Sick FLOWSIC100 Flare-XT - Ultrasonic Mass Flow Measuring Device Operating instructions
SICK FLOWSIC100 Flare-XT - Ultrasonic Mass Flow Measuring Device is a device for non-intrusive and precise measurement of mass flow, standard volume flow, temperature, and pressure. It is designed for use in the flare gas and process gas industry as well as for custody transfer applications. The device is well-suited for the precise measurement of mass flow in large diameter pipes and can be used with gases over a wide temperature range. It provides reliable and accurate measurement, even under harsh conditions, and is designed for easy installation and maintenance.
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FLOWSIC100 Flare-XT
Ultrasonic Mass Flow Measuring Device
Installation
Operation
Maintenance
O P E R A T I N G I N S T R U C T I O N S
Document information
Described product
Product name: FLOWSIC100 Flare-XT
Document identification
Title: Operating Instructions FLOWSIC100 Flare-XT
Part No.:
Version:
Release:
8023761
1-0
2020-10
Manufacturer
SICK Engineering GmbH
Bergener Ring 27 · D-01458 Ottendorf-Okrilla · Germany
Phone:
Fax:
E-Mail:
+49 35205 52410
+49 35205 52450 [email protected]
Original document
The English version 8023761 of this document is an original document from SICK Engineering GmbH.
SICK Engineering GmbH assumes no liability for the correctness of an unauthorized translation.
Please contact SICK Engineering GmbH or your local representa tive in case of doubt.
Legal information
Subject to change without notice.
© SICK Engineering GmbH. All rights reserved.
Warning symbols
IMMEDIATE HAZARD of severe injuries or death
Hazard (general)
Voltage hazard
Hazard in potentially explosive atmospheres
Hazard through explosive substances/substance mix tures
Hazard by noxious substances
Hazard by toxic substances
Warning levels/signal words
DANGER
Risk or hazardous situation which will result in severe personal injury or death.
WARNING
Risk or hazardous situation which could result in severe personal injury or death.
CAUTION
Hazard or unsafe practice which could result in less severe or minor injuries.
NOTICE
Hazard which could result in property damage.
Information symbols
Important technical information for this product
Supplementary information
Link referring to information at another place
2 FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH
Contents Contents
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About this document
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Function of this document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Scope of application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Target groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Data integrity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Further information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
For your safety
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Basic safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
System description
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
System components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Functional principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
System overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
System configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
ASC technology (patented) – active sound correlation technology
(optionally available) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Project planning
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Determining the measuring and installation location for FLSE100-XT . . . . . . . . . . . . . 23
General requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Additional requirements for optional spool piece . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Installation location for external pressure and temperature transmitters (option) 24
Applications with wet gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Clearance for fitting and removing the sender/receiver units . . . . . . . . . . . . . . . . . . 25
Determining the installation location of the Interface Unit . . . . . . . . . . . . . . . . . . . . . . . 26
Installation location requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Clearance for fitting the Interface Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Installation FLSE100-XT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Hazards due to hot, cold (cryogenic) or aggressive gases, or high pressure . . . . . 28
Hazard through electrical equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Hazards through explosive or ignitable gases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Hazards through electrostatic discharges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Retraction mechanism of the sender/receiver units . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Operation in potentially explosive atmospheres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Specific conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Use of FLSE100-XT, depending on the temperature code and process temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Permissible gas temperature, depending on the temperature code of the sender/receiver units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Warning information on device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Requirements on the personnel's qualification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Restrictions on use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH 3
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Contents
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Product description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Product identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Sender/receiver units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Material for parts with process gas contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Spool piece option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Transport and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Transport protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Special notes for handling the spool piece option . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Fitting the spool piece (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Installation sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Geometry calculator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Installation accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Nozzles, blind flanges and seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Ball valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Nozzle installation tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Fitting the nozzles on the pipeline
(measuring system without spool piece option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
General preparation work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Determining the nozzle position for cross-duct versions . . . . . . . . . . . . . . . . . . . 54
Determining the nozzle position for the probe version . . . . . . . . . . . . . . . . . . . . . 56
Welding the nozzle on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Fitting the sender/receiver units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Calculating the wetted part length wL and geometric installation parameters 65
Tightening the self-cutting ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Installing the sender/receiver units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Leak tightness check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Pulling the sender/receiver units back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Fitting the venting valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Fitting the weatherproof cover for the sender/receiver unit . . . . . . . . . . . . . . . . . . . 77
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Fitting the weatherproof cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
General instructions, prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Cable specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Cable glands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Requirements for installation in the Ex zone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Connection overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Connection diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Installation Interface Unit
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Hazard through electrical equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Hazard through electromagnetic interference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Hazards through explosive or ignitable gases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Hazards through electrostatic discharges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Operation in potentially explosive atmospheres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Warning information on device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Requirements on the personnel's qualification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Restrictions on use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH
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Product description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Product identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Type code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Device components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Device description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Basic equipment of mainboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
I/O module definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Tools required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Fitting the Interface Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Wall fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Option “Mounting kit 2-inch pipe mounting” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Fitting the weatherproof cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
Weatherproof cover for Interface Unit for wall fitting . . . . . . . . . . . . . . . . . . . . . .100
Weatherproof cover for Interface Unit for fitting on a 2-inch pipe . . . . . . . . . . .101
Fitting the tag plate (available as option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104
Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106
Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106
Cable specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106
Cable glands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107
Requirements for installation in the Ex zone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108
Electrical connections of the Interface Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110
Overview of electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110
Device module configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111
Connection area for field-side wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112
Connection assignment of I/O modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114
Electronics cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
Switching (Open Collector - Namur) on digital modules . . . . . . . . . . . . . . . . . . . . . . .116
Termination resistors of serial RS485 lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
Internal fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117
Torque values for screw connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .118
Connecting shielding terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119
Commissioning FLOWSIC100 Flare-XT
. . . . . . . . . . . . . . . . . . . . . . . . .121
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122
Opening the display protective flap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122
Setting the display language . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122
Commissioning with the FLOWgate TM operating software . . . . . . . . . . . . . . . . . . . . . . .123
Connect to the device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123
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Field setup wizard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Path setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
System/archives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Pressure/temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
I/O configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Ethernet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
RS485/RS232 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
DI/DO (layout depending on the selected configuration) . . . . . . . . . . . . . . . . . . 128
AI/AO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
FFBUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Molar mass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Algorithm for calculating the molar mass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Compressibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
User Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Completion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Function checks after commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Operation
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Operating concept . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Display and operating elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Display in the symbol bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Menu navigation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Status LEDs on the mainboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Maintenance
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Routine checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Function check on the display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Function check with FLOWgate TM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
i-diagnostics TM Software-Plug-in (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
One-click verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Trend analysis – predictive maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Cleaning the FLSE100-XT sender/receiver units . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Cleaning the Interface Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Exchanging the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Battery types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Troubleshooting
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Detecting malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Error signaling on the display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Contacting Customer Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Starting a diagnostic session . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH
Contents
12
11
13
14
15
Decommissioning
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .151
Returning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .152
Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .152
Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .152
Disposal information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .152
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .152
Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .152
Technical data
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .153
System FLOWSIC100 Flare-XT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .154
FLSE100-XT sender/receiver units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155
F1F-S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155
F1F-M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .156
F1F-H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .156
F1F-P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .157
Interface Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .158
Application Evaluation Datasheet (example) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .162
Applications of FLOWSIC100 Flare-XT in a regulated environment . . . . . . . . . . . . . . .163
Application ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .163
Derating pressure resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .165
Dimension drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .167
Dimension drawings of FLSE100-XT sender/receiver units . . . . . . . . . . . . . . . . . . .167
Dimension drawings Interface Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .169
Spare parts
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .171
Recommended spare parts for FLSE100-XT sender/receiver units . . . . . . . . . . . . . .172
Recommended spare parts for Interface Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .172
Accessories (optional)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .173
Accessories for FLSE100-XT sender/receiver units . . . . . . . . . . . . . . . . . . . . . . . . . . . . .174
Accessories for Interface Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .174
Annex
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .175
Compliances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .176
Compliances of FLSE100-XT sender/receiver units . . . . . . . . . . . . . . . . . . . . . . . . . .176
CE declaration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .176
Standards compatibility and type approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .176
Compliances of Interface Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .176
CE declaration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .176
Standards compatibility and type approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .177
Wiring examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .178
Control drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .180
Gasket installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .185
FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH 7
Contents
8 FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH
About this document
FLOWSIC100 Flare-XT
1
About this document
FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH 9
10
1.1
1.2
1.3
1.4
About this document
Function of this document
These Operating Instructions describe for the FLOWSIC100 Flare-XT measuring system with
FLSE100-XT sender/receiver units and Interface Unit:
● Device components
● Installation
● Operation
● Maintenance work required for reliable operation
For detailed information on functional checks/device settings, data backup, software update, malfunction and error handling and possible repairs, see the Service Manual.
Retention of documents
▸
Keep these Operating Instructions and all associated documents available for refer ence.
▸
Pass the documents on to a new owner.
Scope of application
These Operating Instructions apply exclusively to the FLOWSIC100 Flare-XT measuring sys tem with the described system components.
They are not applicable to other SICK measuring devices.
These Operating Instructions cover standard applications which conform with the technical data specified. Additional information and assistance for special applications are available from your SICK representative.
It is generally recommended to take advantage of qualified consulting services provided by
SICK experts for your specific application.
Target groups
This Manual is intended for persons installing, operating and maintaining the device.
Operation
The device may only be operated by authorized persons who, based on their training on, and knowledge of the specific device, as well as knowledge of the relevant regulations can assess the tasks given and recognize the hazards involved.
Installing and maintaining
Skilled persons are required for installation and maintenance.
Please observe the information at the beginning of the respective Sections.
Data integrity
SICK Engineering GmbH uses standardized data interfaces such as standard IP technology, in its products. The focus here is on the availability of the products and their properties.
SICK Engineering GmbH always assumes that the customer is responsible for the integrity and confidentiality of data and rights involved in connection with using the products.
In all cases, the customer is responsible for the implementation of safety measures suit able for the respective situation, e.g., network separation, firewalls, virus protection and patch management.
FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH
About this document
1.5
Further information
NOTICE:
Observe all supplied documents.
FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH 11
About this document
12 FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH
For your safety
FLOWSIC100 Flare-XT
2
For your safety
FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH 13
2.1
2.2
For your safety
Basic safety information
Observe the safety information here and the warning information in the following Sections of these Operating Instructions to reduce health risks and avoid dangerous situations.
In the case of warning symbols on the devices, the Operating Instructions must be consulted to determine the nature of the potential hazard and the actions required to avoid the hazard.
▸ Only put the FLOWSIC100 Flare-XT into operation after reading the Operating
Instructions.
▸ Observe all safety information.
▸ If there is something you do not understand: Contact SICK Customer Service.
▸ Only use the FLOWSIC100 Flare-XT measuring system as described in these Operating
Instructions. The manufacturer bears no responsibility for any other use.
▸ Do not attempt any work on or repairs to the FLOWSIC100 Flare-XT unless described in this Manual.
▸ Do not modify the FLOWSIC100 Flare-XT in any way unless specifically instructed and permitted to do so by the manufacturer.
▸ Only use accessories approved by the manufacturer.
▸ Do not use damaged components or parts.
▸ If you do not follow these guidelines, the following applies:
– Any warranty by the manufacturer becomes void,
– The FLOWSIC100 Flare-XT can become dangerous
– The approval for use in potentially explosive atmospheres is no longer valid.
Special local requirements
Follow all local laws, regulations and company policies applicable at the respective installation location.
Intended use
Use the system components of the FLOWSIC100 Flare-XT measuring system only as described in this document.
Do not exceed the maximum permissible pressure and temperature values shown on the type plates of the FLSE100-XT sender/receiver units in operation.
The manufacturer bears no responsibility for any other use.
● FLSE100-XT sender/receiver units:
● Interface unit:
14 FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH
System description
FLOWSIC100 Flare-XT
3
System description
FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH 15
3.1
System description
System components
The FLOWSIC100 Flare-XT measuring system comprises the components:
● FLSE100-XT sender/receiver unit (details p. 27, §5 )
For transmitting and receiving ultrasonic pulses, signal processing and controlling the system functions
● Control unit Interface Unit (details
)
For control, evaluation and output of the sensor data connected via the RS485 inter face
● Installation accessories (e.g., nozzle, nozzle installation tool, ball valve)
● Connection cable between sender/receiver units
● Connection cable between sender/receiver units and Interface Unit
● Spool piece option
Spool piece preassembled for installation in an existing pipeline (flange connection or welded connection) including assembly means for installing the sender/receiver units.
Measuring systems with spool piece option additionally available as:
● Dry calibrated (high precision measured system, geometric uncertainties are minimized.)
● Flow calibrated (the complete measuring system has been calibrated on a flow test bench.)
Both variants reduce measurement uncertainty.
● External temperature and pressure transmitters available on request
16 FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH
System description
3.2
Fig. 1
Functional principle
The FLOWSIC100 Flare-XT gas flow rate measuring devices operate according to the principle of ultrasonic transit time difference measurement. Sender/receiver units are
mounted on both sides of a pipeline at a certain angle of inclination to the gas flow (Fig. 1).
