ABB SensyMaster FMT230 User manual

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ABB MEASUREMENT & ANALYTICS | OPERATING INSTRUCTION | OI/FMT230/250-EN REV. C
SensyMaster FMT230, FMT250
Thermal mass flowmeter
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ABB Measurement & Analytics
For your local ABB contact, visit:
www.abb.com/contacts
For more product information, visit:
www.abb.com/flow
Precise and dynamic direct mass
flow measurement of gas in OEM
applications
Measurement made easy
OI/FMT230/250-EN Rev. C 12.2021
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SensyMaster FMT230
SensyMaster FMT250
Introduction
The SensyMaster FMT230 is a top-quality cost-
effective solution for the precise and direct
dynamic mass flow measurement of gases at low
and medium operating pressure levels. The model
is delivered preconfigured, ready for use by OEM
customers.
In addition, the FMT250 offers the highest level of
accuracy and extended functionality for
demanding industrial applications.
Additional Information
Additional documentation on SensyMaster FMT230,
FMT250 is available for download free of charge at
www.abb.com/flow.
Alternatively simply scan this code:
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We reserve the right to make technical changes or modify the contents of this document
without prior notice. With regard to purchase orders, the agreed particulars shall prevail.
ABB does not accept any responsibility whatsoever for potential errors or possible lack of
information in this document.
We reserve all rights in this document and in the subject matter and illustrations contained
therein. Any reproduction, disclosure to third parties or utilization of its contents – in whole
or in parts – is forbidden without prior written consent of ABB.
© ABB 2021 3KXF421014R4201

2 SensyMaster FMT230, FMT250 THERMAL MASS FLOWMETER | OI/FMT230/250-EN REV. C
Table of contents
1Safety..........................................................................4
General information and instructions..................................4
Warnings....................................................................................4
Intended use .............................................................................4
Improper use.............................................................................5
Warranty provisions.................................................................5
Cyber security disclaimer .......................................................5
Software downloads ...............................................................5
Manufacturer’s address..........................................................5
Service address.........................................................................5
2Use in potentially explosive atmospheres .............6
Device overview ........................................................................6
ATEX, IECEx and UKCA .......................................................6
cFMus ....................................................................................6
Ex marking................................................................................. 7
ATEX, IECEx and UKCA ....................................................... 7
cFMus .................................................................................... 7
Temperature data ....................................................................8
Temperature resistance for the connecting cable........8
Environmental and process conditions for model
FMT2xx… ..............................................................................8
Electrical data ......................................................................... 11
Modbus outputs and digital outputs ............................ 11
Special connection conditions........................................ 11
Installation instructions........................................................ 12
ATEX, IECEx and UKCA ..................................................... 12
cFMus .................................................................................. 12
Use in areas exposed to combustible dust .................. 12
Opening and closing the terminal box .......................... 12
Cable entries in accordance with ATEX/IECEx and
UKCA.................................................................................... 13
Cable entries in accordance with cFMus....................... 13
Electrical connections ......................................................14
Process sealing .................................................................. 14
Operating instructions.......................................................... 15
Protection against electrostatic discharges................ 15
Repair................................................................................... 15
Changing the type of protection – ATEX, IECEx and
UKCA.................................................................................... 16
Changing the type of protection – cFMus .................... 17
3Design and function ................................................ 18
Overview ..................................................................................18
Sensor.................................................................................. 18
Process connections.........................................................19
Device description .................................................................20
Measuring principle ...............................................................20
4Product identification ............................................ 21
Name plate .............................................................................. 21
Plates and symbols ................................................................ 21
5Transport and storage ............................................22
Inspection ............................................................................... 22
Transport ................................................................................ 22
Storing the device.................................................................. 22
Ambient conditions.......................................................... 22
Returning devices .................................................................. 22
6Installation................................................................23
Safety instructions ................................................................ 23
Installation conditions.......................................................... 23
Installation location and assembly................................ 23
Inlet and outlet sections.................................................. 24
Installation at high ambient temperatures.................. 24
Sensor insulation .............................................................. 24
Ambient conditions............................................................... 25
Ambient temperature ...................................................... 25
Process conditions ................................................................ 25
Measured medium temperature .................................... 25
Material loads for process connections ....................... 26
Assembly of the pipe component....................................... 26
Wafer type design (FMT091) and partial measuring
section (FMT092)................................................................... 27
Assembly of the welding adapter with flange or threaded
connector ................................................................................ 28
Welding adapter with flange connector ....................... 28
Weld-on adapter with ball valve ..................................... 29
Welding adapter with threaded connection in
accordance with DIN 11851..............................................30
Mounting .............................................................................31
Assembly of the welding adapter with compression ring
fitting ....................................................................................... 32
Mounting ............................................................................ 33
Assembly of the welding adapter with hot tap fitting ... 36
Installing the sensor.............................................................. 38
Wafer type design and welding adapter ...................... 38
Installation / Disassembly of the sensor in connection
with the hot tap fitting......................................................... 39
Safety instructions ........................................................... 39
Overview............................................................................. 39

