STI FasTrak Instruction Manual

INSTRUCTION MANUAL
FasTrak®
_____________________________________________________________________________________
STI S.r.l. –Via Dei Caravaggi 15, 24040 Levate (BG) –ITALY www.imi-critical.com
Manual 4028 –rev.06 11/2018 –FT - 1 -
Instruction, installation and
maintenance manual

INSTRUCTION MANUAL
FasTrak®
_____________________________________________________________________________________
STI S.r.l. –Via Dei Caravaggi 15, 24040 Levate (BG) –ITALY www.imi-critical.com
Manual 4028 –rev.06 11/2018 –FT - 2 -
INDEX
See also addendum:
•4044 –FT Software
•4035 –Field barrier (ID)
1.0
General information
3
1.1
General warnings
3
1.2
Generalities
3
1.3
Manufacturer
3
1.4
Terms and conditions
3
1.5
Manufacturer’s liability
3
1.6
Applicable Standards and Directives
3
2.0
Description
4
2.1
Specifications for intrinsically safe execution
5
2.2
Specifications for explosion proof execution
6
2.3
Specifications for natural gas execution
6
2.4
Manufacturer’s identification
7
3.0
General safety instruction
8
3.1
Device Safety instruction
9
3.2
Installation
9
3.3
Maintenance
9
3.4
Special instructions for FT positioner intrinsically safe
10
3.5
Electromagnetic interference
11
3.6
Pneumatic safety
11
3.7
Electrical safety
11
3.8
Correct use
11
4.0
Installation
12
4.1
Pneumatic connections
12
4.2
Electrical connections
13
4.2.1
Intrinsically safe
13
4.2.2
Explosion proof
17
4.3
Mechanical feedback linkage mounting
19
5.0
Fail freeze option
21
6.0
FasTrak with remote sensor
22
6.1
Installation
22
6.2
Shield connection
22
7.0
Display interface and push buttons option
23
8.0
Dimensions
25
8.1
Intrinsically safe (aluminum case)
25
8.2
Intrinsically safe (stainless steel 316 case)
25
8.3
Intrinsically safe (display and push buttons version)
26
8.4
Explosion proof (aluminum case)
27
8.5
Explosion proof (stainless steel 316 case)
28
8.6
Explosion proof (display and push buttons version)
29

INSTRUCTION MANUAL
FasTrak®
_____________________________________________________________________________________
STI S.r.l. –Via Dei Caravaggi 15, 24040 Levate (BG) –ITALY www.imi-critical.com
Manual 4028 –rev.06 11/2018 –FT - 3 -
1.0 GENERAL INFORMATION
1.1 General warnings
Important
This Instruction Manual is an integral part of the device, it should be carefully read before
carrying out any operation and it should be kept for future references.
This Instruction Manual covers only the FT positioner.
This Instruction Manual is realized in accordance with the Directive 2006/42/CE.
1.2 Generalities
STI S.r.l. products are conceived, manufactured and controlled according to the Quality Control System in compliance
with EN ISO 9001 International Standard.
1.3 Manufacturer
With respect to Machinery Directive 2006/42/EC the Manufacturer of the described product, is STI S.r.l. as specified on
nameplate.
Address: STI S.r.l.
Via Dei Caravaggi 15
24040 Levate (Bergamo) –ITALY
1.4 Terms and conditions
STI S.r.l. guarantees each single product to be free from defects and to conform to current goods specifications. The
warranty period is one year from the date of installation by the first user, or eighteen months from the date of shipment
to the first user, whichever occurs first.
The warranty does not cover special products or components not covered by warranty in their turn by subcontractors.
No warranty is given for products which have been subject to improper storage, improper installation, misuse, or
corrosion, or which have been modified or repaired by unauthorised personnel. Repair work due to improper use will
be charged at standard rates.
1.5 Manufacturer’s liability
STI S.r.l. declines all liability in the event of:
•use of the device in contravention of local safety at work legislation;
•incorrect installation, disregard or incorrect application of the instructions provided on the nameplate and in
this manual;
•modifications without STI’s authorisation;
•work done on the unit by unqualified or unsuitable persons.
1.6 Applicable Standards and Directives
•EN ISO 12100:2010: Safety of machinery - General principles for design. Risk asses and risk reduction.
•2006/95/EC: Directive for Low Voltage Equipment (LV).
•2004/108/EC: Directive relating to the Electromagnetic Compatibility (EMC).
•2014/34/UE: Directive concerning equipment for use in potentially explosive atmospheres (ATEX).