These sender/receiver units contain piezoelectric ultrasonic transducers that function alternately as senders and receivers. The sound pulses are emitted at an angle to the flow direction of the gas. Depending on angle α and gas flow rate v, the transit time of the respective sound direction varies as a result of certain ”acceleration and braking effects”.
The higher the gas velocity and the smaller the angle to the flow direction, the more the transit times of the sound pulses differ.
Gas flow rate v is calculated from the difference between both transit times, independent of the sound velocity value. With this measuring method, changes of the sound velocity due to pressure or temperature variations therefore have no influence on the gas velocity determined.
Functional principle FLOWSIC100 Flare-XT
Sender/ receiver unit, master
(probe A)
Higher level control system (Interface Unit) v
t
AB
Sender/receiver unit, slave
(probe B) t
BA
L
POWER
Meas v = velocity of gas in m/s
L = measuring path in m
= angle of inclination in ° t
AB t
BA
= sound transit time
in flow direction
= sound transit time
against flow direction
Linearization
Further process values are required to calculate mass flow, molecular weight, gas density and Reynolds number. Especially pressure, temperature and viscosity have a significant influence. The best accuracy is achieved when externally installed pressure and tempera ture sensors can be connected to the measuring system. The viscosity can be configured as a medium constant value.
Re = v D
v = Speed of sensor
D = Inner pipe diameter
ρ = Density of medium
η = Viscosity of medium
NOTICE:
The correct evaluation of the Reynolds number is decisive for the determination of the correct calibration function. The Reynolds number must be determined with an accuracy of 20% in order to achieve the device accuracy offered by
SICK.
FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH 17
3.3
Fig. 2
System overview
System overview FLOWSIC100 Flare-XT
1 2
To Interface Unit
Zur Interface unit
6
System description
3
4
5
8
7
1 Sender/receiver unit FLSE-XT Master
2 Connection cable
3 Weatherproof cover for Interface Unit
4 Interface Unit
5 Temperature sensor
6 Pressure sensor
7 Sender/receiver unit FLSE-XT Slave
8 Optional spool piece
18 FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH
System description
3.4
Configuration
System configuration
FLOWSIC100 Flare-XT is available as 1- or 2-path measuring system. The following Figures show cross-duct installations (F1F-S, F1F-M, F1F-H). In principle, the configuration also applies to one-sided installation (F1F-P).
Description
Two sender/receiver units are mounted on the pipeline.
The measuring path is positioned across the center of the pipeline.
Special operating conditions can make it necessary to position the path outside the pipeline center (shortens the measuring path).
A probe version can also be used instead of two sender/receiver units (type F1F-P).
1-path measurement
2-path measurement
Two pairs of sender/receiver units are installed at the same measuring location and are connected to the same Interface Unit.
Both measuring paths are positioned outside the center of the pipeline and run parallel to one another.
The Interface Unit calculates a measuring result from both measuring paths.
2-path measurement is used to achieve higher measurement accuracy or when flow conditions are complicated.
FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH 19
3.5
Fig. 3
System description
ASC technology (patented) – active sound correlation technology
(optionally available)
If the ultrasonic signal is scattered due to extreme gas velocity, the ASC technology (active sound correlation technology) takes over.
The ultrasonic transducer works like a microphone and correlates the strong noises at high flow rates to gas velocity.
This ensures measurement is still available even for extreme flare gas behavior.
Measurement uncertainty is higher as compared to ultrasonic transit time difference
measurement, see technical data, p. 153, §12 .
ASC technology
Fig. 4
Normal conditions,
Ultrasonic transit time difference measurement
Increased gas velocity,
Ultrasonic transit time difference measurement
Scattered ultrasonic signal,
ASC technology active
“Extended VOG Range” is signalled in the path status of FLOWgate TM when the ASC technology is active.
Signaling “Extended VOG Range” in the path status
20 FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH
Project planning
FLOWSIC100 Flare-XT
4
Project planning
Determining the measuring and installation location for FLSE100-XT
Determining the installation location of the Interface Unit
FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH 21
Project planning
4.1
Overview
The following Table provides an overview of the project planning work necessary as prerequisite for trouble-free assembly and subsequent device functionality.
Task
Determine measuring and installation locations
Select device components
Plan power supply
Requirements
Flow distribution, inlet and outlet piping
Access, accident prevention
Installation free of vibrations
Lowest possible influence on the measurement accuracy
Easy and safe
Acceleration < 1 g
Ambient conditions
Limit values in accordance with Technical
Data
Internal pipe diameter Sender/receiver unit type
Gas temperature Sender/receiver unit type
Gas composition
Fitting locations
Material of duct probe and transducer
Cable lengths
Operating voltage, power requirements According to Technical Data
Work step
Follow specifications for new equipment; select best possible location for existing equipment
Provide platforms or pedestals as required.
Avoid/reduce vibrations through adequate measures.
If necessary:
Provide weatherproof covers / sun protection, enclose or lag device components.
Select components according to the
Configuration Table and information as from
p. 49, §5.6.6. as well as the Application
Evaluation Sheet
Plan adequate cable cross-sections and fuses
22 FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH
Project planning
4.2
Determining the measuring and installation location for FLSE100-XT
Measurement accuracy is influenced, among other things, by flow behavior and the position of the measuring axis. Large cross-section variations, curved pipes, fittings, air flaps or inlets can cause profile deformations or turbulences with a negative effect on the accuracy of the measuring result.
Select the FLSE-XT installation location at a position with as little interference as possible to ensure best possible device performance.
Criteria
4.2.1
General requirements
Flow behavior
Pipeline design
Requirements
Position with twist-free as well as rotationally symmetrical flow profile
Balanced, uniform profiles are most likely to be expected for long inlet and outlet piping
Whenever possible, no deflections, cross-section variations, curves, feed and drain lines, flaps or fittings in the area of the inlet and outlet piping
Isometric conditions at the measuring point are most important for determining the required inlet and outlet piping and should be investigated carefully. The conditions depend on the specific application and the device configuration. Typically, an upstream 20 D straight pipe section and a downstream 5 D straight pipe section are required.
Measuring location
Wall and insulation thickness
Inlet and outlet piping lengths
● Uncritical flow inlet conditions require straight inlet piping.
● More complex inlet disturbances require longer inlet and outlet piping.
● If the 2-path configuration is used, the needed minimum inlet and outlet sections can be further reduced compared to 1-path measurement with the same measurement uncertainty.
● SICK offers expertise support for optimal adjustment of the meter for the given inlet and outlet piping conditions.
Pipelines with vertical, horizontal or inclined direction
Installation location
Working platform
Pipelines with horizontal or vertical direction
● Horizontal installation:
Align the spool piece so that the planes formed by the measuring paths are horizontal. This minimizes the problem of dirt in the pipeline entering the transducer ports.
● Vertical installation:
Only possible if the measuring system is used for dry, non-condensing gases.
Installation free of vibrations, acceleration < 1 g
Largest possible distance to control valves or other noisy fixtures
With electrical connections and lighting
Easy and safe access for installation and maintenance work of the sender/receiver units
Platform secured by a railing to prevent possible accidents
Sufficient clearance to fit/remove the sender/receiver units
● Maximum wall thickness 15 mm
Larger wall thicknesses require customer-specific solutions (available on request only).
● Minimum wall thickness depends on pressure, temperature, pipe size and static/dynamic load at the measurement location (contact SICK for support).
Nozzles may only be isolated when the gas temperature is < 100 °C.
Ball valve, venting valve and electronics must not be insulated.
FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH 23
Project planning
4.2.2
Additional requirements for optional spool piece
Criteria
Pipeline design
Gas flow
Seals between spool piece and pipeline
Pressure sensor
Temperature sensor
Fastening and sealing material
Requirements
● Same nominal size of adjacent pipes and spool piece.
● Differences of internal diameters of inlet pipe and spool piece < 1%.
● No welding beads and burs on the flanges of the inlet pipe
Free from any foreign material, dust and liquids. Otherwise, filters and traps shall be used.
Must not protrude into the pipeline. Any protrusion into the flowing gas stream may change the flow profile and thus may adversely affect measuring accuracy.
Pressure tapping over the measuring path
Spool piece with standard installation length with integrated pressure tapping, temperature sensor
5 D
T
( = 5 * diameter of the thermowell) in the outflow area
Bolts, nuts and flange seals used must be suitable for the operational conditions and comply with legal regulations and relevant standards.
4.2.3
Fig. 5
Installation location for external pressure and temperature transmitters (option)
Pressure tappings and thermowells for external transmitters have to be installed in the following way:
● Pressure tapping connection: Directly at the measuring point, centrally above the measuring path, on the top of the pipeline
● Thermowell: Outlet section with distance 5 D
T
( = 5 * thermowell diameter), measured from the middle of the measuring path, on the top of the pipeline
Installation location
Top view
1
5 D
T
*
24
* D
T
=Diameter of thermowell
4
3 2
1 Sender/receiver unit FLSE-XT Master
2 Pressure sensor
3 Temperature sensor
4 Sender/receiver unit FLSE-XT Slave
FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH
Project planning
4.2.4
4.2.5
The Table shows for which calculations the use of external pressure and temperature transmitters is required.
Calculation of
Volumetric flow in standard condition
Mass flow
Molecular weight
Reynolds number
External pressure transmitter External temperature transmitter x x x
— x x x x
Applications with wet gas
Condensate can accumulate in the nozzle pipes. The following solutions can help to prevent measurement problems (malfunctions caused by solid-borne noise, see Service Manual), or damage when removing the sender/receiver unit (condensate runs out).
● Use a nozzle position which prevents accumulations of condensates in nozzle pipes.
● Use a closed continuous or periodical condensate drain with backflow to the pipeline.
● Isolate the nozzle pipe to reduce dew point underruns (only for low gas temperatures
< 100 °C).
Clearance for fitting and removing the sender/receiver units
NOTICE:
Observe the dimension drawings in
.
FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH 25
4.3
4.3.1
4.3.2
Project planning
Determining the installation location of the Interface Unit
Installation location requirements
▸
Fit the Interface Unit in an easily accessible and protected position.
▸
Observe the information in p. 96, §6.4
Providing suitable cables are used, the Interface Unit can be installed up to 1000 meters from the sender/receiver units. The installation of a flameproof version of the interface unit directly on site is therefore unnecessary in many situations. For easier access to the
Interface Unit, we recommend installation in a control room (measuring station or similar).
This considerably simplifies communication with the FLOWSIC100 Flare-XT for configuration or location of failure or error causes.
NOTICE:
The Interface Unit is only suitable for vertical installation.
Clearance for fitting the Interface Unit
NOTICE:
Observe the dimension drawings in p. 169, §12.8.2
26 FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH
Installation FLSE100-XT
FLOWSIC100 Flare-XT
5
Installation FLSE100-XT
FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH 27
5.1
5.2
5.2.1
Installation FLSE100-XT
Intended use
FLSE100-XT sender/receiver units may only be used to measure the gas velocity, gas volume, mass flow and molecular weight in pipelines.
Do not exceed the maximum permissible pressure and temperature values shown on the type plates of the FLSE100-XT sender/receiver units in operation.
Using the device for purposes other than those intended can lead to safety-critical conditions. The manufacturer bears no responsibility for any other use.
Safety information
Hazards due to hot, cold (cryogenic) or aggressive gases, or high pressure
The FLSE100-XT sender/receiver units are mounted directly on the gas-carrying pipeline.
On equipment with low hazard potential, e.g., non-toxic, aggressive or explosive gases, gases not hazardous to health, uncritical pressure, moderate gas temperature (not hot, very low/cryogenic), the installation or removal can be performed while the equipment is in operation, however only as far as the valid regulations and equipment safety notices are observed and suitable protective measures are taken. Special regulations that apply to the plant must be observed.
WARNING: Gas hazard
▸
Activities on equipment with increased hazard potential, e.g. by toxic, aggressive, explosive gases, health endangering, higher pressure, high temperatures, low temperature (cryogenic), have to follow legitimate regulations, general standards and guidelines as well as plant operator instructions. Only authorized personnel with special qualification for fitting using the ”Hot Tapping” method may install the devices when the plant is in
operation (requirements on the qualification of the personnel, see p. 34,
). Otherwise, serious injuries might occur, e.g. poisoning, burns etc.
These persons must be trained and technically adept in ”hot tapping” installation work and must know and implement legal as well as generally applicable regulations and in-house regulations.
▸
The express approval of the plant operator in written form is required for installations on running equipment at all times. The plant operator carries the responsibility for professional implementation alone. All safety requirements relevant for the equipment must be observed as well as essential and suitable protective measures taken. All regulations/special regulations that can be applicable for the plant must be observed.
28 FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH
Installation FLSE100-XT
5.2.2
5.2.3
5.2.4
Hazard through electrical equipment
WARNING: Danger through power voltage
▸ Disconnect power supply lines before working on power connections or parts carrying power voltage.
▸
Refit any contact protection removed before switching the power voltage back on again.
Hazards through explosive or ignitable gases
FLSE100-XT sender/receiver units may be used in potentially explosive atmospheres only according to the respective specifications.
WARNING: Hazards through explosive or ignitable gases
▸
In potentially explosive atmospheres, only use the version of the
FLSE100-XT sender/receiver units specified for such use (
▸
Observe the information on p. 37, §5.3
during installation work on running
equipment (”hot tapping” method).