SensyMaster FMT230, FMT250 THERMAL MASS FLOWMETER | OI/FMT230/250-EN REV. C 3
7Electrical connections.............................................43
Safety instructions.................................................................43
Installing the connection cables..........................................43
Opening and closing the housing ...................................... 44
Position of the terminals ..................................................... 44
Terminal assignment............................................................ 45
Electrical data for inputs and outputs .............................. 45
Modbus® communication............................................... 46
Cable specification ...........................................................47
Connection on the device .................................................... 48
8Commissioning and operation ..............................49
Safety instructions................................................................ 49
Write-protection switch, service LED and local operator
interface.................................................................................. 49
Checks prior to commissioning ......................................... 50
Switching on the power supply .......................................... 50
Parameterization of the device .......................................... 50
Parameterization via the Modbus interface................ 50
Parameterization via the local operating interface ....52
Interface description............................................................ 54
Register tables (overview).............................................. 54
Supported Modbus function codes ...............................55
Modbus function codes ...................................................56
Modbus error handling (exception codes) .................. 60
Modbus data types ........................................................... 61
Available units....................................................................62
Available gas types............................................................63
Available process variables............................................. 64
Application of the Health Indication Registers
(Condensed Status Registers)).......................................65
Using the scan register ....................................................65
Parameter descriptions ...................................................67
Software history................................................................91
FillMass batch function.........................................................92
Setup ...................................................................................92
Filling process run.............................................................93
9Diagnosis / error messages...................................94
General .................................................................................... 94
Overview ..................................................................................95
Alarm status and alarm history status.............................. 96
‘SensorCheck’ diagnosis function...................................... 98
Assessment of the result ................................................ 98
10Maintenance.............................................................99
Safety instructions................................................................ 99
Sensor ..................................................................................... 99
Cleaning ................................................................................ 100
Cleaning the sensor element........................................ 100
Integrated hot tap fitting .................................................. 100
11Repair ..................................................................... 102
Safety instructions .............................................................. 102
Spare parts ........................................................................... 102
Replacing the fuse ............................................................... 103
Returning devices ................................................................ 103
12Recycling and disposal......................................... 104
Dismounting.........................................................................104
Disposal................................................................................. 104
13Specification ......................................................... 105
14Additional documents.......................................... 105
15Appendix ................................................................ 106
Return form........................................................................... 106
FMT200 Installation diagram 3kxf000094G0009 ......... 107

4 SensyMaster FMT230, FMT250 THERMAL MASS FLOWMETER | OI/FMT230/250-EN REV. C
1Safety
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.
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
‘
NOTIC
E
’
indicates possible material damage.
Note
‘Note’ indicates useful or important information about the
product.
Intended use
This device can be used in the following applications:
• As an insertion sensor for flange mounting pipe
component in piping with nominal diameters
DN 25 to 200 (1 to 8 in).
• Through a welding adapter directly in piping 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 volume flows
(through standard density and mass flow).
• 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 measuring media, 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 operational security of the materials of the
wetted parts of the flowmeter sensor will not be
adversely affected during the operating time.
• 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 is able
to perform regular and suitable tests to ensure the safe
condition of the device

SensyMaster FMT230, FMT250 THERMAL MASS FLOWMETER | OI/FMT230/250-EN REV. C 5
Improper use
The following are considered to be instances of especially
improper use of the device:
• Operation as a flexible compensating adapter in piping,
for example for compensating pipe offsets, pipe
vibrations, pipe expansions, etc.
• For use as a climbing aid, for example for mounting
purposes.
• For use as a bracket for external loads, for example as a
support for piping, etc.
• Material application, for example by painting over the
housing, name plate or welding/soldering on parts.
• Material removal, for example by spot drilling the
housing.
Warranty provisions
Using the device in a manner that does not fall within the scope
of its intended use, disregarding this manual, using
underqualified personnel, or making unauthorized alterations
releases the manufacturer from liability for any resulting
damage. This renders the manufacturer's warranty null and void.
Cyber security disclaimer
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 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.
Software downloads
By visiting the web page indicated below, you will find
notifications about newly found software vulnerabilities and
options to download the latest software. It is recommended that
you visit this web page regularly:
www.abb.com/cybersecurity
Manufacturer’s address
ABB AG
Measurement & Analytics
Schillerstr. 72
32425 Minden
Germany
Tel: [phone]
Fax: [phone]
Service address
Customer service center
Tel: [phone]
Email: [email protected]

6 SensyMaster FMT230, FMT250 THERMAL MASS FLOWMETER | OI/FMT230/250-EN REV. C
2Use in potentially explosive atmospheres
Note
Further information on the approval of devices for use in potentially explosive atmospheres can be found in the type examination
certificates or the relevant certificates at www.abb.com/flow.
Device overview
ATEX, IECEx and UKCA
Standard / No explosion protection Zones 2, 22 Zone 1, 21 (Zone 0)
Model number FMT2xx Y0 FMT2xx A2, U2 FMT2xx A1, A3, U1, U4
• Standard
• Zone 2, 22
• Zone 1, 21
• Zone 0
cFMus
Standard / No explosion protection Class I Div. 2 Zone 2, 22 Class I Div. 1 Zone 1, 21
Model number FMT2xx Y0 FMT2xx F2 FMT2xx F1
• Standard
• Class I Div. 2
• Class I Div. 1
• Zone 2, 22
• Zone 1, 21