INSTRUCTION MANUAL
FasTrak®
_____________________________________________________________________________________
STI S.r.l. –Via Dei Caravaggi 15, 24040 Levate (BG) –ITALY www.imi-critical.com
Manual 4028 –rev.06 11/2018 –FT - 4 -
2.0DESCRIPTION
The FasTrak™ positioner is a high-capacity, high-precision digital-pneumatic valve controller that replaces
conventional positioner. The FasTrak™ has several advanced control and diagnostic features.
•Excellent dynamic performance
•High precision and high flow positioner.
•Configuration and calibration through HART, serial or handheld device.
•Self calibration.
•Compatible with double and single acting actuators, with/without spring, piston or diaphragm.
•Auto tuning on control stroking time applications from 0.5 sec to 50 sec.
•Control and PID parameter independently adjustable for open and close.
•Stroking time user independently adjustable to open and to close.
•Travel limit position independently user adjustable to open and to close up to 50% of stroke.
•Tight shut off position to open and to close independently adjustable up to 50% of stroke.
•Pressure shut off to open and to close independently adjustable.
•Split range user adjustable capability.
•Travel characterization linear, eq% 25:1, 30:1, 50:1, 1:50, 1:30, 1:25, user adjustable 16 point.
•Visualization of selected characterization curve with limit and shut off by Remote Control.
•Analog output 4 20mA position.
•Two digital input user configurable to fully open or to fully close.
•Two digital output user configurable as virtual limit switch or to indicate position error or low pressure.
•Power/signal fail position mechanically configured (not software adjustable).
Fig. 1

INSTRUCTION MANUAL
FasTrak®
_____________________________________________________________________________________
STI S.r.l. –Via Dei Caravaggi 15, 24040 Levate (BG) –ITALY www.imi-critical.com
Manual 4028 –rev.06 11/2018 –FT - 5 -
2.1 Specifications for intrinsically safe
•Connections
oPOWER: 2 wires from signal (min 3.5 mA,
12÷30 Vdc –Z equivalent 550 ohm)
oELECTRICAL CONNECTION:
▪Signal ½” NPT (or metric M20x1.5 on
request)
▪Auxiliary input/output ½” NPT (or metric
M20x1.5 on request)
oPNEUMATIC CONNECTION: ½” NPT
female
oCOMUNICATION PROTOCOL: HART, TTL
RS232
•Input
oANALOG: 4÷20 mA –HARTTM
oON OFF: 2x configurable digital
(optocoupler 24 Vdc)
•Output
oANALOG: 4÷20 mA passive loop 10÷26,5 V
oON OFF: 2x configurable digital
(optocoupler 24 Vdc)
•Stroke Movement
oFEEDBACK ANGLE OF ROTATION:
30°÷120° (<30° with lower resolution)
oADJUSTABLE SPEED: range 0÷300
seconds, individually configurable for each
direction
oCHARACTERISTIC CURVE:
▪linear
▪equal percentage
▪configurable
oCONTROL PARAMETER: individually
configurable for each direction
oTRAVEL CONTROL: Min. and Max settable
stroke limits; adjustable pressure on seat
•Air supply
oINSTRUMENT AIR: free of oil, water and
dust to ISO 8573-1 –Class 3
oSUPPLY PRESSURE: 2.5÷10 bar
oAIR CONSUMPTION: 1.5 Nm3/h at 6 bar
•Performance Data (for angle > 90°)
according to IEC 61514-2
oHYSTERESIS+DEADBAND: ±0.15%
oREPEATIBILITY: ±0.15%
oSENSITIVITY: ±0.1%
oLINEARITY: ±0.3%
oINFLUENCE OF AMBIENT
TEMPERATURE: ≤0.3% for every 10°C
oFLOW CAPABILITY: 180Nm3/h at 6bar (CV
2.3)
oACTION: configurable single or double
•Environmental capabilities
oHAZARDOUS PROTECTION: ATEX II 1G
Ex ia IIC T6/T5/T4
oAMBIENT:
▪protection IP66 (NEMA 4x)
▪operation temperature: -40°C / +80°C
(-55°C / +80°C for TR CU)
▪storage temperature: -40°C / +80°C
(storehouse must be clean and dry,
absence of corrosive gases or vapours)
oHUMIDITY: up to 100%
oVIBRATIONS: up to 2g (ISA-S75.13)
oCE MARK: CE conformity and EMC
•Case materials and weights
oAluminium, low copper content with
stainless steel feedback shaft –3,25 kg
oStainless steel 316 –8,82 kg
•Options available
oFAIL FREEZE (for more information see
page 20)
oREMOTE FEEDBACK SENSOR (for more
information see page 21)
oDISPLAY AND PUSH BUTTON (only with
aluminum case) (for more information see
page 22)
oUNIVERSAL LINKAGE FOR:
▪Linear long stroke actuator
(70÷1500 mm)
▪VDE/VDI 3845 for quarter turn
applications
▪Lever for side yoke or top mounting
application
oSPECIFIC ACCESSORIES:
▪gauges
▪CF device
▪BV and BW boosters
oCOLLECTED OR HIGHLY SILENCED
EXHAUST
oHIGH SPEED COMUNICATION KIT
oHIGH CORROSION RESISTENCE WITH
316 STAINLESS STEEL CASE
*See selection guide for options / certifications available