Hazards through electrostatic discharges
The electronic housing of the sender/receiver units and the optionally available spool piece are painted by the manufacturer with a layer thickness of max. 0.2 mm as standard.
WARNING: Ignition hazard through electrostatic discharge
Ignition hazards through electrostatic discharges exist when FLSE100-XT sender/receiver units with special paintwork and a layer thickness > 0.2 mm are used in applications with ignition group IIC according to ATEX and IECEx.
▸
For installation, the risk of electrostatic charging of the surface must be reduced to a minimum.
▸ Use appropriate caution when performing maintenance and cleaning work.
For example, the surfaces should only be cleaned with a damp cloth. The respective devices will be identified by the manufacturer with a warning sign.
FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH 29
5.2.5
Installation FLSE100-XT
Retraction mechanism of the sender/receiver units
The retraction mechanism serves to remove and fit complete sender/receiver units of the
FLSE100-XT for maintenance or replacement without relieving pressure in the pipeline in which the measuring system is fitted. Sender/receiver units with ball valve must be installed to use the retraction mechanism.
This allows maintenance work without having to interrupt the process.
WARNING: Hazard through incorrect use of the retraction mechanism
The retraction mechanism may only be used when the sender/receiver unit is fitted with a ball valve. The retraction mechanism must not be used when a ball valve is not installed.
Only operate the retraction mechanism within the following pressure ranges:
● Maximum operating pressure
– For use of the retraction mechanism: 0.5 bar (g)
– With additional fitting tool (SICK Service only): 8 bar (g)
● Temperature range:
For health and safety reasons (high/low temperatures), SICK recommends only operating the retraction mechanism in the temperature range 0 °C ...
70 °C.
WARNING: Hazardous gas (possibly explosive or toxic)
Small gas quantities escape during the removal and installation of the transducer assemblies. When used correctly, the gas amount enclosed in the retraction nozzle is max. 0.81 dm 3 with F1F-P and max. 0.27 dm 3 with F1F-S,
F1F-M and F1F-H.
▸
Personnel performing tasks on plants with poisonous or other gases dangerous to health must use suitable safety equipment to prevent personal injuries.
WARNING: Hazardous gas (possibly explosive or toxic)
The retraction nozzle of the sender/receiver units has a connection for optional venting.
▸
This connection is closed with a blind plug at the factory.
▸ The blind plug may only be removed when a venting valve is installed,
30 FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH
Installation FLSE100-XT
F1F-S
5.2.6
Table 1
Version
Operation in potentially explosive atmospheres
Depending on the respective device version, the FLSE100-XT sender/receiver units are designed for use in potentially explosive atmospheres:
Device versions
IECEX
Ex db [ia Ga] IIA T4 Ga/Gb
Ex db [la Ga] IIB T4 Ga/Gb
Ex db [ia Ga] IIC T6/T4 Ga/Gb
Ex ia IIC T6/T4 Ga
Approval
ATEX
II 1/2G Ex db [ia Ga] IIA T4 Ga/Gb
II 1/2G Ex db [la Ga] IIB T4 Ga/Gb
II 1/2G Ex db [ia Ga] IIC T6/T4 Ga/Gb
II 1G Ex ia IIC T6/T4 Ga
NEC/CEC (USA/CA)
Class I, Division 1, Group D, T4;
Class I, Zone 1, Ex/AEx d[ia] IIA, T4;
Class I, Division 2, Group D, T4;
Class I, Zone 2, Ex/AEx nA[ia] IIA, T4
F1F-M
F1F-H
F1F-P
Class I, Division 1, Groups C and D, T4;
Class I, Zone 1, Ex/AEx d[ia] IIB, T4;
Class I, Division 2, Groups C and D, T4;
Class I, Zone 2, Ex/AEx nA[ia] IIB, T4
Ex db [ia Ga] IIA T4 Ga/Gb
Ex db [la Ga] IIB T4 Ga/Gb
Ex db [ia Ga] IIC T6/T4 Ga/Gb
Ex ia IIC T6/T4 Ga
II 1/2G Ex db [ia Ga] IIA T4 Ga/Gb
II 1/2G Ex db [la Ga] IIB T4 Ga/Gb
II 1/2G Ex db [ia Ga] IIC T6/T4 Ga/Gb
II 1G Ex ia IIC T6/T4 Ga
Class I, Division 1, Groups B, C and D, T4;
Class I, Zone 1, Ex/AEx d[ia] IIB + H2, T4;
Class I, Division 2, Groups A, B, C and D, T4;
Class I, Zone 2, Ex/AEx nA[ia] IIC, T4
Class I, Division 1, Group D, T4;
Class I, Zone 1, Ex/AEx d[ia] IIA, T4;
Class I, Division 2, Group D, T4;
Class I, Zone 2, Ex/AEx nA[ia] IIA, T4
Ex db IIC T6/T4 Gb
Ex db [ia Ga] IIA T4 Ga/Gb
Ex db [ia Ga] IIB T4 Ga/Gb
Ex db [ia Ga] IIC T6/T4 Ga/Gb
II 2G Ex db IIC T6/T4 Gb
II 1/2G Ex db [ia Ga] IIA T4 Ga/Gb
II 1/2G Ex db [ia Ga] IIB T4 Ga/Gb
II 1/2G Ex db [ia Ga] IIC T6/T4 Ga/Gb
Class I, Division 1, Groups C and D, T4;
Class I, Zone 1, Ex/AEx d[ia] IIB, T4;
Class I, Division 2, Groups C and D, T4;
Class I, Zone 2, Ex/AEx nA[ia] IIB, T4
Class I, Division 1, Groups B, C and D, T4;
Class I, Zone 1, Ex/AEx d[ia] IIB + H2, T4;
Class I, Division 2, Groups A, B, C and D, T4;
Class I, Zone 2, Ex/AEx nA[ia] IIC, T4
Class I, Division 1, Groups B, C and D, T4;
Class I, Zone 1, Ex/AEx d IIB + H2, T4;
Class I, Division 2, Groups A, B, C and D, T4;
Class I, Zone 2, Ex/AEx nA IIC, T4
Class I, Division 1, Group D, T4;
Class I, Zone 1, Ex/AEx d[ia] IIA, T4;
Class I, Division 2, Group D, T4;
Class I, Zone 2, Ex/AEx nA[ia] IIA, T4
Class I, Division 1, Groups C and D, T4;
Class I, Zone 1, Ex/AEx d[ia] IIB, T4;
Class I, Division 2, Groups C and D, T4;
Class I, Zone 2, Ex/AEx nA[ia] IIB, T4
Class I, Division 1, Groups B, C and D, T4;
Class I, Zone 1, Ex/AEx d[ia] IIB + H2, T4;
Class I, Division 2, Groups A, B, C and D, T4;
Class I, Zone 2, Ex/AEx nA[ia] IIC, T4
FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH 31
32
5.2.6.1
5.2.6.2
Installation FLSE100-XT
Specific conditions
Specific conditions of use denoted by X after the certificate number.
Specific conditions relating to all FLSE models
● As an option, offshore painting is used, where the layer thickness exceeds the limit of
0.2 mm for Gas group IIC (see Table 8 in IEC 60079-0:2011). In this case, the device is marked with a warning label according to IEC 60079-1, Table 16 g).
Under certain extreme circumstances, the device may generate an ignition-capable level of electrostatic charge. Therefore, the device shall not be installed in a location where the external conditions are conducive to the build-up of electrostatic charge on such surfaces. In addition, the device shall only be cleaned with a damp cloth (see clause
7.4.2 of IEC 60079-0:2011).
● The ultrasonic transducers are manufactured from titanium. In rare cases, ignition sources could arise due to impact or friction sparks. The user must ensure the enclosure and ultrasonic transducers are adequately protected against danger arising from impacts or friction (see Section 8.3 of IEC 60079-0:2011).
● The lengths of the flameproof joints are sometimes longer and the widths of the flame proof joints are sometimes shorter than required in Table 2 or 3 of IEC 60079-1: 2014.
Flameproof joints are not intended to be repaired. Contact the manufacturer when dimensional information of flameproof joints is needed.
Specific conditions relating to the FLSE100-XT with intrinsically safe transducers
● The device contains a shunt zener diode, which requires connection to a barrier ground in accordance with IEC 60079-14. The protective ground conductor terminals of the device are to be connected to the potential equalization system of the installation area.
● The maximum permitted voltage in the safe area (Um) must not exceed the rated
125 V AC. Connect the device only to device which does not carry voltage higher than
125 V AC. Use SELV power supplies and device that meet the requirements of IEC/
EN 60950 or IEC/EN 61010-1.
● The maximum piezo-electric energy released by an impact on the ultrasonic transducers exceeds the limit for Gas Group IIC specified in Clause 10.7 of IEC 60079-11:2011. The user must ensure that the ultrasonic transducers are suitably protected against danger from impact.
● The sender/receiver units with the intrinsically safe transducers may be installed into a duct wall separating Zone 0 from another area, e. g. Zone 1. The user must ensure that the material of the ultrasonic transducers shall not be subject to environmental conditions, e.g. chemical exposure or abrasion, which might adversely affect their enclosure and in particular their membrane.
Use of FLSE100-XT, depending on the temperature code and process temperature
Installation and use of sender/receiver units - electronics and transducers parts in the same area
This area is a hazardous area, i.e. Zone 1 or Zone 2 in which an explosive atmosphere exists under normal atmospheric conditions of:
– Specified ambient temperature -40 ... +70 °C for T4 or -40 ... +55 °C for T6,
Optionally minimum ambient temperature -50 °C
– Ambient pressure 80 kPa (0.8 bar) to 110 kPa (1.1 bar)
– Air with normal oxygen content, typically 21 percent by volume.
FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH
Installation FLSE100-XT
5.2.6.3
Permissible gas temperature, depending on the temperature code of the sender/ receiver units
):
Under normal atmospheric conditions, an explosive atmosphere categorized as Zone 1 or
Zone 2 exists outside the pipeline. Process conditions in the pipeline can differ from the atmospheric conditions. Process conditions can be in the range specified on the type plate of the sender/receiver units. In this case the gas or gas mixture can be combustible but must not be explosive.
Case 2 and 3 (see
On both sides of the pipeline an explosive atmosphere exists under normal atmospheric conditions. The pipe wall separates different zones, i.e. Zone 1 exists inside the pipe and
Zone 2 outside. This means gas temperature and line pressure may not exceed the specified ambient values.
NOTICE:
The pipe wall can separate different hazardous areas (zones).
Table 2
Classified tempera ture code in the hazard ous area
Permitted gas temperature for temperature code
Case 1
● Ultrasonic sensor outside explosive atmosphere Zone
1 or 2
● Electronics in explosive atmosphere Zone 1 or 2
● Gas pressure and gas temperature according to specification on device label
Case 2
● Ultrasonic sensor in explosive atmosphere Zone 1 or 2
● Electronics in explosive atmosphere Zone 1 or 2
● Gas pressure and gas tempera ture according to ambient specification of device
Case 3
● Ultrasonic sensor in explosive atmosphere Zone 0
● Electronics in explosive atmosphere Zone 1 or 2
● Gas pressure atmospheric, gas temperature max +60 °C
● Not for F1F-H
Zone 1 or 2 Non-Ex atmosphere
Zone 1 or 2 Zone 1 or 2 Zone 1 or 2 Zone 0
T4
T3
T2
The sender/receiver units can be used with the following gas temperatures:
T6 -196 1) … +80 °C -196 1) … +55 °C
-196 1) … +130 °C
-196 1) … +195 °C
-196 1) … +280 °C
-196
-196
-196
1)
1)
1)
… +70 °C
… +70 °C
… +70 °C
1) For F1F-H: -70 °C
-50 … +55 °C
-50 … +70 °C
-50 … +70 °C
-50 … +70 °C
FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH 33
34
5.2.7
5.2.8
Installation FLSE100-XT
NOTICE: Observe the ambient temperature
Be aware that the ambient air around the pipeline might heat up.
● The ambient temperature around the electronic housing may not exceed
+70 °C for the sender/receiver unit marked with T4.
● The ambient temperature around the electronic housing may not exceed
+55 °C for the sender/receiver unit marked with T6.
The compliance with these requirements is the sole responsibility of the user.
A temperature fuse protects the transmitter/receiver unit electronics against impermissible high temperatures. The temperature fuse interrupts the function of the electronics should such high temperatures occur. The switch-off reaction of the temperature fuse is permanent and can only be reset by the manufacturer through repair.
Warning information on device
WARNING: Danger identification on device
The following symbol draws attention to important dangers directly on the device:
▸ Consult the Operating Instructions in all cases where the symbol is attached to the device or shown on the display.
Requirements on the personnel's qualification
Designated users
The FLSE100-XT sender/receiver units may only be installed and operated by skilled technicians who, based on their technical training and knowledge as well as knowledge of the relevant regulations, can assess the tasks given and recognize the hazards involved.
Skilled persons are persons according to DIN VDE 0105, DIN VDE 1000-10 or IEC 60050-
826 or directly comparable standards.
The named persons must have exact knowledge of operational hazards caused, e.g., by low voltage, hot, toxic, explosive gases or gases under pressure, gas-liquid mixtures or other media as well as adequate knowledge of the measuring system gained through training.