SensyMaster FMT230, FMT250 THERMAL MASS FLOWMETER | OI/FMT230/250-EN REV. C 7
Ex marking
Note
• A specific marking applies, depending on the design.
• ABB reserves the right to modify the Ex-marking. Refer to the name plate for the exact marking.
ATEX, IECEx and UKCA
Model FMT2xx-A2, U2… in Zone 2, 22
Certificate (Atex) FM19ATEX0178X
Certificate (IECEx) IECEx FMG 19.0025X
Certificate (UKCA) FM21UKEX0136X
II 3G Ex ec mc IIC T6…T2 Gc
II 3D Ex tc IIIC T85°C…Tmedium Dc
Model FMT2xx-A1, U1… in Zone 1, 21
Certificate (Atex) FM19ATEX0177X
Certificate (IECEx) IECEx FMG 19.0025X
Certificate (UKCA) FM21UKEX0135X
II 2G Ex eb ia mb IIC T6...T2 Gb
II 2G Ex ia IIC T6...T1 Gb
II 2D Ex ia tb IIIC T85°C...Tmedium Db
permitted supply short-circuit current: 35A
Model FMT2xx-A3, U4… in Zone 0, 1, 21
Certificate (Atex) FM19ATEX0177X
Certificate (IECEx) IECEx FMG 19.0025X
Certificate (UKCA) FM21UKEX0135X
II 1/2 G Ex eb ia mb IIC T6...T2 Ga/Gb
II 1G Ex ia IIC T6...T1 Ga
II 2D Ex ia tb IIIC T85°C...Tmedium Db
permitted supply short-circuit current: 35A
cFMus
Designation for model FMT2xx-F2… in Division 2
FM (marking for US)
Certificate FM19US0110X
NI: CL I, Div 2, GPS ABCD, T6...T2
NI: CL II,III Div 2, GPS EFG, T6…T3B
DIP: CL II, Div 1, GPS EFG, T6...T3B
DIP: CL III, Div 1,2, T6...T3B
CL I, ZN 2, AEx ec IIC T6...T2 Gc
ZN 21, AEx tb IIIC T85°C...T165°C Db
See handbook for temperature class information
FM (marking for Canada)
Certificate FM19CA0055X
NI: CL I, Div 2, GPS ABCD, T6...T2
NI: CL II,III Div 2, GPS EFG, T6...T3B
DIP: CL II, Div 1, GPS EFG, T6...T3B
DIP: CL III, Div 1,2, T6...T3B
CL I, ZN 2, Ex ec IIC T6...T2 Gc
Ex tb IIIC T85°C...T165°C Db
ANSI/ISA 12.27.01: Dual Seal
Designation for model FMT2xx-F1… in Division 1
FM (marking for US)
Certificate FM19US0110X
XP-IS: CL I, Div 1, GPS BCD,T6...T2
DIP: CL II,III, Div 1, GPS EFG,T6...T3B
CL I, ZN 1, AEx db ia IIB+H2 T6...T2 Ga/Gb
ZN21, AEx ia tb IIIC T85°C...T165°C Db
Permitted supply short-circuit current: 35A
See handbook for temperature class information and installation drawing
3kxf000094G0009
FM (marking for Canada)
Certificate FM19CA0055X
XP-IS: CL I, Div 1, GPS BCD,T6...T2
DIP: CL II,III, Div 1, GPS EFG,T6...T3B
CL I, ZN 1, Ex db ia IIB+H2 T6...T2 Ga/Gb
Ex ia tb IIIC T85°C...T165°C Db
IN-/OUTPUTS: Urated=30V
Ex ia INTRINSICALLY SAFE
SECURITE INTRINSEQUE

8 SensyMaster FMT230, FMT250 THERMAL MASS FLOWMETER | OI/FMT230/250-EN REV. C
… 2 Use in potentially explosive atmospheres
Temperature data
Temperature resistance for the connecting cable
The temperature at the cable entries of the device is dependent
on the measuring medium temperature Tmedium and the ambient
temperature Tamb..
For the electrical connection of the device, use only cables with
sufficient temperature resistance in accordance with the
following table.
Tamb. Temperature resistance for the connecting cable
≤50 °C (≤122 °F) ≥70 °C (≥158 °F)
≤60 °C (≤140 °F) ≥80 °C (≥176 °F)
≤70 °C (≤158 °F) ≥90 °C (≥194 °F)
From an ambient temperature of Tamb. ≥60 °C (≥140 °F), the
wires in the connection boxes with the enclosed silicone hoses
need to be additionally insulated.
Note
The signal cable supplied by ABB can be used without
restrictions up to an ambient temperature of ≤80 °C (≤176 °F).
Environmental and process conditions for model
FMT2xx…
Ambient temperature Tamb. −20 to 70 °C (−4 to 158 °F)
−40 to 70 °C (−40 to 158 °F)*
Measuring medium temperature
Tmedium
−20 to 150 °C (−4 to 302 °F)
−40 to 150 °C (−40 to 302 °F)*
IP rating / NEMA rating IP 65, IP 67 / NEMA 4X,Type 4X
* Low temperature design (optional)