INSTRUCTION MANUAL
FasTrak®
_____________________________________________________________________________________
STI S.r.l. –Via Dei Caravaggi 24040 Levate (BG) –ITALY www.imi-critical.com
Manual 4028 –rev.06 11/2018 –FT - 6 -
2.2 Specifications for explosion proof
•Connections
oPOWER: 2 wires from signal (min 3.6 mA,
19÷24 Vdc –Z equivalent 950 ohm)
oELECTRICAL CONNECTION:
▪Signal ½” NPT (or metric M20x1.5 on
request)
▪Auxiliary input/output ½” NPT (or
metric M20x1.5 on request)
oPNEUMATIC CONNECTION: ½” NPT
female
oCOMUNICATION PROTOCOL: HART,
TTL RS232
•Input
oANALOG: 4÷20 mA –HARTTM
•Output
oANALOG: 4÷20 mA passive loop powered
14,5÷24,5 V
•Stroke Movement
oFEEDBACK ANGLE OF ROTATION:
30°÷120° (<30° with lower resolution)
oADJUSTABLE SPEED: range 0÷300
seconds, individually configurable for each
direction
oCHARACTERISTIC CURVE:
▪linear
▪equal percentage
▪configurable
oCONTROL PARAMETER: individually
configurable for each direction
oTRAVEL CONTROL: Min. and Max
settable stroke limits; adjustable pressure
on seat
•Air supply
oINSTRUMENT AIR: free of oil, water and
dust to ISO 8573-1 –Class 3
oSUPPLY PRESSURE: 2.5÷10 bar
oAIR CONSUMPTION: 1.5 Nm3/h at 6 bar
•Performance Data (for angle > 90°)
according to IEC 61514-2
oHYSTERESIS+DEADBAND: ±0.15%
oREPEATIBILITY: ±0.15%
oSENSITIVITY: ±0.1%
oLINEARITY: ±0.3%
oINFLUENCE OF AMBIENT
oTEMPERATURE: ≤0.3% for every 10°C
oFLOW CAPABILITY: 180Nm3/h at 6bar
(CV 2.3)
oACTION: configurable single or double
•Environmental capabilities
oHAZARDOUS PROTECTION: ATEX II 2
(1) G Ex d IIC T6/T5/T4
oAMBIENT:
▪protection IP66 (NEMA 4x)
▪operation temperature: -40°C / +80°C
(-55°C / +80°C for TR CU)
▪storage temperature: -40°C / +80°C
(storehouse must be clean and dry,
absence of corrosive gases or
vapours)
oHUMIDITY: up to 100%
oVIBRATIONS: up to 2g (ISA-S75.13)
oCE MARK: CE conformity and EMC
•Case materials and weights
oAluminium, low copper content with
stainless steel feedback shaft –4,11 kg
oStainless steel 316 –10,78 kg
•Options available
Same of intrinsically safe execution (excluded
fail freeze version)
*See selection guide for options / certifications available
2.3 Specifications for natural gas execution
•Natural gas supply
oNatural gas clean and dry as ISO 8573-1 –Class 3
oSUPPLY PRESSURE: 2.5÷6 bar
oGAS CONSUMPTION: 1.5 Nm3/h at 6 bar