Specific requirements for use of devices in hazardous areas
▸ Cabling/installation, device setup, maintenance and testing may only be carried out by experienced persons familiar with the rules and regulations for hazardous areas, in particular:
– Degree of protection
– Fitting instructions
– Area definition
▸ Regulations to be applied:
– IEC 60079-14
– IEC 60079-17 or comparable national regulations.
FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH
Installation FLSE100-XT
5.2.9
Restrictions on use
WARNING: Hazard through pressure/temperature
▸
Use the FLSE100-XT sender/receiver units only within the pressure and temperature limits as specified in these Operating Instructions and on the device type plate.
▸
The selected materials must be resistant to the process gases. It is the responsibility of the plant operator to ensure this.
WARNING: Dangerous voltage
● The rated voltage U
M
may not exceed 125 V in the safe area for use of the sender/receiver units F1F-S, F1F-M and F1F-P for Zone 1. Higher voltages can jeopardize intrinsic safety of the ultrasonic transducer circuit when errors occur.
▸
Ensure the rated voltage U
M
used in the safe area does not exceed
125 V.
● The FLSE100-XT sender/receiver units are not equipped with a main power switch for switching off the operating voltage.
▸ Plan and install a suitable switching off device.
The sender/receiver units are intended for installation in gas-carrying pipelines. It is not absolutely necessary that atmospheric conditions prevail within the pipeline. The pipe wall is then a zone-separating wall, i.e. no Ex zone is defined within the pipeline, at least
, Case 1).
WARNING: Leakage hazard
Operation with leakage is not permitted.
● The metallic and hermetically sealed, fully welded enclosure and the seal must comply with all safety requirements which must also be fulfilled by the pipeline itself with respect to design pressure and temperature and compatibility of the material with the medium.
● The ultrasonic transducers with their gas-tight and pressure-proof enclo sures must be installed in the pipeline gas-tight and pressure-tight.
The FLSE100-XT is fitted with standardized sealing flanges for this purpose.
● The sealing itself must consist of material which is compatible with the medium and is suitable for the application conditions.
▸ Check the sealing surfaces and elements for intactness before installation.
▸ Check the sealing effect with suitable methods after installation.
▸
Leak tightness is to be checked regularly during operation and the seal replaced, as required.
● Before every re-installation new seals have to be used in the required design.
FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH 35
Installation FLSE100-XT
Application limitations for use in Ex zone 1
▸
Ultrasonic probes made of titanium may be used in Zone 1 only when risks of ignition arising from impacts or friction on the sensor enclosure can be ruled out.
▸
When ultrasonic probes are installed in pipelines with a defined hazardous area, solid parts, e.g. dust or other particles may not cause an ignition hazard.
Application limitations for use in hazardous area classification Ex zone 0 in the pipeline
Use in applications of Zone 0 is generally only possible for device types F1F-S, F1F-M and
F1F-P under consideration of the application limitations described in these Operating
Instructions.
● Ultrasonic probes can also be operated in Zone 0 under atmospheric conditions (ambient temperature -40°C to +70°C and ambient pressure
0.8 bar to 1.1 bar absolute). The devices must be labeled at least with the information Ex ia.
● Ultrasonic probes made of titanium may be used in Zone 0 only when no rigid components transported through the medium (e.g. dust and other particles) are present and the ultrasonic probes are fitted in Zone 0 in a way (e.g. inside a pipeline) that risks of ignition arising from impacts or friction can be ruled out. The intrinsically safe ultrasonic transducers with their gas-tight and pressure-proof enclosures must be installed gas-tight and pressure-tight in the zone-separating wall to Zone 0. The wall must be thicker than 3 mm. The requirements in EN 60079-26 Section 4.6 must be adhered to.
36 FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH
Installation FLSE100-XT
5.3
5.3.1
Fig. 6
Product description
Product identification
Product name:
Manufacturer
FLSE100-XT
SICK Engineering GmbH
Bergener Ring 27
01458 Ottendorf-Okrilla
Germany
Type plate
Type plate example FLSE100-XT-S
Example of marking plate FLSE100-XT-S (ATEX/IECEx)
Fig. 7 Type plate example FLSE100-XT-M
3
Example of marking plate passive (SLAVE)
FLSE100-XT-S (ATEX/IECEx)
Example of marking plate FLSE100-XT-M (ATEX/IECEx)
Example of marking plate passive (SLAVE)
FLSE100-XT-M (ATEX/IECEx)
FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH 37
Fig. 8 Type plate example FLSE100-XT-H
Installation FLSE100-XT
Example of marking plate FLSE100-XT-H (ATEX/IECEx)
Fig. 9 Type plate example FLSE100-XT-P
3
Example of marking plate FLSE100-XT3 (ATEX/IECEx)
Example of marking plate passive (SLAVE)
FLSE100-XT-H (ATEX/IECEx)
38 FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH
Installation FLSE100-XT
5.3.2
Fig. 10
Sender/receiver units
Cross-duct
F1F-S (Master and slave shown as examples)
2 3 5 6
1 4
Sensor length
7
10 5 6
1 Pressure compensation element
2 Electronics unit
3 T-connector
4 TNC connector (connection for Slave)
5 Self-cutting ring
6 Retraction nozzle
7 Duct probe
8 Sensor contour
9 Transducer
10 TNC connector (connection for Master)
7 9
FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH 39
Fig. 11 F1F-M (only master shown)
2 3 5
Installation FLSE100-XT
6 8 9
1 4
Fig. 12
1 Pressure compensation element
2 Electronics unit
3 T-connector
4 TNC connector (connection for Slave)
5 Self-cutting ring
F1F-H (only master shown)
2 4
6 Retraction nozzle
7 Duct probe
8 Sensor contour
9 Transducer
5
Sensor length
6
7
7 8
1 3
1 Pressure compensation element
2 Electronics unit
3 Cable gland (connection for Slave)
4 Self-cutting ring
Sensor length
5 Retraction nozzle
6 Duct probe
7 Sensor contour
8 Transducer
40 FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH
Installation FLSE100-XT
Fig. 13
2
Probe version
F1F-P
3 5 6 8
1
4
1 Pressure compensation element
2 Electronics unit
3 T-connector
4 Pressure compensation element
5 Self-cutting ring
6 Retraction nozzle
7 Duct probe
8 Transducer
9 Sensor contour
7 9
FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH 41
Installation FLSE100-XT
5.3.3
Fig. 14
Material for parts with process gas contact
Parts with process gas contact
Cross-duct versions F1F-S / -M / -H
1 2 12 11 10 9
Probe version F1F-P
1 12
2 3 4 5
18 17
6 7
16
11
3 4 5
10 15
6 7
13
8
14
42
17
1 Pipe screw fitting
2 Threaded ring
3 Spring
4 Sealing disc
5 Sealing profile
6 Retraction nozzle
7 Retraction flange
8 Transducer
9 Sensor contour
8
10 Duct probe
11 Connection for optional venting
12 Centering
13 Sensor contour probe version F1F-P
14 Adjusting ring
15 Thrust ring
16 Probe tube
17 Transducer pipe screw fitting
18 Transducer and contour holder
FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH
Installation FLSE100-XT
Table 3 Overview of parts with process gas contact
Material
Stainless steel
1.4404
Component
Retraction flange (7), threaded ring (2)
Connection for optional venting (11), retraction nozzle (6)
Duct probe (10), sensor contour (13), transducer and contour holder
(18), transducer pipe screw fitting (17)
Titanium
PTFE
Adjusting ring (14), pipe screw fitting (1), sealing disc (4)
Duct probe (10), transducer assembly (8)
Transducer assembly (8), probe tube (16)
Centering (12)
Sensor contour (9)
Thrust ring (15)
PTFE/graphite Sealing profile (5)
Stainless steel
1.4568
Spring (3)
Type FLSE100-XT
F1F-S F1F-M F1F-H F1F-P x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x
5.4
Fig. 15
Spool piece option
The FLOWSIC100 Flare-XT can also be fitted with an optional spool piece to reduce geometric uncertainty of device installation and to simplify assembly. The exact design
(nominal diameter, connection, material) always depends on the customer specifications.
The installation length of the spool piece depends on the nominal diameter of the pipe:
– Installation length 800 mm for pipe diameter up to 28”
– Installation length 1100 mm for pipe diameter 30” ... 60”
– Installation length for pipe diameter >60”...72” on request
All system solutions (FLOWSIC100 Flare-XT + spool piece) are optionally available with pressure and temperature sensors. For the positioning of pressure and temperature transmitters the following configurations are available:
– Spool piece with standard installation length with integrated pressure tapping, temperature sensor 5 D
T
( = 5 * diameter of the thermowell) in the outflow area
– Spool piece, extended length with integrated pressure and temperature tapping.
Spool piece option (example)
800 mm
FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH 43
5.5
5.5.1
Fig. 16
Installation FLSE100-XT
Transport and storage
Comply with permissible storage conditions (
Transport protection
To prevent transport damage, the FLSE100-XT sender/receiver units must be secured
according to Fig. 16 before each transport.
▸ Retract the transducer fully into the retraction nozzle.
▸ Ensure in a suitable manner that the transducer cannot slip out of the retraction nozzle during transport.
Transport protection
5.5.2
1
1 Retraction nozzle
Special notes for handling the spool piece option
Transport and storage
▸ During all transport and storage work, ensure:
– The spool piece is well secured at all times
– Measures are taken to avoid mechanical damage
▸ Protect sealing surfaces of the flanges and the interior of the spool piece if it must be stored outside for more than one day, e.g. with Anticorit spray (not required for spool pieces made of stainless steel). Do the same if the meter must be stored in dry conditions, but for more than a week.
44 FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH
Installation FLSE100-XT
Fig. 17
Lifting requirements
WARNING: Danger due to size and mass of the spool piece
▸ Only use lifting gear and load handling equipment (e.g. lifting straps) which are suitable for the weight to be lifted. Max. load information can be found on the type plate of the lifting gear.
▸ Only use the eye bolts when lifting the spool piece.
▸
Do not lift the spool piece using these eye bolts when additional loads (e.g. blind flanges, filling for pressure tests or tubes) are attached.
▸
During transport, the spool piece must not be turned over or start to swing.
Lifting requirements (installed sender/receiver units are not shown)
Max. 60 °
FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH 45
5.6
5.6.1
Fig. 18
Installation FLSE100-XT
Installation
Safety information
WARNING: Risks during installation
▸ Observe the relevant safety regulations as well as the safety notices on
p. 13, §2 during all installation work.
▸
Carry out assembly work on equipment with hazard potential (hot or aggressive gases, higher internal pipeline pressure) only when the equipment is at a standstill.
Fitting when the equipment is running is only possible using the “hot tapping method”. Such work may only be carried out by a specialized contractor authorized by the plant operator.
▸
Take suitable protection measures against possible local hazards or hazards arising from the equipment.
WARNING: Mechanical burden
The static load moment of all parts to be installed on the pipeline can be up to approx. 600 Nm. Strong pipe vibrations can cause damage and can lead to dangerous situations.
▸
Use a mechanical support for the nozzles welded to the pipeline, e.g.
”gusset plates”.
NOTICE:
The plant operator is responsible for the safety of the system under mechanical load.
Option mechanical support for nozzle ”gusset plates”
46
5.6.2
Scope of delivery
▸ Check that delivery includes all ordered parts.
▸ Check parts for possible transport damage. Pay particular attention to transducer surfaces, sealing surfaces on the flanges and, if delivered, the interior of the spool piece.
▸ Immediately document and report damage to the manufacturer.
NOTICE:
To ensure safe and reliable operation of the measuring devices, ensure that the current operating conditions on the system correspond to the specifications on the type plates of the sender/receiver units.
FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH
Installation FLSE100-XT
5.6.3
Fitting the spool piece (option)
The spool piece must be mounted in the pipeline so that the arrow marking on it corresponds to the flow direction.
The flow is output by the measuring system as a positive value when master and slave of the sender/receiver units for the cross-duct versions are installed according to
.
WARNING: Danger due to size and mass of the spool piece
▸
Observe the transport information in p. 44, §5.5.2
!
Required fitting work
▸ Position the spool piece at the desired section of the pipeline using the hoist.
▸ After attaching the flange bolts, but before tightening, check the correct seating and alignment of the flange seal.
▸ Align the spool piece so that the offset between inlet pipe, spool piece and outlet pipe is minimized.
▸ Insert the remaining fixing screws and tighten the nuts crosswise. The applied torque must not be lower than specified in the project planning.
▸ Install the pressure measurement line between the pressure tapping point (option) and the pressure sensor (option).
Perform a leak tightness check with suitable means after completion of the installation work,
FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH 47
48
5.6.4
5.6.5
Installation FLSE100-XT
Installation sequence
Carry out all assembly work on-site.
This includes:
▸ Determining the nozzle position
▸ Welding the nozzle on
The nozzles are manufactured precisely at the factory according to customer specifications for fitting on the pipeline.
▸ For retractable installation:
Fitting the ball valves (measuring system without optional spool piece)
▸ Fitting the sender/receiver units
NOTICE:
To ensure measurement accuracy, the geometric parameters must be determined as exactly as possible. Maximum tolerances:
– Nozzle positions and fitting angle of the nozzles: ±1 mm / ±1 °
– Measurement of nozzle length: ±1 mm
– Measurement of ball valves: ±1 mm
NOTICE:
The exact wall thickness must be determined for precise calculation of the pipeline inner diameter. “Schedule” information from the applicable standards is less accurate than an exact measurement.