SensyMaster FMT230, FMT250 THERMAL MASS FLOWMETER | OI/FMT230/250-EN REV. C 9
Measuring medium temperature (Ex data) for model FMT2x0-A1… in Zone 1, Zone 21
The table shows the maximum permissible measuring medium temperature as a function of ambient temperature and temperature
class. The permissible measuring medium temperature specified in Environmental and process conditions for model FMT2xx… must
not be up-scaled!
Temperature class
Ambient temperature Tamb. T1 T2 T3 T4 T5 T6
−40 °C to 40 °C
(−40 °F to 104 °F) 280 °C (536 °F) 185 °C (365 °F) 90 °C (194 °F) 90 °C (194 °F) — —
−40 °C to 50 °C
(−40 °F to 122 °F) 280 °C (536 °F) 185 °C (365 °F) 90 °C (194 °F) 90 °C (194 °F) — —
−40 °C to 60 °C
(−40 °F to 140 °F) 280 °C (536 °F) 185 °C (365 °F) 90 °C (194 °F) 90 °C (194 °F) — —
−40 °C to 70 °C
(−40 °F to 158 °F) 280 °C (536 °F) 185 °C (365 °F) 90 °C (194 °F) 90 °C (194 °F) — —
Measuring medium temperature (Ex data) for model FMT2x0-A2… in Zone 2, Zone 22
The table shows the maximum permissible measuring medium temperature as a function of ambient temperature and temperature
class. The permissible measuring medium temperature specified in Environmental and process conditions for model FMT2xx… must
not be up-scaled!
Temperature class
Ambient temperature Tamb. T1 T2 T3 T4 T5 T6
−40 °C to 40 °C
(−40 °F to 104 °F) 300 °C (572 °F) 290 °C (554 °F) 195 °C (383 °F) 130 °C (266 °F) 95 °C (203 °F) 80 °C (176 °F)
−40 °C to 50 °C
(−40 °F to 122 °F) 300 °C (572 °F) 290 °C (554 °F) 195 °C (383 °F) 130 °C (266 °F) 95 °C (203 °F) —
−40 °C to 60 °C
(−40 °F to 140 °F) 300 °C (572 °F) 290 °C (554 °F) 195 °C (383 °F) 130 °C (266 °F) — —
−40 °C to 70 °C
(−40 °F to 158 °F) 300 °C (572 °F) 290 °C (554 °F) 195 °C (383 °F) 130 °C (266 °F) — —

10 SensyMaster FMT230, FMT250 THERMAL MASS FLOWMETER | OI/FMT230/250-EN REV. C
… 2 Use in potentially explosive atmospheres
… Temperature data
Measuring medium temperature (Ex data) for model FMT2x0-F1… in Class I Division 1 and Class II Division 1
The table shows the maximum permissible measuring medium temperature as a function of ambient temperature and temperature
class. The permissible measuring medium temperature specified in Environmental and process conditions for model FMT2xx… on
page 8 must not be up-scaled!
Temperature class
Ambient temperature Tamb. T1 T2 T3 T4 T5 T6
−40 °C to 40 °C
(−40 °F to 104 °F) 280 °C (536 °F) 185 °C (365 °F) 90 °C (194 °F) 90 °C (194 °F) — —
−40 °C to 50 °C
(−40 °F to 122 °F) 280 °C (536 °F) 185 °C (365 °F) 90 °C (194 °F) 90 °C (194 °F) — —
−40 °C to 60 °C
(−40 °F to 140 °F) 280 °C (536 °F) 185 °C (365 °F) 90 °C (194 °F) 90 °C (194 °F) — —
−40 °C to 70 °C
(−40 °F to 158 °F) 280 °C (536 °F) 185 °C (365 °F) 90 °C (194 °F) 90 °C (194 °F) — —
Measuring medium temperature (Ex data) for model FMT2x0-F1… in Class I Division 2 and Class II Division 2
The table shows the maximum permissible measuring medium temperature as a function of ambient temperature and temperature
class. The permissible measuring medium temperature specified in Environmental and process conditions for model FMT2xx… on
page 8 must not be up-scaled!
Temperature class
Ambient temperature Tamb. T1 T2 T3 T4 T5 T6
−40 °C to 40 °C
(−40 °F to 104 °F) 300 °C (572 °F) 290 °C (554 °F) 195 °C (383 °F) 130 °C (266 °F) 95 °C (203 °F) 80 °C (176 °F)
−40 °C to 50 °C
(−40 °F to 122 °F) 300 °C (572 °F) 290 °C (554 °F) 195 °C (383 °F) 130 °C (266 °F) 95 °C (203 °F) —
−40 °C to 60 °C
(−40 °F to 140 °F) 300 °C (572 °F) 290 °C (554 °F) 195 °C (383 °F) 130 °C (266 °F) — —
−40 °C to 70 °C
(−40 °F to 158 °F) 300 °C (572 °F) 290 °C (554 °F) 195 °C (383 °F) 130 °C (266 °F) — —