INSTRUCTION MANUAL
FasTrak®
_____________________________________________________________________________________
STI S.r.l. –Via Dei Caravaggi 24040 Levate (BG) –ITALY www.imi-critical.com
Manual 4028 –rev.06 11/2018 –FT - 7 -
2.4 Manufacturer’s identification
The serial number is shown in the HART panel.
(*) In the old version the year of manufacturing was indicated by the first two digits of the serial number. For example:
P141968 ➔ year of manufacturing 2014.
Fig. 2
Every FT positioner is provided with
a name plate with its serial number
and with the year of manufacturing
(*).
Year of manufacturing

INSTRUCTION MANUAL
FasTrak®
_____________________________________________________________________________________
STI S.r.l. –Via Dei Caravaggi 24040 Levate (BG) –ITALY www.imi-critical.com
Manual 4028 –rev.06 11/2018 –FT - 8 -
3.0 GENERAL SAFETY INSTRUCTIONS
In order that you can make the best use of this document and to ensure safety during commissioning, operation and
maintenance of the equipment, please note the following explanation of the symbols used: as well as the instructions
in this document, you must also follow applicable accident prevention and safety regulations.
Please read this document carefully before installation and commissioning.
Symbol definitions
DANGER_
Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. (High level of
risk)
WARNING_
Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. (Medium
level of risk)
CAUTION_
Indicates a potentially hazardous situation which, if not avoided, could result in minor or moderate injury. (Low level
of risk)
NOTE_
Indicates a potentially harmful situation which, if not avoided, may result in damage of the product itself or of
adjacent objects. (Damage to property)
Signs of warning
Be careful where these symbols are shown, they indicate a potentially hazardous situation and they warn that if the
steps are not properly performed, MAY RESULT CAUSING serious injury, death or long-term risks to the health of
exposed persons.
Safety measures
General
obligation (with
the possible
supplementary
signboard).
Must wear
protective
clothing.
Obligation to
wear protective
footwear.
Is required to
wear a helmet.
Is required to
protect the eyes.
Obligation to
protect your
hearing.
This chapter provides important instructions for your safety. Proper and safe operation of the FT positioner requires:
•proper transportation and storage;
•mounting, electrical and pneumatic installation and commissioning by qualified personnel;
•correct operation according to the instructions in this manual;
•correct use;
•careful maintenance.
GENERAL DANGER
DANGER POWER SUPPLY
CRUSHING HAZARD