The wall thickness must be determined accurately to 0.1 mm. SICK recommends using a suitable ultrasonic measuring instrument to determine the wall thickness.
Geometry calculator
The geometry calculator for installation of the FLSE100-XT sender/receiver units is available on the delivered product CD (Geometry calculator for “Flare-
XT”).
Certain geometric parameters must be determined and calculated for installation of
FLSE100-XT sender/receiver units.
The following dimensions can be calculated using the geometry calculator:
● Probe offset a (nozzle offset), p. 54, §5.6.7.2
.
The following parameters must be determined during installation for calculation of the probe offset:
– Circumference and nominal nozzle angle
● Wetted part length wL,
For installation of the sender/receiver units, the wetted part length is calculated from:
– Circumference
– Wall thickness
– Gasket thickness
– Nozzle length
– For retractable installation: Ball valve length
– Nozzle angle
– Additionally for cross-duct versions: Probe offset a
● Gemometric installation parameters for commissioning the measuring system,
FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH
Installation FLSE100-XT
5.6.6
Fig. 19
Installation accessories
Sender/receiver units are fitted to the pipeline using the following material:
Installation accessories (using ANSI CL150 as example)
7
6
1 2 3 4 5
1 Blind flange
2 Ball valve (only when sender/receiver units are to be retracted in operation)
3 Seal
4 Nozzle
5 Marking
6 Welding bevel
7 Pipeline
Connection ANSI CL150 2"
NOTICE:
Use of installation accessories for temperature range according to type plate:
● The ball valve must not be insulated for media temperatures below -40 °C or higher than +160°C.
● For gas temperatures higher than +180°C or below -40 °C , the temperature at the nozzle flange must be checked after through-heating during initial start-up. If required, the nozzle insulation must be removed as required to stay in the specified temperature limit.
● Do not exceed temperature and pressure ranges listed in
It must be ensured that the temperature of the nozzle and ball valve is not so high that the material strength can no longer be guaranteed when
derating the pressure over the temperature, p. 165, §12.7
.
FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH 49
5.6.6.1
Fig. 20
Installation FLSE100-XT
Nozzles, blind flanges and seals
Nozzles are delivered with factory adaption to the nominal pipe diameter, welding bevel and marking for nozzle alignment according to the gas flow.
Nozzle
50
Table 4
Table 5
2
1
1 Welding bevel
2 Marking
Nozzles and blind flanges
NOTICE:
Observe the diagrams on p. 165, §12.7
.
Available nozzles and blind flanges
Flange connection Material
CL150
CL300
PN25 DN50
LTCS P355 QH1 / A350 LF2
SS 1.4401, 1.4404, ASTM A182 Gr. 316, 316L
LTCS P355 QH1 / A350 LF2
SS 1.4401, 1.4404, ASTM A182 Gr. 316, 316L
LTCS P355 QH1 / A350 LF2
SS 1.4401, 1.4404, ASTM A182 Gr. 316, 316L
Temperature ranges
-46 … +280°C
-196 … +280°C
-46 … +280°C
-196 … +280°C
-46 … +280°C
-196 … +280°C
NOTICE:
Observe the diagrams on p. 165, §12.7
.
Dimension drawings of the nozzles are available on the product CD and/or available from SICK.
To prevent galvanic corrosion between LTCS nozzles and stainless steel ball valves, a nozzle insulation set (sealing material set with polymer seals and sleeves) is available as an accessory,
Seals
NOTICE:
Observe the diagrams on p. 165, §12.7
.
Flat seals are required for the flange connection between nozzle and ball valve and between the ball valve and the sender/receiver unit. These seals are included in the standard scope of delivery of the ball valve and/or sender/receiver unit.
Available seals
Material
Serrated gasket B9A 1.4571
Temperature range
-196 … +280°C
FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH
Installation FLSE100-XT
5.6.6.2
Table 6
Table 7
Ball valve
The ball valve serves for safe separation of the sender/receiver units from the process and is required when the sender/receiver units are to be dismounted during the process. SICK recommends using a ball valve.
Ball valves for various flange connections (Cl150, CL300, PN25 DN50) and temperature ranges) are available.
NOTICE:
Observe the diagrams on
Ball valve according to ANSI
Component
Standard temperature
Ball valve CL150 2" SS
Connection Material (ASTM)
CL150 2"
Gas temperature range
Ball valve CL300 2" SS CL300 2"
Stainless steel 1.4408
(CF08M)
Stainless steel 1.4408
(CF08M)
-46...+200°C
(-50...+392°F)
-46...+200°C
(-50...+392°F)
Low temperature
Ball valve CL150 2" SS CL150 2"
Ball valve CL300 2" SS CL300 2"
Stainless steel 1.4408
(CF08M)
Stainless steel 1.4408
(CF08M)
-196...+200°C
(-320...+392°F)
-196...+200°C
(-320...+392°F)
High temperature
Ball valve CL150 2" SS CL150 2"
Ball valve CL300 2" SS CL300 2"
Stainless steel 1.4408
(CF08M)
Stainless steel 1.4408
(CF08M)
-50...+400°C
(-58...+752°F)
-50...+400°C
(-58...+752°F)
Ball valve according to DIN
Component
Standard temperature
Ball valve PN16 DN50 SS
Connection Material (ASTM)
PN16 DN50 Stainless steel 1.4408
(CF08M)
Gas temperature range
-46...+200°C
(-50...+392°F)
Low temperature
Ball valve Stainless steel 1.4408
(CF08M)
-196...+200°C
(-320...+392°F)
High temperature
Ball valve PN40 DN50 PN40 DN50 Stainless steel 1.4408
(CF08M)
-50...+400°C
(-58...+752°F)
FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH 51
5.6.6.3
Fig. 21
Installation FLSE100-XT
Nozzle installation tool
The installation tool serves to align and weld the nozzle on the pipeline. SICK offers various nozzle installation tools depending on the nominal pipe diameter and path configuration.
The nozzle installation tool contains, per nozzle
● Welding aid M16 75 °(1),
● Centering plate 2” (2),
● Threaded rod M16 length 290 mm (3),
● Centering 2” (4),
● Assembly material
● Installation paper strip as tool to determine the exact nozzle position on the pipeline.
Nozzle installation tool
4 3 2
1
52 FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH
Installation FLSE100-XT
5.6.7
5.6.7.1
Fitting the nozzles on the pipeline (measuring system without spool piece option)
General preparation work
The installation tool ( p. 52, §5.6.6.3
) contains a foil strip (length approx. 4 times the pipe diameter, width approx. 0.75 of the pipe diameter) as a resource to determine the exact position of the nozzle on the pipeline. The foil strip is prepared with nozzle markings for different pipe diameters.
Fig. 22 General preparation work
1) Wind the strip around the pipeline at the selected measur ing point (ensure exact right-angled alignment) and secure
(e.g. with adhesive strips).
2) Mark the strip where overlapping starts.
3) Loosen the fastening, take the strip off and lay it out on a level surface.
Overlap line
U
For 1-path measurements, fold the strip to the overlap line so that the part matching pipe circumference (U) is halved.
FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH 53
Installation FLSE100-XT
5.6.7.2
Determining the nozzle position for cross-duct versions
NOTICE:
Note probe offset a and circumference U; these values are required to calculate path angle and path length during commissioning with FLOWgate TM .
Calculating probe offset a with the geometry calculator
The probe offset can be determined with the geometry calculator delivered on the product
.
1 Open the geometry calculator.
2 First select in the “Meter type” field of the “Calc transducer distance” tab whether it is a
1-path or 2-path installation.
3 Enter circumference U and wall thickness w.
4 Enter the “nominal nozzle angle” (e.g. 75, 60°, 45°).
5 Probe offset “Transducer Distance a” is calculated.
Marking the nozzle positions on the pipeline
Fig. 23 Determining the nozzle positions on the strip
1-path measurement
4a) Roll the strip out again and mark the kink line.
Overlap line U/2 Kink line
2-path measurement
4b) Roll the strip out again and mark the lines as follows:
2.498•r 2.498•r
0.6435•r 0.6435•r r = D/2
90 ° 90 °
90 ° 90 ° 90 ° 90 ° 90 °
5) Draw guide lines (1) for the nozzle positions with the previously calculated nozzle offset a, mark crossing points (2) and draw marking points (3) in distance 60 mm (x) from the crossing points.
U / 2 U x
x x x a x
x Path 1 Path 2 a
2 3 x x
2 3 1
54 FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH
Installation FLSE100-XT
Fig. 24 Marking the nozzle positions on the pipeline for cross-duct versions
1-path measurement 2-path measurement
6) Roll the strip back around the pipeline and mark the nozzle positions with crossing and marking points by using a metal center punch.
Path 1
Crossing point (marking for the center of the nozzle)
Marking point (aid for aligning the nozzle)
Crossing point (marking for the center of the nozzle)
Path 1
Path 2
Path 2
Marking point (aid for aligning the nozzle)
7) Take the strip off again and join the additional markings with a line.
Marking lines Marking lines
FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH 55
Installation FLSE100-XT
5.6.7.3
Determining the nozzle position for the probe version
Fig. 25 Determining the nozzle positions on the strip
1-path measurement 2-path measurement
1) Start preparation work as shown in p. 53, Fig. 22.
4a) Roll the strip out again and mark the kink line.
4b) Roll the strip out again and mark the lines as follows:
Overlap line U/2 Kink line r = U/2
2.498•r 2.498•r
90 ° 90 °
90 ° 90 ° 90 °
5) Draw a guide line (1) for the nozzle position(s), mark crossing points (2) and draw marking points (3) in distance 80 mm (x) from the crossing points.
U/2 1 U
2
3 x x x
x x x x
x
2 3 1
Path 1 Path 2
56 FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH
Installation FLSE100-XT
Fig. 26 Marking the nozzle position(s) on the pipeline for the probe version
1-path measurement 2-path measurement
6) Roll the strip back around the pipeline and mark the nozzle positions with crossing and marking points by using a metal center punch.
Path 1
Crossing point (marking for the center of the nozzle)
Marking point (aid for aligning the nozzle)
7) Take the strip off again and join the additional markings with a line.
Crossing point (marking for the center of the nozzle)
Path 1
Path 2
Path 2
Marking point (aid for aligning the nozzle)
5.6.7.4
Marking lines Marking lines
Welding the nozzle on
Use the installation tool that corresponds to the nozzle to be welded on the pipeline to carry out the following work.
WARNING: Hazards through combustible gases or high pressure
If “hot tapping” is not used, depressurize the pipeline and flush free of flammable gases before starting the work.
WARNING: Risk of explosion/health hazard
A faulty welding seam can allow gas to escape from the pipeline. This can immediately lead to a dangerous situation.
▸ Ensure welding seams are gas-tight.
▸ Check strength and durable tightness of the welding seams.
FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH 57
58
Fig. 27
Installation FLSE100-XT
WARNING: Qualified personnel required
● Any welding and installation work on pipelines may only be carried out by authorized personnel with a specific qualification.
● Special qualified and approved procedures have to be followed. This procedure requires the written agreement by the plant operator.
● The general safety requirements and all other plant operator instructions have to be followed.
▸
Position the welding aid (1) on the pipeline (2) as shown in → Fig. 27.
NOTICE:
Check the welding aid position after welding. The deviation from the drawn lines must not be more than 0.5 mm. Otherwise reposition the welding aid.
▸ Screw in threaded rod (3) with the sharp tip in the welding aid.
NOTICE:
The threaded rod is fitted by the manufacturer with a clamp ring. This is to aid removal of the centering plate following installation of the nozzles. The clamp ring should therefore not be removed.
Positioning of the welding aid
View B
A
View A
1
2
Marking lines
View B
Flow direction
1
3
2
1
2
3
Welding aid
Pipeline
Threaded rod
Angle Type FLSE100-XT
75 ° F1F-S, F1F-M, F1F-H, F1F-P
▸
Slide centering plate (4) on the cone of the welding aid (1) and fasten with the nut (5).
▸
Slide nozzle (6) over threaded rod and centering plate.
FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH
Installation FLSE100-XT
Fig. 28
▸
Position centering (7) into the nozzle opening so that the marking on the centering cor responds to the nozzle type (ANSI or DIN, size).
▸
Screw counternuts (8), (9) onto the threaded rod, position and secure the nozzle with suitable auxiliary materials so that the required weld gap is achieved (e.g. use an uncoated wire).
Align the nozzle so that the marking lines on nozzle and pipe wall are flush.
▸
Then fasten the nozzle.
Fitting the nozzle
10
4 5 6 7 8 9
1
5
6
1
4
Welding aid
Centering plate
Nut
Nozzle
7 Centering
8, 9 Counter nuts
10 Clamp ring
Marking lines
▸ Unscrew the threaded rod as a whole from the welding aid. To do this, place a wrench on the counternuts. The centering plate will be removed by the clamp ring.
▸ Finish off the weld seam piece by piece and allow sufficient time for cooling down to avoid unnecessary strain or distortion on the nozzle and pipe wall.