SensyMaster FMT230, FMT250 THERMAL MASS FLOWMETER | OI/FMT230/250-EN REV. C 11
Electrical data
Modbus outputs and digital outputs
Model ATEX/IECEx: FMT2xx-A1…, FMT2xx-A2…, FMT2xx-A3…
Model cFMus: FMT2xx-F1…, FMT2xx-F2…
Operating values Type of protection
(general) ‘Ex ec’ / ‘NI’
(Zone 2, 22)
(Div. 2, Zone 2)
‘Ex e’ / ‘XP’
(Zone 1, 21)
(Div. 1, Zone 1)
‘Ex ia’ / ‘IS’
(Zone 1, 21)
(Div. 1, Zone 1)
Outputs UN[V] IN[mA] UN[V] IN[mA] UM[V] IM[mA] UO[V] IO[mA] PO[mW] CO[nF] CO
p
a[nF] LO[µH]
Modbus, active
Terminals A / B
30 30
30 30 30 100
4,2 150 150 13900 — 20
Ui [V] Ii[mA] Pi[mW] Ci[nF] Cipa [nF] Li[µH]
4,2 150 150 13900 — 20
Digital output DO1, passive
Terminals 41 / 42
30 30
30 30 30 100 30 25 187 20 — 200
Digital output DO2, passive
Terminals 51 / 52
30 30
30 30 30 100 30 25 187 20 — 200
All outputs are electrically isolated from each other and from the power supply.
Digital outputs DO1 / DO2 are not electrically isolated from each other. Terminals 42 / 52 have the same potential.
Special connection conditions
Note
If the protective earth (PE) is connected in the flowmeter's
terminal box, you must ensure that no dangerous potential
difference can arise between the protective earth (PE) and the
potential equalization (PA) in areas with explosion risk.
The output circuits are designed so that they can be connected
to both intrinsically-safe and non-intrinsically-safe circuits.
• Combining intrinsically safe and non-intrinsically safe circuits
is not permitted.
• On intrinsically safe circuits, potential equalization should be
established along the entire length of the cable used for the
signal outputs.
• The rated voltage of the non-intrinsically safe circuits is
UM= 30 V.
• Intrinsic safety is preserved If the rated voltage UM= 30 V is
not up-scaled when connections are established to non-
intrinsically safe external circuits.
• The information in Changing the type of protection – ATEX,
IECEx and UKCA on page 16 must be observed when
changing the type of protection.

12 SensyMaster FMT230, FMT250 THERMAL MASS FLOWMETER | OI/FMT230/250-EN REV. C
… 2 Use in potentially explosive atmospheres
Installation instructions
ATEX, IECEx and UKCA
The installation, commissioning, maintenance and repair of
devices in potentially explosive atmospheres must only be
carried out by appropriately trained personnel. Works may be
carried out only by persons, whose training has included
instructions on different types of protection and installation
techniques, concerned rules and regulations as well as general
principles of zoning. The person must possess the appropriate
competences for the type of work to be conducted.
When operating with combustible dusts, comply with
EN 60079-31.
Observe the safety instructions for electric apparatus for
potentially explosive atmospheres in accordance with Directive
2014/34/EU (ATEX) or British Regulations (UKCA) and
for example IEC 60079-14 (installation of electric equipment in
potentially explosive atmospheres).
Comply with the applicable regulations for the protection of
employees to ensure safe operation.
It is essential that the temperature classes as per the approvals
in ‘Temperature data on page 8’ are observed.
The information in the installation diagram 3kxf000094G0009
on page 107 must be observed.
cFMus
The installation, commissioning, maintenance and repair of
devices in areas with explosion hazard must only be carried out
by appropriately trained personnel.
The operator must strictly observe the applicable national
regulations with regard to installation, function tests, repairs,
and maintenance of electrical devices. (e. g. NEC, CEC).
It is essential that the temperature classes as per the approvals
in ‘Temperature data on page 8’ are observed.
The information in the installation diagram 3kxf000094G0009
on page 107 must be observed.
Use in areas exposed to combustible dust
When using the device in areas exposed to combustible dusts
(dust ignition), the following points must be observed:
• The maximum surface temperature of the device may not
up-scale 85 °C (185 °F).
• The process temperature of the attached piping may up-
scale 85 °C (185 °F).
• Approved dust-proof cable glands must be used when
operating in Zone 21, 22 or in Class II, Class III.
Opening and closing the terminal box
DANGER
Danger of explosion if the device is operated with the
transmitter housing or terminal box open!
Before opening the transmitter housing or the terminal box,
note the following points:
• A valid fire permit must be present.
• Make sure that there is no explosion hazard.
• Switch off the power supply and wait for t > 20 minutes
before opening.
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.
See also Opening and closing the housing on page 44.
Only original spare parts must be used to seal the housing.
Note
Spare parts can be ordered from ABB Service.
www.abb.com/contacts

