work on the electrical connections can result in
electric shock.
— Connect the device only with the power supply switched
off.
— Observe the applicable standards and regulations for the
electrical connection.
The electrical connection may only be established by authorized
specialist personnel and in accordance with the connection
diagrams.
The electrical connection information in this manual must be
observed; otherwise, the IP rating may be adversely affected.
Ground the measurement system according to requirements.
4.7.1 Installing the connecting cables
Ensure that a drip loop (water trap) is used when installing the
connecting cables for the sensor.
G12070
1
1
1
Fig. 18: Laying of the connecting cable
1Drip loop
4.7.2 Electrical connection
G12065
1+ 2- AB
+-
41
52
42 51
+
Modbus
(RS485) PA
Fig. 19: Electrical connection
PA = Functional ground (potential equalization)
Connections for the power supply
DC voltage
Terminal Function / comments
1+ +
2- -
Connections for the outputs
Terminal Function / comments
A / B Modbus RTU (RS485)
41 / 42 Passive digital output DO1
The output can be configured as a pulse output,
frequency output or switch output.
51 / 52 Passive digital output DO2
The output can be configured as a pulse output,
frequency output or switch output.
4.7.3 Electrical data for inputs and outputs
Power supply
Supply voltage 24 V DC ± 20 %
(ripple: ≤5 %)
Power consumption P ≤10 W

20 SENSYMASTER FMT230, FMT250 THERMAL MASS FLOWMETER | CI/FMT230/250-EN REV. A
Digital output 41 / 42, 51 / 52
Can be configured via Modbus.
G11597-02
A
16...30 V DC
B
RB
U
CE
I
CE
RB
U
CE
I
CE
41+
51+
IE
42-/
52-
41+
51+
IE
42-/
52-
R
B
R
B
012345
16...30 V DC
012345
R
B
Fig. 20: Passive digital outputs (I = internal, E = external)
APassive digital output 41 / 42 as pulse or frequency output, Passive
digital output 51 / 52 as pulse output BPassive digital output 51 / 52
as binary output
Pulse / frequency output (passive)
Terminals 41 / 42, 51 / 52
Output
“closed (pulse)”
0 V ≤UCEL ≤3 V
For f < 2.5 kHz: 2 mA < ICEL < 10 mA
For f > 2.5 kHz: 10 mA < ICEL < 30 mA
Output
“open (pause)”
16 V ≤UCEH ≤30 V DC
0 mA ≤ICEH ≤0.2 mA
fmax 10.5 kHz,
Pulse width 0.05 … 2000 ms
Binary output (switch output, passive)
Terminals 41 / 42, 51 / 52
Output "closed" 0 V ≤UCEL ≤3 V
2 mA ≤ICEL ≤30 mA
Output "open" 16 V ≤UCEH ≤30 V DC
0 mA ≤ICEH ≤0.2 mA
Switching function Can be configured via Modbus.
NOTICE
— Terminals 42 / 52 have the same potential. Digital outputs
41 / 42 and 51 / 52 are not electrically isolated from each
other.
4.7.4 Modbus protocol
NOTICE
The Modbus protocol is not secure, as such the intended
application should be assessed to ensure that these protocols
are suitable before implementation.
Modbus is an open standard owned and administrated by an
independent group of device manufacturers styled the Modbus
Organization (www.modbus.org).
Using the Modbus protocol allows devices made by different
manufacturers to exchange information via the same
communication bus, without the need for any special interface
devices to be used.
120 Ω
120 Ω
DR
DR
DR
A
B
GND
G11603
1
2
34
2
Fig. 21: Communication via the Modbus protocol
1Modbus master 2Terminating resistor 3Modbus slave 1
4Modbus slave n … 32
Modbus protocol
Configuration Via the Modbus interface or via the local
operating interface in connection with Asset
Vision Basic (DAT200) and a corresponding
Device Type Manager (DTM)
Transmission Modbus RTU - RS485 serial connection
Baud rate 2400, 4800, 9600, 19200, 38400, 56000,
57600, 115200 baud
Factory setting: 9600 baud
Parity None, even, odd
Factory setting: odd
Stop bit One, two
Factory setting: One
IEEE format Little endian, big endian
Factory setting: Little endian
Typical response time < 100 ms
Response delay
(Response Delay
Time)
0 ... 200 milliseconds
Factory setting: 10 milliseconds