To achieve the measurement uncertainty according to p. 153, §12 "Technical data",
avoid lowering the nozzles into the pipe wall or distortion of the nozzles.
▸ For cross-duct versions of FLOWSIC100 Flare-XT (F1F-S, F1F-M, F1F-H):
– Determine the distance D1 between outer pipe wall and centering after a sufficient time for cooling down.
– On cross-duct versions, weld the nozzle on the opposite pipeline side in the same manner and then determine distance D2.
– Note measures D1 and D2; these measures are required for the geometric calculation during commissioning .
FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH 59
Fig. 29 Determining the effective nozzle length
Installation FLSE100-XT
(Nozzle)
Centering
D1
▸ Ball valves have to be installed when using retractable sender/receiver units. The ball valves are installed after finishing nozzle welding.
▸ Check and ensure gas tightness of ball valve installation before you continue.
WARNING: Hazard through leakage
▸ Operation in leaky condition is not allowed and potentially dangerous.
▸
Hazard through explosive, toxic and hot gas!
Drilling holes into the pipeline if plant is out of operation
The pipe wall must be drilled out at the nozzle position so that the sender/receiver unit can be inserted into the pipeline (
▸ Only once on each nozzle.
▸ Have this work done by skilled persons specially qualified for this work.
60 FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH
Installation FLSE100-XT
Drilling holes into the pipeline if plant is in operation (hot tap)
WARNING: Hazards during hot tapping
When sender/receiver units are installed on the pipeline when the pipeline is in operation (hot tapping):
▸ Only have this work done by skilled persons qualified for hot tapping.
▸
Comply with all legal, general and company-internal regulations.
▸ Only start installation work when all planned measures have been checked and approved by the plant operator.
▸
Only once on each nozzle.
▸
The hole cutter diameter must be 46 ... 48 mm for 2“ nozzles.
▸
Mount the drilling tool on the ball valve.
▸
Open the ball valve and drill out the holes in the pipeline in the center of the nozzle position.
▸
Retract the drilling tool.
▸
Close the ball valve again. Then, remove the drilling tool.
▸
Mount a blind flange on the ball valve as long as no sender/receiver unit is installed.
WARNING: Accident risk
When the hole has been drilled and no sender/receiver unit has been installed:
Gas flows through the pipeline when the ball valve is opened.
▸ Keep the ball valve closed and fitted until a sender/receiver unit has been fitted.
▸ Secure the ball valve against unintentional activation.
▸
Instruct other persons accordingly.
FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH 61
62
5.6.8
Fig. 30
1
Installation FLSE100-XT
Fitting the sender/receiver units
WARNING: General risks during installation
▸
Observe and follow the valid regulations and safety regulations as well as
the safety notices in p. 28, §5.2
▸ Take special precautions for plants with increased hazard potential (toxic/ aggressive/explosive gases, higher pressure, higher temperature).
Otherwise serious injuries are possible.
▸ Take suitable protection measures against possible local hazards or hazards arising from the equipment.
▸ Observe the allowable operating parameters during all work.
▸
Ball valve and sender/receiver unit do not function correctly following incorrect installation. Both parts can be damaged. Serious injuries are possible.
Overview
2 4 5
6 7 8
1
3
2 4
1 Electronics unit
2 Duct probe
3 Cutting ring screw connection
4 Retraction nozzle
3 6 7 8
5 Mounting kit (gasket, fastening screws, nuts, washers, centering sleeves)
6 Ball valve
7 Nozzle
8 Pipeline
FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH
Installation FLSE100-XT
Fig. 31
Using the centering sleeves
The mounting kit for the sender/receiver units includes centering sleeves.
The centering sleeves serve to ensure the centering of the process flanges of the sender/ receiver units.
Using the centering sleeves
4
3
4
5
Fig. 32
2
1
1 Centering sleeve
2 Washer
3 Nut
2
6
4 Flange
5 Fastening screw
6 Gasket
Using the nozzle insulation set (accessory)
To prevent galvanic corrosion of the LTCS nozzles and stainless steel ball valves, a nozzle insulation set is available as an option (Part No. 2057569). The sleeves included in the nozzle insulation set replace the standard centering sleeves. In this case, dispose of the centering sleeves and use the longer insulation sleeves instead.
Using the nozzle insulation set
5
4
2
3
1
1 Insulation sleeve
2 Washer
3 Insulating disc
4 Nut
5
6
2
3
7
5 Flange
6 Fastening screw
7 Gasket
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Installation FLSE100-XT
Check the following points before installation
● Sender/receiver units to be fitted for a particular measuring point must belong to the same system to ensure the maximum measurement accuracy possible. Exchanging structurally identical sender/receiver units from different measuring systems is not allowed.
● Sender/receiver unit pairs are matched and can only be exchanged in pairs for identical units.
● Sender/receiver units from one system are marked with sequential serial numbers
(printed on the device label).
The FLSE100-XT Master always has the lower number and the FLSE100-XT Slave the higher number.
● The flange connections of the sender/receiver units and nozzles must be compatible.
● The flange connections of the nozzles must be free of welding beads on the inside.
NOTICE:
The deformation characteristic of the flange gasket has an influence on the geometry of the installation and therefore on the uncertainty of the measurement. SICK recommends:
● Only use the same gasket type as the original delivery.
● Apply a tightening torque according to the installed gasket,
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Installation FLSE100-XT
5.6.8.1
Calculating the wetted part length wL and geometric installation parameters
Before installation, calculate how deep the sender/receiver units will be pushed into the pipeline.
The wetted part length depends on:
● Nozzle length
● Gasket thickness
● Ball valve length
● Wall thickness
NOTICE:
The wall thickness must be determined accurately to 0.1 mm. SICK recommends using a suitable ultrasonic measuring instrument to determine the wall thickness.
Calculating the wetted part length with the geometry calculator
1 Open the geometry calculator.
2 First select in the “Path number” field of the “Calc length, angle, diameter” tab whether it is a 1-path or 2-path installation.
3 In the field “Sensor type” (Transducer type), select whether the device is a “Cross duct” or “Probe” version.
4 Select “retractable” for installations with ball valve and “non retractable” for installa tions without ball valve.
5 For cross-duct versions, enter the probe distance “Transducer distance” a determined
for the nozzle installation tool, p. 54, §5.6.7.2
6 Enter the required dimensions:
– Circumference U
– Wall thickness w
– Gasket thickness S
– Gasket thicknesses D1 and D2
– For installation with ball valve: Length of ball valve VL
– Angle β: For cross-duct versions, enter the nominal nozzle angle (e.g. 75°, 60°,
45°). For the probe version, measure the installation angle and enter the exact value (maximum value for measuring the installation angle: ±0,3 °).
The wL (“wetted part length”) and geometric installation parameters are calculated.
NOTICE:
The geometric installation parameters in the “Result: Parameters for configu ration” area and the wall thickness are required for configuring the measuring system during commissioning.
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Fig. 33
Installation FLSE100-XT
Installation of F1F-S, F1F-M, F1F-H (cross-duct versions)
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Installation FLSE100-XT
Fig. 34 Installation of F1F-P (probe version)
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68
5.6.8.2
Fig. 35
Installation FLSE100-XT
Tightening the self-cutting ring
SICK recommends that the correct setting of the wetted part length and tightening the cutting ring be carried out in a workshop before installation in the pipeline.
Tightening the self-cutting ring in the correct position ensures the correct wetted part length for installation in the pipeline.
WARNING: Risk of leakage due to damage to the duct probe
If the duct probe is displaced when the pipe screw fitting is tightened, the duct probe may be damaged so that no tightness can be achieved after tightening the cutting ring.
▸ Only move the duct probe when the pipe screw fitting is loosened.
▸
Tighten the pipe screw fitting with a torque of 150 Nm after positioning the duct probe.
Otherwise there is a risk of leakage.
NOTICE: Damage due to incorrect position of the self-cutting ring
The position of the self-cutting ring cannot be changed after tightening! If the self-cutting ring is tightened in the wrong position, the sender/receiver unit must be replaced; for cross-duct versions both sender/receiver units must be replaced.
Before tightening the self-cutting ring, make sure that the wetted part length has been calculated correctly:
▸ Check the measured values.
▸
Check that the wetted part length is plausible compared with nozzle length and ball valve length.
Positioning of self-cutting ring (overview)
2
1 3
4
Wetted part length wL
1 Cap nut (self-cutting ring fitting)
2 Self-cutting ring marking
3 Pipe screw fitting
4 Duct probe
FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH
Installation FLSE100-XT
Fig. 36
Proceed as follows to set the wetted part length and to tighten the self-cutting ring:
1 Loosen the pipe screw fitting.
The pipe screw fitting is screwed hand-tight at the factory. Loosen the pipe screw fitting completely to set the wetted part length.
2 Set the calculated wetted part length wL and check with a length gauge (maximum
3 Screw in the pipe screw fitting and tighten with a torque of 150 Nm. Secure the sender/ receiver unit in a suitable manner, e.g.
– Screw the retraction nozzle to a suitable flange connection that provides the space required inside for the duct probe (diameter and length of the set wetted part length wL).
– Alternatively, install threaded bolts/screws in the through-holes of the retraction nozzle to prevent slipping. Position a suitable rigid rod between the threaded bolts/ screws for countering. Ensure that the duct probe and the flange sealing surface are not damaged.
Securing the sender/receiver unit (example)
4 First tighten the self-cutting ring fitting hand-tight.
NOTICE: Damage due to incorrect position of the self-cutting ring
The position of the self-cutting ring cannot be changed after tightening! If the self-cutting ring is tightened in the wrong position, the sender/receiver unit must be replaced; for cross-duct versions both sender/receiver units must be replaced.
Before tightening the self-cutting ring, make sure that the wetted part length has been calculated correctly:
▸
Check the measured values.
▸ Check that the wetted part length is plausible compared with nozzle length and ball valve length.
5 Now tighten the self-cutting ring fitting tight 1.25 turns.
Counter with a jaw wrench at the pipe screw fitting.
6
Mark the self-cutting ring fitting position, → Fig. 35.
7 Completely loosen the pipe screw fitting again.
8 Loosen the cap nut again and fully retract the sender/receiver unit for transport and installation in the pipeline.
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Installation FLSE100-XT
9 The self-cutting ring remains in the fixed position on the duct probe.
10 Then tighten the pipe screw fitting again hand-tight.
WARNING: Leakage hazard
Repeated use may damage the gasket of the pipe screw fitting.
▸
Before reuse, i.e. whenever the pipe screw fitting is to be tightened again, check the gasket of the pipe screw fitting:
▸
Replace the gasket if it has visible deformations, indentations or damage. In this case contact SICK Service.
Otherwise there is a risk of leakage.
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Installation FLSE100-XT
5.6.8.3
Installing the sender/receiver units
1 Make sure the ball valves are closed.
– If applicable, close ball valves.
– If applicable, remove blind flanges.
2 Position the flange gasket.
3 Position the sender/receiver unit on the ball valve.
Make sure the gasket does not move during positioning.
For cross-duct versions, make sure to install the Slave sender/receiver unit (→ Fig. 10)
on the nozzle on the downstream side so that the sender/receiver unit points against the flow direction.
4
Insert the 4 bolts with the centering sleeves (→ Fig. 31) and screw the sender/receiver
unit onto the ball valve.
Apply a tightening torque according to the installed gasket, p. 185, §15.4
.
5 Completely loosen the pipe screw fitting.
6 Open the ball valve.
WARNING: Danger due to gas leaks
When gas escapes, close the ball valve again and contact SICK Service.
7 Push the sender/receiver unit into the pipeline.
8 Check the gasket of the pipe screw fitting for damage.
WARNING: Leakage hazard
Repeated use may damage the gasket of the pipe screw fitting.
▸ Before reuse, i.e. whenever the pipe screw fitting is to be tightened again, check the gasket of the pipe screw fitting:
▸
Replace the gasket if it has visible deformations, indentations or damage. In this case contact SICK Service.
Otherwise there is a risk of leakage.
9 Screw in the pipe screw fitting and tighten with a torque of 150 Nm.
10 Push the sender/receiver unit to the stop.
11 On probe version F1F-P, now align the measuring path correctly before securing the selfcutting ring fitting. For cross-duct versions, proceed with the next step.
12 Tighten the self-cutting ring fitting tight 1.25 turns.
Make sure the markings for the self-cutting ring fitting are next to each other again,
13 For cross-duct versions, install the Master sender/receiver unit on the nozzle on the upstream side so that the sender/receiver unit points in the flow direction.
Observe when aligning the probe version
Before securing the self-cutting ring fitting again, align probe version F1F-P correctly:
The measuring path must be aligned in flow direction, i.e. the arrow shown must point in flow direction.
FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH 71
Fig. 37 Marking on probe version F1F-P
Installation FLSE100-XT
Flow direction
▸
Align the measuring path of probe version F1F-P as shown, see → Fig. 37. The
maximum deviation of the rotation angle of the probe to the flow direction may be ±3°.
To ensure this, use a laser to align probe version F1F-P:
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Installation FLSE100-XT
Fig. 38
Alignment of the device to the flow direction using a laser
WARNING: Risk of explosion
The laser may only be used if no Ex atmosphere is present. Use of the laser is not permitted under Ex conditions.