SensyMaster FMT230, FMT250 THERMAL MASS FLOWMETER | OI/FMT230/250-EN REV. C 13
Cable entries in accordance with ATEX/IECEx and UKCA
The cable glands supplied are ATEX-/IECEx-certified.
The use of standard cable glands and seals is prohibited.
The black plugs in the cable fittings are intended to provide
protection during transport. Any unused cable entries must be
sealed prior to commissioning, using the seals supplied.
The outside diameter of the connection cable must measure
between 6 mm (0.24 in) and 12 mm (0.47 in) to guarantee the
required tightness.
Black cable fittings are installed by default when the device is
supplied. If signal outputs are connected to intrinsically safe
circuits, replace the black cap on the corresponding cable gland
with the blue one supplied.
Note
In order to provide the required temperature resistance, devices
in the low-temperature design (optional – in preparation,
ambient temperature up to −40 °C [40 °F]) are delivered with
metal cable glands.
These are then also to be used in intrinsically safe circuits.
Cable entries in accordance with cFMus
1Transport protection plugs
Figure 1: Cable entry
The devices are delivered with ½ in NPT threads with transport
protection plugs.
• Unused cable entries must be sealed off prior to
commissioning using either approved pipe fittings or cable
glands in accordance with national regulations (NEC, CEC).
• Make sure that the pipe fittings, cable glands and, if
applicable, sealing plugs are installed properly and are leak-
tight.
• If the device is to be operated in areas with combustible
dusts, a threaded pipe connection or cable gland with
suitable approval must be used.
• The use of standard cable glands and closures is prohibited.
Note
Devices which are certified for use in North America are supplied
with a ½ in. NPT thread only and without cable glands.

14 SensyMaster FMT230, FMT250 THERMAL MASS FLOWMETER | OI/FMT230/250-EN REV. C
… 2 Use in potentially explosive atmospheres
… Installation instructions
Electrical connections
Note
The temperature at the cable entries of the device depends on
the design, the measuring medium temperature Tmedium and the
ambient temperature Tamb..
For the electric connection of the device, use only cables with
sufficient temperature resistance in accordance with the tables
at Temperature resistance for the connecting cable on page 8.
Grounding
The sensor must be grounded in accordance with the applicable
international standards.
Perform grounding of the device in accordance with Terminal
assignment on page 45.
In accordance with NEC standards, an internal ground
connection is present in the device between the sensor and the
transmitter.
Perform grounding of the device in accordance with Terminal
assignment on page 45.
Process sealing
In accordance with ‘North American Requirements for Process
Sealing between Electrical Systems and Flammable or
Combustible Process Fluids’.
Note
The device is suitable for use in Canada.
• For use in Class II, Groups E, F and G, a maximum surface
temperature of 165 °C (329 °F) may not be up-scaled.
• All cable (conduits) should be sealed from the device within a
distance of 18 in (457 mm).
ABB flowmeters are designed for the worldwide industrial
market and are suitable for functions such as the measurement
of flammable and combustible liquids and can be installed in
process pipes.
Connecting devices with cable (conduits) to the electric
installation makes it possible for measuring media to reach the
electric system.
To prevent measuring media from seeping into the electric
installation, the devices are equipped with process gaskets
which meet requirements in accordance with ANSI / ISA 12.27.01.
SensyMaster flowmeters are designed as ‘Dual Seal Devices’.
In accordance with the requirements of standard
ANSI / ISA 12.27.01, the existing operating limits of temperature,
pressure and pressure bearing parts must be reduced to the
following limit values:
Limit values
Flange or pipe material No limitations
Nominal sizes DN 25 to 2000 (1 to 78 in)
Operating temperature
– Standard design
– Low temperature design
−20 °C to 150 °C (−4 °F to 302 °F)
−40 °C to 150 °C (−40 °F to 302 °F)
Process pressure PN 40 / Class 300

SensyMaster FMT230, FMT250 THERMAL MASS FLOWMETER | OI/FMT230/250-EN REV. C 15
Operating instructions
Protection against electrostatic discharges
DANGER
Risk of explosion!
The painted surface of the device can store electrostatic
charges.
As a result, the housing can form an ignition source due to
electrostatic discharges in the following conditions:
• The device is operated in environments with a relative
humidity of ≤30 %.
• The painted surface of the device is thereby relatively free
from impurities such as dirt, dust or oil.
• Instructions on avoiding ignition in potentially explosive
environments due to electrostatic discharges in
accordance with PD CLC/TR 60079-32-1 and IEC TS 60079-
32-1 must be complied with!
Instructions on cleaning
The painted surface of the device must be cleaned only using a
moist cloth.
Devices which are approved for use in potentially explosive
atmospheres have an additional warning plate.
1Warning – Do not open in a flammable or potentially explosive
atmosphere.
1WARNING! – Danger due to electrostatic discharge.
Figure 2: Warning signs on the device
Repair
Contact ABB before commencing repair work.