INSTRUCTION MANUAL
FasTrak®
_____________________________________________________________________________________
STI S.r.l. –Via Dei Caravaggi 24040 Levate (BG) –ITALY www.imi-critical.com
Manual 4028 –rev.06 11/2018 –FT - 9 -
In order to keep the device in a safe condition and ensure safe operation, please carefully read and follow the
instructions given in the sections marked with the respective symbols.
The device must be shut down and secured reliably against unintentional restart if it must be assumed that safe
operation is no longer ensured. Possible reasons for this assumption can be:
•visible damage of the device;
•failure of the electrical function;
•exposure to a storage temperature of more than 85°C for a long time period;
•exposure to considerable strain or wear during transport.
Only the manufacturer is authorized to repair the device.
If the device is damaged or faulty do not continue use.
WARNING_
For display version do not hit the display, do not use cleaning solvent for cleaning it and do not use cutting tools
because display is composed by a sensitive diaphragm.
3.1 Device safety instructions
Observe the accident prevention rules of the H&S organizations. The non-observation of the following safety
instructions and of the instruction manuals can result in serious injury. Installation must be carried by our qualified
person.
3.2 Installation
•The electrical connections must be done according to the diagram and label.
•To achieve optimum performance from the FT Positioner, it is recommended that shielded cables be used when
installing the positioner.
•The use of a ground strap between the FT positioner housing and a suitable earthed point is necessary.
•When changing electrical connections inside the FT positioner housing, observe ESD handling precautions.
The use of a conductive, earthed, wrist strap is recommended.
•The pneumatic connections must be done according to the diagram and label, is not allow the FT Positioner
supply pressure to exceed 10 bar.
•The supply circuit must be protected to prevent the voltage or current exceeding the stated limits.
•The equipment must be provided with cable entries and filler plugs certified according to the required
certification.
•The actuator must be installed and used according to the design specification.
•The fluid must be chemically compatible with the gaskets and lubricant used in the installation.
•When FT positioner is installed in a hazardous area, ensure that electrical barriers are used between the FT
positioner and the electrical power sources.
•To prevent injuries always ensure that the air supply is removed from the FT positioner before the Mode
Selection Plate is changed.
•Only trained personnel should permitted to alter the software control parameters stored within the FT positioner
electronics. Incorrect settings may lead to personnel injury and or property damage.
3.3 Maintenance
Before making changes to the pneumatic configuration make sure that the compressed air supply is isolated from the
FT positioner and to avoid unpredictable movement of the actuator always remove the electrical power to the FT
positioner electronics before changing electrical connections.
•Must be done by qualified person.
•Cleaning must be done with a humid cloth (also for display version).
•Use instrument air. Clean and dry. Free of oil and dust according to ISO 8573-1.
Product Disposal
The disposal of this product should be carried out in a way that conforms to the 2007 Weee Directive, and any other
locally applicable directions an regulations.

INSTRUCTION MANUAL
FasTrak®
_____________________________________________________________________________________
STI S.r.l. –Via Dei Caravaggi 24040 Levate (BG) –ITALY www.imi-critical.com
Manual 4028 –rev.06 11/2018 –FT - 10 -
3.4 Special instructions for FT positioner intrinsically safe execution
In hazardous area FT positioner is to be installed with electrical barriers between the FT positioner and the electrical
power sources.
The type plate is attached to the positioner. It indicates the degree of explosion protection and the certificate valid for
your positioner. Additional electrical information are shown in the internal electronic board label.
FT positioner’s mechanical enclosure and components are suitable for installation in hazardous atmospheres.
The complete FT positioner is suitable for installation in potentially explosive atmospheres 94/9/CE ATEX directive.
II 2G Ex ia IIC T6/T5/T4
Equipment group II surface industry, category 2 for use in zone 1 with explosive atmospheres caused by gases,
vapours or mists, Group II and class of ignitability C in conformity to types of protection standardized EN 60079-0. The
component is considerated to be suitable for installation with temperature classification:
•with FT positioner supplied via connector J3, 4÷20 mA loop, only, with no connection to connectors J6, digital
input & J1 digital output or connector J10, analogue feedback:
T5 in ambient temperature -40°C / +80°C;
T6 in ambient temperature -40°C / +60°C.
•With FT positioner supplied using all of the inputs:
T4 in ambient temperature -40°C / +80°C;
T5 in ambient temperature -40°C / +60°C.
See dedicated certificate for operating temperature.
WARNING_
•Any user-made changes or manipulations of the device are prohibited! Only the manufacturer and an expert for
explosion protection are authorized to modify the device.
•Before re-using a FT positioner that has already been used in another installation place always reset the device
to the factory setting. Never start the auto adjustment function before having restored the factory setting!
Otherwise, hazardous situations may occur due to improper settings.
•Do not use the (J7) communication interface when the positioner is installed and used in the hazardous area.
WARNING_
•Do not use flammable gas mixture nor oxygen or oxygen-enriched gas as a pressure medium.
•Use cable entries and cables approved for a service temperature corresponding to the maximum ambient
temperature increased by 10 K or corresponding to the minimum ambient temperature, respectively.
3.5 Electromagnetic interference
•Do not lay signal lines close to power lines. Power lines produce interference in their near vicinity, which may
affect measured value transmission on the signal line.
•When changing electrical connections inside the FT positioner housing, observe ESD handling precautions.
The use of a conductive, earthed, wrist strap is recommended.
Fig. 3