1 Mark the pipe center one meter before and after probe version F1F-P, e.g. with chalk or
2 Place a laser on the side of the electronics housing and let the laser beam hit the pipe at the level of the end of the first marking.
3 Measure the distance between the point of impact of the laser and the marking on the pipeline.
4 Repeat the procedure for the second marking.
5 Align the electronics housing so that distance a corresponds approximately to distance b.
The maximum permissible difference between value a and value b is 10 mm.
6 After alignment, tighten the self-cutting ring fitting 1.25 turns.
Make sure the markings for the self-cutting ring fitting are next to each other again,
Alignment of probe version F1F-P
2
1
2 a b
Marking: 1 m Marking: 1 m
1 Laser
2 Laser beam
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5.6.8.4
Installation FLSE100-XT
Leak tightness check
NOTICE:
▸ Perform a leak tightness check with suitable means after completion of the installation work.
▸ Also perform a leak tightness check with suitable means after completion of the installation work with spool piece. No leakage check has been made at the factory.
▸
After a successful leak tightness check, connect the sender/receiver units electrically,
.
NOTICE:
Proceed as follows when leak tightness is not established:
Pull the sender/receiver units back and disconnect them from the process
by closing the ball valve, p. 75, §5.6.9
.
Contact SICK Service.
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Installation FLSE100-XT
5.6.9
Fig. 39
Pulling the sender/receiver units back
WARNING: Hazard through incorrect use of the retraction mechanism
▸
Observe the information on activating the retraction mechanism, p. 30,
1
Completely loosen the cap nut of the self-cutting ring fitting, → Fig. 39.
2
Completely loosen the pipe screw fitting, → Fig. 39.
3 Pull the sender/receiver unit back completely to the stop.
4 Close the ball valve.
NOTICE:
The ball valve must close without resistance.
If this is not possible:
▸ Make sure the sender/receiver unit has been pulled back completely.
NOTICE:
Do not use force when the sender/receiver unit cannot be pulled back.
▸ Tighten the pipe screw fitting again with a torque of 150 Nm.
▸
Contact SICK Service.
Cap nut
2
1
1 Cap nut (self-cutting ring fitting)
2 Pipe screw fitting
WARNING: Hazardous gas (possibly explosive or toxic)
Consider the gas trapped in the retraction nozzle,
.
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5.6.10
Fig. 40
Installation FLSE100-XT
Fitting the venting valve
A venting valve is available as an option from SICK (Order No. 2108210).
Use a suitable valve with 1/8" NPT thread when the valve available from SICK is not used.
WARNING: Hazard through gas in the pipeline
▸ Install the venting valve only when the sender/receiver unit is not yet installed in the pipeline or when the pipeline is free from pressure and dangerous gas.
▸ During installation and operation, adjust the position of the vent so that personnel do not come into direct contact with the medium.
▸
Open the vent slowly.
▸ Small quantities of medium can escape via the spindle in the open position. Take appropriate protective measures for the operating personnel.
1
Remove the blind plug on the sender/receiver unit, → Fig. 40.
2 Wrap the sealing tape (PTFE) 2.5 layers around the external thread of the venting valve in thread direction.
3 Screw the venting valve in.
Pay attention to the alignment of the key surfaces: The valve must not hit the ball valve; align the wrench surfaces as parallel as possible to the flange sealing surface.
4 Tighten the screw plug of the valve so that no gas escapes there.
5 Then carry out a leak tightness check with suitable means.
Venting valve connection
1 Blind plug; venting valve connection
1
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Installation FLSE100-XT
5.6.11
5.6.11.1
Fig. 41
Fitting the weatherproof cover for the sender/receiver unit
The weatherproof cover (Order No. 2105581) serves to shield the electronics of the sender/receiver unit from sunlight and weather influences.
Overview
Weatherproof cover overview
3
2
1
2
4
5
6
1 Holder
2 Safety splints
3 Weatherproof cover
4 Washers
5 Hexagon nuts
6 Round steel bow
4 5
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Fig. 42 Dimensions [mm]
188
Installation FLSE100-XT
271
5.6.11.2
Fitting the weatherproof cover
1 Fasten the holder on the sender/receiver unit:
Fasten the holder with round steel bow to the probe neck of the sender/ receiver unit using hexagon nuts with washers.
Make sure the holder is correctly aligned and the probe is not damaged. See the adjacent Figure.
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Installation FLSE100-XT
2 Push the weatherproof cover into the holder.
3 Fix the weatherproof cover with the four safety splints.
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80
5.7
5.7.1
5.7.2
5.7.3
Installation FLSE100-XT
Electrical installation
General instructions, prerequisites
All assembly work previously described must be completed (as far as applicable) before starting installation work. Unless otherwise agreed with SICK or an authorized representative, all of the installation work must be carried out by the plant operator. This includes laying and connecting the power supply and signal cables and installing switches and power fuses.
WARNING: Electrical hazard
Incorrect cabling can cause serious injuries, device malfunctions or failure of the measurement system.
▸
Observe the relevant safety regulations as well as the safety notices in
during all installation work.
▸
Take suitable protection measures against possible local hazards or hazards arising from the equipment.
Cable specification
The following cable specifications correspond to the standard SICK cables. Special require ments on cabling in the Ex zone are not considered here. The plant operator is responsible that all cables used comply with valid regulations and guidelines for cabling in hazardous areas at the plant.
Standard connection cables between sender/receiver units
The standard connection cables between sender/receiver units are included in the scope of delivery.
● Connection cable between sender/receiver units of device types F1F-M, F1F-S
Cable type:
Exi, coaxial, RG62, connection TNC with safeguard against pulling off, length
3 m
● Connection cable between sender/receiver units of device type F1F-H
Cable type:
Armored cable with certified flameproof cable glands including separating seal, completely mounted, length 5 m
Connection cable between sender/receiver units and higher level control system
The connection cable between sender/receiver units and the higher level control system must comply with the following standard and can optionally be ordered from SICK:
Cable type: Li2YCYv(TP) 2x2x0.5 mm², with reinforced outer sheath, from Lappkabel
The cable must fulfill the following requirements for function of the device:
– Operating capacity < 150 pF/m
– Wire cross-sectional area at least 0.5 mm² (AWG20 to AWG16 max.)
– Screen with Cu wire mesh
Cable glands
The enclosure inputs are closed with certified sealing plugs. Cable glands are not included in the scope of delivery, except for the completely installed connection cables between the sender/receiver units type F1F-H.
Only use installation material approved for the applied hazard zone.
The user is responsible for correct selection.
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Installation FLSE100-XT
5.7.4
Requirements for installation in the Ex zone
WARNING: Risk of explosion
▸ Do not open the enclosures while energized.
▸
Do not connect or disconnect the circuits unless the voltage has been turned off or the area is safe.
▸ When using alternative connection of devices not belonging to the system, especially external power supply devices, power supply units, etc., ensure that the maximum voltage at the connections does not exceed 125 V even if a fault occurs.
▸
Do not use the device when cables or terminals are damaged.
General information
● The documentation for zone classification according to EN 60079-10 must be available.
● The devices to be used must be checked for suitability for the application area.
● After installation, an initial test of the device and the plant according to EN/
IEC 60079-17 must be performed.
Cables
● Cables must fulfill the requirements according to EN 60079-14.
● Protect cables especially endangered by thermal, mechanical or chemical stress, e.g. by laying in protective tubes.
● Cables must be flame-retardant according to DIN VDE 0472 Part 804. The fire behavior according to B / IEC 60332-1 must be approved.
● Observe the clamping range of the cable glands for cable selection.
● Ex-d cable gland must be suitable for the intended cable type (e.g. cables with or without armoring).
● Cables and lines for Ex-d cable glands must comply with the requirements in
EN 60079-14.
● Protect the wire ends with connector sleeves against fraying.
● Replace unused cable glands with certified Ex-d sealing plugs.
● Connect or safeguard unused wires to ground so that a short circuit with other conductive parts is excluded.
● Carry out potential equalization in accordance with EN 60079-14 (see also the following
Section).
● “Conduit” systems must comply with the requirements in EN 60079-14 9.4 and 9.6. In addition, compliance with national and other relevant standards is required.
● “Conduits” according to IEC 60614-2-1 or IEC 60614-2-5 are not suitable.
● “Conduit” systems must be protected against vibration.
● Use thread sealant according to EN/IEC 60079-14, Section for threads with ½" NPT.
The following applies additionally for intrinsically safe cable connection with intrinsically safe ultrasonic transducers/probes for the F1F-M, F1F-P, F1F-S sender/receiver units:
● The device marking must at least include the information Ex ia.
● Use only cables delivered by SICK.
The connections of the intrinsically safe ultrasonic probes are designed so that the individual circuits are safely separated from other intrinsically safe and non-intrinsically safe circuits.
If the transducer circuits are disconnected while energizing, it still must be observed that the safe separation from other intrinsically safe and non-intrinsically safe circuits is not overridden and thus intrinsic safety endangered. For this reason, the associated connection
FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH 81
Installation FLSE100-XT cable should be disconnected at both ends, i.e. unplugged individually and successively, first from the electronics and then, if required, from the ultrasonic probes, or suitably attached to prevent uncontrolled movement of the cable with the unprotected, open cable connector.
The cables for the intrinsically safe components are marked either with “Exi” or a blue cable covering or with blue shrink sleeves on the cable ends or with the SICK item number, at least on the associated packaging. The technical safety data are shown in the Type Examination
Certificate.
● Operation of the sender/receiver units type F1F-M, F1F-P, F1F-S with sensors and components not belonging to the system and sensors from other manufacturers is not permitted. See the Type Examination Certificate for the technical safety data.
Specific requirements for installation in the USA and Canada
● Installations in USA must be carried out according to NEC (ANSI/NFPA70).
● Installations in Canada must be carried out according to CEC part 1.
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Installation FLSE100-XT
5.7.5
Fig. 43
Connection overview
Pin assignment in the terminal compartment of the sender/receiver units
Terminal compartment FLSE100-XT sender/receiver with electronics (Master)
1
2
Table 8
1 Terminal compartment open
2 Grounding terminals
Connection of the sender/receiver units
Terminals
Designation in
Terminal box
B
Master
Description
A +24 V DC GND
External connection ** yellow green white brown
Assignment IF1 IF1 +24 V DC GND
Slave
MCX connector
**: Applicable only for cables with wire color code according to DIN 47100
IF1: Communication between FLSE Master and a higher level control system (Interface 1)
MCX: Signal for FLSE Slave
NOTICE:
Self-locking terminals for wire sizes 0.5 .. 1.5 mm² (AWG20 ... AWG16).
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84
5.7.6
Fig. 44
Installation FLSE100-XT
Connection diagrams
Cabling of the sender/receiver units gnd B A
Service
RS485**
Display connection
Higher level
MCUP processor board
control system
(Interface Unit)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
A B C D E
On-site cabling in explosion protected
version according to p. 37, §5.3
br ws gn ge gnd
+24 V DC
RS485a
RS485b
Terminals
RS485b
RS485a
+24 V DC gnd ge gn ws br gnd
+24 V DC
RS485a
RS485b
FLSE100-XT (passive ultrasonic transducer *
*: Not for FLSE100-XT-P
FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH
Installation Interface Unit
FLOWSIC100 Flare-XT
6
Installation Interface Unit
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6.1
6.2
6.2.1
6.2.2
6.2.3
Installation Interface Unit
Intended use
The Interface Unit is a device for recording, processing and transferring of measured values. For example, the Interface Unit can be used for controlling the sender/receiver units FLSE100-XT as well as for the calculation, evaluation, output and display of measured value data.
Using the device for purposes other than those intended can lead to safety-critical conditions. The manufacturer bears no responsibility for any other use.
Safety information
Hazard through electrical equipment
WARNING: Danger through power voltage
▸ Disconnect power supply lines before working on power connections or parts carrying power voltage.
▸
Refit any contact protection removed before switching the power voltage back on again.
▸
The device may only be operated with the cover closed.
▸ Before opening the cover, the device must be disconnected from the power supply.
▸
The device must not be used if the electrical wiring (cables, terminals, ...) is damaged.
Hazard through electromagnetic interference
NOTICE:
According to EN55011:2009, the Interface Unit is a device of group 1, class A.
It is intended for operation in an industrial environment. In other environments, especially in living areas, it could possibly be difficult to ensure electromag netic compatibility due to the occurring conducted as well as radiated interferences. In this case, the operator may be required to take appropriate measures.
Hazards through explosive or ignitable gases
The Interface Unit may be used in potentially explosive atmospheres only according to the respective specifications.
WARNING: Hazards through explosive or ignitable gases
▸
In potentially explosive atmospheres, only use the version of the Interface
Unit specified for such use ( p. 87, §6.2.5
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Installation Interface Unit
6.2.4
6.2.5
Table 9
6.2.6
Hazards through electrostatic discharges
The electronic housing is painted in the factory with a layer thickness of max. 0.2 mm.
Special paintwork can have a higher layer thickness.
WARNING: Ignition hazard through electrostatic discharge
The plastic display surface dimensions of the display door and of the display exceed the allowable value for ignition group IIC. The user must take appropriate precautions to avoid ignition hazards through electrostatic dis charge.
Ignition hazards through electrostatic discharges exist when gas flow meters with special paintwork and a layer thickness >0.2 mm are used in applications with ignition group IIC in accordance with ATEX and IECEx.