16 SensyMaster FMT230, FMT250 THERMAL MASS FLOWMETER | OI/FMT230/250-EN REV. C
… 2 Use in potentially explosive atmospheres
… Operating instructions
Changing the type of protection – ATEX, IECEx and UKCA
When installing in Zone 1, the Modbus interface and digital outputs of the FMT230/250 models can be operated with different types
of protection:
• Modbus interface and digital output with intrinsically safe ia design
• Modbus interface and digital output in non-intrinsically safe design
If a device that is already operational is operated with a different type of protection, the following measures must be
implemented/insulation checks performed in accordance with applicable standards.
Original installation New installation Necessary test steps
Zone 1:
Modbus interface and digital
outputs in non-intrinsically safe
design
Zone 1:
Modbus interface and digital
outputs in intrinsically safe
ia / IS design
• 500 × 1.414 = 710 V DC/1min
Test between terminals A / B, 41 / 42 as well as 51 / 52 and the terminals A, B, 41, 42, 51 and
the housing. When this test is performed, no voltage flashover is permitted in or on the
device.
• Optical evaluation particularly of the electronic circuit boards, no visible damage or evidence
of explosion.
Zone 1:
Modbus interface and digital
outputs in intrinsically safe
ia(ib) / IS design
Zone 1:
Modbus interface and digital
outputs in non-intrinsically safe
design
• Visual inspection, no damage visible on the threads (cover, ½ in NPT cable glands).
Note
For further details on explosion protection, types of protection and device models, refer to the installation diagram in the annex!

SensyMaster FMT230, FMT250 THERMAL MASS FLOWMETER | OI/FMT230/250-EN REV. C 17
Changing the type of protection – cFMus
The Modbus interface and the digital outputs of the models FMT230/250 can be operated with different types of protection:
• When connecting to an intrinsically safe circuit in Div. 1 as an intrinsically safe device (IS).
• When connecting to a non-intrinsically safe circuit in Div. 1 as a device with flameproof enclosure (XP).
• When connecting to a non-intrinsically safe circuit in Div. 2 as a non-sparking device (NI).
If a device that is already operational is operated with a different type of protection, the following measures must be
implemented/insulation checks performed in accordance with applicable standards.
Original installation New installation Necessary test steps
Housing: XP, Umax = 30 V
Outputs non IS
Housing: XP
Outputs: IS
• 500 × 1.414 = 710 V DC/1min
Test between terminals A / B, 41 / 42 as well as 51 / 52 and the terminals A, B, 41, 42, 51 and
the housing. When this test is performed, no voltage flashover is permitted in or on the
device.
• Optical evaluation particularly of the electronic circuit boards, no visible damage or evidence
of explosion.
Housings: Div 2
Outputs: NI
• 500 × 1.414 = 710 V DC/1min
Test between terminals A / B, 41 / 42 as well as 51 / 52 and the terminals A, B, 41, 42, 51 and
the housing. When this test is performed, no voltage flashover is permitted in or on the
device.
• Optical evaluation particularly of the electronic circuit boards, no visible damage or evidence
of explosion.
Outputs: IS
Housing: XP
Housing: XP
Outputs: non IS
• Visual inspection, no damage visible on the threads (cover, ½ in NPT cable glands).
Housing: XP
Outputs: NI
• No special measures.
Housing: XP, Umax = 30 V
Outputs: NI
Housing: XP
Outputs: IS
• 500 × 1.414 = 710 V DC/1min
Test between terminals A / B, 41 / 42 as well as 51 / 52 and the terminals A, B, 41, 42, 51 and
the housing. When this test is performed, no voltage flashover is permitted in or on the
device.
• Optical evaluation particularly of the electronic circuit boards, no visible damage or evidence
of explosion.
Housing: XP
Outputs: non IS
• Visual inspection, no damage visible on the threads (cover, ½ in NPT cable glands).
Note
For further details on explosion protection, types of protection and device models, refer to the installation diagram in the annex!

18 SensyMaster FMT230, FMT250 THERMAL MASS FLOWMETER | OI/FMT230/250-EN REV. C
3Design and function
Overview
Sensor
Figure 3: Sensor FMT230, FMT250 (example)
Model FMT230 FMT250
Measuring media Gas and gas mixtures with known composition, see table Available gas types on page 63
Measuring accuracy for gases*
Air
±1.2 % of Qm in the range of 10 to 100 % of the standard
measuring range;
±0.12 % of the QmaxDN possible in the nominal diameter in
the range of 0 to 10 % of the measuring range
±0.6 % of the measured value ± 0.05 % of the QmaxDN
possible in the nominal diameter
Other gases
(with optional operating gas calibration)
— ±1.6 % of the measured value ±0.1 % of the QmaxDN
possible in the nominal diameter
Extended measuring range Yes, optional (depending on the gas type, with limited
measuring accuracy possibly)
Yes, optional (depending on the gas type, with limited
measuring accuracy possibly)
Measuring medium temperature Tmedium Standard and explosion-proof design:
−20 to 150 °C (−4 to 302 °F)
Standard and explosion-proof design:
−20 to 150 °C (−4 to 302 °F)
Temperature information for high temperature**, low temperature and DVGW design, see Measured medium
temperature on page 25.
Ambient temperature Tambient Standard: −20 to 70 °C (−4 to 158 °F)
Optional: −40 to 70 °C (−40 to 158 °F)
Sensor connection
1
Flange DN 25 – PN 40, threaded connection DIN 11851, compression fitting
Wetted materials Stainless steel, ceramic sensor element
Power supply 24 V DC, ±20 %
IP rating In accordance with EN 60529: IP 65 / IP 67
NEMA rating In accordance with NEMA 4X
Communication Modbus® RTU, RS485
Outputs in serial production Two passive digital outputs
ApplicationSelector Yes, up to 2 applications Yes, up to 8 applications
Preconfigured applications Yes, up to 2 applications Yes, up to 4 applications
Freely configurable applications No Yes, up to 4 applications
Selectable nominal diameters Yes Yes
Selectable gas type No Yes
Filling function No Yes, optional
"VeriMass" diagnosis function Yes, optional Yes, optional
Approvals and certificates
ATEX/IECEx/UKCA explosion protection Zone 0, 1, 2, 21, 22 Zone 0, 1, 2, 21, 22
Explosion protection conforming to cFMus Class I Div. 1, Class I Div. 2, Zone 1, 2, 21 Class I Div. 1, Class I Div. 2, Zone 1, 2, 21
Additional approvals Available on our website abb.com/flow or on request
* The stated measuring accuracy only applies under the reference conditions in the stated standard measuring range.
** Not in connection with explosion-proof design.

SensyMaster FMT230, FMT250 THERMAL MASS FLOWMETER | OI/FMT230/250-EN REV. C 19
Process connections
FMT091 – Wafer type design FMT094 – Weld-on adapter FMT094 – Weld-on adapter with clamp ring threading
FMT092 – Partial measuring section
Figure 4: Pipe components (examples)
Pipe components
FMT091 – Wafer type design In accordance with EN 1092-1: DN 40 to 200, PN 40
In accordance with ASME B16.5: 1½ to 8 in, CL 150 to 300
FMT092 – Partial measuring section Flange in accordance with EN 1092-1: DN 40 to 100 (larger nominal diameters on request), PN 10 to 40
Flange in accordance with ASME B16.5: 1½ to 8 in, CL 150 to 300
Male thread DN 25 to 80, R1 to 3 in
FMT094 – Weld-on adapter For rectangular ducts or pipe diameters ≥DN 80 (3 in.), PN 16 to 40
Wetted materials
Stainless steel, galvanized

20 SensyMaster FMT230, FMT250 THERMAL MASS FLOWMETER | OI/FMT230/250-EN REV. C
… 3 Design and function
Device description
The SensyMaster FMT230, FMT250 works in accordance with the
measuring principle of a hot-film anemometer. This
measurement method allows for direct measurement of the gas
mass flow.
Taking into account the standard density, the norm volume flow
can be displayed without the need for additional pressure and
temperature compensation.
The device is equipped with a Modbus® interface and two fast
digital outputs that can be configured as pulse, frequency or
binary outputs.
The SensyMaster FMT230, FMT250is used in the process
industry for the flow measurement of gases and gas mixtures.
ASensor
BPipe component
CSensor with pipe component
1Transmitter
2Sensor connection
3Thermal sensor elements
Figure 5: Sensor (example, wafer type design)
The SensyMaster FMT230, FMT250 is composed of the
components sensor and pipe component (process connection).
The pipe component can be delivered in various designs. In
addition, a weld-on adapter makes it possible to install the
flowmeter sensor in rectangular ducts or pipelines with any
diameter.
Measuring principle
Thermal flow metering procedures use different ways to
evaluate the flow dependent cooling of a heated resistor as
measuring signal.
In a hotfilm anemometer with constant temperature difference
control, the heated platinum resistor is maintained at a constant
overtemperature in relation to an unheated platinum sensor
inside the gas flow.
The heating power required for maintaining the
overtemperature depends directly on the flow rate and the
material properties of the gas. With a known (and constant) gas
composition the mass-flow can be determined by electronically
evaluating the heater current / mass-flow curve without
additional pressure and temperature compensation.
Together with the standard density of the gas this results
directly in the standard volume flow.
Considering the high measuring range dynamics up to 1:100, an
accuracy smaller than 1 % of the measuring value is achieved.
1 Transmitter
2 Gas temperature measurement
resistor
3 Heating resistor
Figure 6: Measuring principle (simplified)
The transmitter has three signals available. In addition to the
heating power, the temperatures of the measuring medium and
the heater resistance are included herein, which can be used to
compensate the temperature dependency of gas parameters.
By storing the gas data in the transmitter the optimal tailoring
can be calculated and performed at any operating point.