▸ For installation, the risk of electrostatic charging of the surface must be reduced to a minimum.
Therefore, the device should not be installed in a location where the external conditions are conducive to the build-up of electrostatic charge on such surfaces. change previous text
▸ Use appropriate caution when performing maintenance and cleaning work.
For example, the surfaces should only be cleaned with a damp cloth. The respective devices will be identified by the manufacturer with a warning sign.
Operation in potentially explosive atmospheres
The Interface Unit is designed for use in potentially explosive atmospheres according to the respective device version:
Device versions
Version
Zone 2 / Div. 2
FCF-A
ATEX: II 3G Ex ec ia IIC T4 Gc
IECEx: Ex ec ia IIC T4 Gc
FCF-C
Ex ec ia IIC T4 Gc
Class I Zone 2, AEx ec ia IIC T4 Gc
Class I Division 2, Groups A, B, C and D,
T4
Operation in potentially explosive atmospheres
This is a hazardous area in which an explosive atmosphere exists under the following normal atmospheric conditions:
● Specified ambient temperature -40 ... +60 °C, optional maximum ambient temperature of +65 °C
● Ambient pressure 80 kPa (0.8 bar) to 110 kPa (1.1 bar)
● Air with normal oxygen content, typically 21 percent by volume.
Warning information on device
WARNING: Danger identification on device
The following symbol draws attention to important dangers directly on the device:
6.2.7
▸ Consult the Operating Instructions in all cases where the symbol is attached to the device or shown on the display.
Requirements on the personnel's qualification
▸ Read the Operating Instructions before putting the Interface Unit into operation.
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Installation Interface Unit
▸
Observe all safety information.
▸
If anything is not clear: Please contact SICK Customer Service.
Designated users
All operators of the Interface Unit should be specifically trained on this device, knowledgeable of relevant regulations, and able to assess potential hazards related to its operation. Skilled persons are persons according to DIN VDE 0105, DIN VDE 1000-10 or
IEC 60050-826 or directly comparable standards.
The named persons must have exact knowledge of operational hazards caused, e.g., by low voltage, hot, toxic, explosive gases or gases under pressure, gas-liquid mixtures or other media as well as adequate knowledge of the measuring system gained through training.
Specific requirements for the use of devices in hazardous areas
▸ Cabling/installation, device setup, maintenance and testing may only be carried out by experienced persons familiar with the rules and regulations for hazardous areas, in particular:
– Degree of protection
– Fitting instructions
– Area definition
▸
Regulations to be applied:
– IEC 60079-14
– IEC 60079-17 or comparable national regulations.
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Installation Interface Unit
6.2.8
Restrictions on use
WARNING: Hazard through pressure/temperature
▸ Only use the Interface Unit within the pressure and temperature limits as specified in these Operating Instructions as well as on the type plate.
WARNING: Dangerous voltage
▸
Do not open the enclosure while energized.
▸ Only operate internal switches if the device is not live or the area is safe.
▸
Do not connect or disconnect the circuits unless the power has been turned
▸ off or the area is safe.
It must be ensured that the rated voltage U connected to devices not belonging to the system, in particular external power supply devices, power supply units, etc.; except for the main power supply with U
M
< 253 V.
M
60 V is not exceeded when
▸
A suitable main power switch must be provided.
▸ Do not use the device when cables or terminals are damaged.
WARNING: Risk of explosion
In a closed enclosure, degree of contamination 2 according to IEC 60664-1 is assumed. Opening the enclosure is only permitted when the environment does not endanger degree of contamination 2 inside the enclosure (e.g. through penetration of conductive dust or moisture).
WARNING: Device restrictions/high risk use
The device firmware is not designed for any use requiring fail-safe performance in which the failure of the computer system could lead to death, serious personal injury, or severe environmental damage, and therefore must not be used in such areas.
FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH 89
6.3
6.3.1
Fig. 45
Installation Interface Unit
Product description
Product identification
Product name:
Manufacturer
Type plate
Interface Unit
SICK Engineering GmbH
Bergener Ring 27
01458 Ottendorf-Okrilla
Germany
The type plate is located on the right side of the device.
Type plate ATEX (example)
AC version DC version
Fig. 46 Type plate CSA (example)
90 FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH
Installation Interface Unit
6.3.2
Fig. 47
Type code
Interface Unit type code (example)
Product name
Application
Ex classification
Mechanical properties
Ambient conditions
Electroncis
Customized
FC F - AEC A1A1S TS 1S111F N
FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH 91
Installation Interface Unit
92
6.3.3
Fig. 48
Device components
Overview
1
2
3
4
11
1 Type plate
2 Display
3 Infrared interface
4 Display cover
5 Screw-on tabs
6 Electronics cover
10
7 Enclosure base
8 Pressure compensation element
9 Exterior ground terminal
10 Cable inlets
11 Enclosure door
FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH
5
6
7
8
5
9
Installation Interface Unit
Fig. 49 Metric cable glands (optionally available with 9 cable glands)
1 1 1
Fig. 50
1
1 Metric cable gland M20
2 Metric cable gland M25
3 Exterior ground terminal
2 1
Sealing plugs NPT (optionally available with 9 cable entries)
1 1 1 5
3
3
4
1 2
1 Sealing plugs NPT 1/2"
2 Sealing plugs NPT 3/4"
3 Exterior ground terminal
4 Flange plate
5 Identification plates for thread size
1
FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH 93
94
6.3.4
Fig. 51
Installation Interface Unit
Device description
The Interface Unit is used for the acquisition, processing and output of measured values and serial data. A multitude of different digital, analog and serial sensors can be connected to the Interface Unit.
As a modular expandable system, the Interface Unit contains a processor board on its motherboard as well as a basic set of serial interfaces. In addition, module slots are available for connecting up to six I/O modules (depending on device version). For the con nection of the field-side interfaces of the I/O modules, up to six slots with pluggable termi nal strips are available on the mainboard.
Up to nine cable inlet openings, either NPT or with metric cable glands, are available for routing all connection cables (depending on device version). The internally installed realtime clock also has a replaceable backup battery.
The Interface Unit is optionally supplied via DC voltage 12 ... 24 V DC or by an internally installed SELV wide range power supply with 24 V DC output voltage for the connection range from 115 ... 230 V AC.
It is possible to connect additional sensors to the Interface Unit. These can be connected to the internal terminal blocks. The sensors are supplied either via the internally generated
24 V DC or by routing the external supply voltage. The data connection between sensors and Interface Unit runs via the internal RS485. Additional terminal blocks provided can be used to connect several sensors.
Layout
Module Slots
CPU Module
Display
RTC
Back-up
Internal
Memory
Optional AC/DC Converter
Uout = 24 V DC
Serial
Interface
Power IN
12 ... 24 V DC
PA
115 .. 230 V AC IN optional
24 V DC Out
FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH
Installation Interface Unit
6.3.5
6.3.5.1
6.3.5.2
Interfaces
Basic equipment of mainboard
The mainboard is available in two versions: Standard and Extended
The following interfaces are provided:
● 1 Ethernet interface (Modbus TCP) for the Standard variant
2 Ethernet interfaces (Modbus TCP) for the Extended variant
● 3 RS485 interfaces (Modbus RTU / ASCII)
● 1 RS232 interface, for firmware updates
I/O module definition
Analog module type 1 (2AI/2AO)
● Two analog inputs, switchable as voltage input or 4 ... 20 mA current input
● The first analog input also has a serial HART master interface
● Two analog outputs (4 ... 20 mA)
● The first analog input also has a serial HART slave interface which can be optionally configured as HART master.
● Two electrically isolated auxiliary voltages for supplying up to two current loops; the module can be operated both passively and actively with two auxiliary voltages per module
Analog module type 2 (2AO)
● Two analog outputs 4 ... 20 mA
● The first analog output also has a serial HART slave interface which can be optionally configured as HART master.
● Two electrically isolated auxiliary voltages for supplying up to two current loops; the module can be operated both passively and actively with two auxiliary voltages per module
Digital module type 1
● Two switching outputs, individually switchable as digital input
● 4 digital outputs, one of which can be used as frequency output
Interface module FOUNDATION Fieldbus (FF)
● One serial FOUNDATION Fieldbus Slave interface
Detailed descriptions of the MODBUS, HART and FOUNDATION Fieldbus protocols are available as separate documents on the product CD, at www.sick.de or from SICK Service.
FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH 95
6.4
6.4.1
6.4.2
6.4.3
Installation Interface Unit
Installation
Safety information
WARNING: Risks during installation
▸ Observe the safety information in
▸
Observe and comply with regulations of the plant operator.
Otherwise hazards are possible and safe operation is not ensured.
CAUTION: Accident risk through inadequate fastening of the device
▸
Consider the device weight specifications when planning the mounting supports.
▸ Ensure sufficient stability:
– When fitting the device on a wall, ensure that the wall construction is sufficiently stable.
– When fitting the device on a pipe, ensure sufficient stability of the pipe.
▸ Use suitable fasteners to secure the device and optional accessories.
▸
Take the vibration load into account.
NOTICE:
The plant operator is responsible for the safety of the system under mechanical load.
NOTICE:
The Interface Unit is only suitable for vertical installation.
Scope of delivery
▸
Check that delivery includes all ordered parts.
▸
Check parts for possible transport damage.
NOTICE:
Do not put the interface Unit into operation if you notice any damage!
Tools required
● Allen keys SW 6 and 8
● Jaw wrenches size 13, 17 and 19
● Drill and tools for wall fitting
96 FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH
Installation Interface Unit
6.4.4
6.4.4.1
Fig. 52
Fitting the Interface Unit
Fit the Interface Unit in an easily accessible and protected position. The following must be taken into account:
▸ Maintain the ambient temperature range in accordance with the Technical Data under consideration of possible radiant heat (shield when necessary).
▸ Protect the Interface Unit against direct sunlight and atmospheric conditions (weather proof cover available as option).
▸ Select an installation location free from vibrations when possible and stabilize vibrations when necessary.
▸ Provide sufficient clearance for cables and opening the front panel.
▸ Select an installation location free of chemical influence.
Wall fitting
NOTICE:
▸ Use suitable fixing material for mounting.
▸
Observe the total weight of the Interface Unit as well as local and legal regulations for the design of the wall construction and fastening material.
▸ Ensure sufficient assembly clearance.
Dimension drawing, see
.
▸ Maintain a general clearance of 15 cm around the enclosure to ensure better heat circulation.
▸ The distance between enclosure base and wall must be 10 mm; the wall must be flat.
The air circulation behind the Interface Unit must not be obstructed.
General clearance to Interface Unit
15 cm
FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH 97
6.4.4.2
Fig. 53
Installation Interface Unit
Option “Mounting kit 2-inch pipe mounting”
▸
Use two round steel bows (1), nuts (2) and washers (3) to fasten installation plate (4)
2-inch pipe (Order No. 2109763), → Fig. 53.
▸
Use nuts (5), washers (6) and screws (7) to fasten the Interface Unit on the installation
plate through the 4 marked openings, → Fig. 54.
Fitting the installation plate on the 2-inch pipe (dimensions in mm)
Detail 1
Ø 60.3
Detail 1
45
2 3
1 4
1 Round steel bow DIN3570
2 Washer A13 -A4
3 Nut M12 -A4
4 Installation plate
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Installation Interface Unit
Fig. 54 Fitting the Interface Unit on the installation plate
Detail 2
5 Nut M10 DIN934
6 Washer B10.5 DIN125
7 Screw M10 DIN912
8 Holes for fitting the Interface Unit Zone 2
8
Detail 2
5 6
7
FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH 99
6.4.5
6.4.5.1
Fig. 55
Installation Interface Unit
Fitting the weatherproof cover
Weatherproof cover for Interface Unit for wall fitting
NOTICE:
The weatherproof cover for wall fitting (Part No. 2108970) is delivered without fastening material.
▸
Use suitable fastening material to fit the weatherproof cover on the wall.
▸ Observe the total weight of the Interface Unit together with the weather proof cover as well as local and legal regulations for the design of the wall construction and fastening material. Weight of Interface Unit and weather -
proof cover, see Technical Data p. 158, §12.3
Dimensions [mm]
554
448
Fig. 56
1 First screw the weatherproof cover to the wall through the two holes marked in
Fitting the weatherproof cover on the wall
100
2 Then screw the Interface Unit also to the wall through the four holes in the weatherproof
FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH
Installation Interface Unit
Fig. 57 Fitting the Interface Unit on the weatherproof cover
1
6.4.5.2
1 Holes for fitting the Interface Unit Zone 2
Weatherproof cover for Interface Unit for fitting on a 2-inch pipe
The weatherproof cover for fitting on a 2-inch pipe (Part No. 2109217) is delivered as a set comprising the following components:
● Mounting plate
● Weatherproof cover
● Fastening material (round steel bow, screws, washers, nuts)
Fitting the weatherproof cover
1 The installation plate for the Interface Unit is screwed with the weatherproof cover for transport. For fitting on the 2-inch pipe, first dismount the mounting plate from the weatherproof cover.
2
Fasten the installation plate to the 2-inch pipe according to p. 98, §6.4.4.2
and
3 Screw the weatherproof cover with the supplied fastening material through the four
holes marked on the mounting plate, → Fig. 58.
FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH 101
Fig. 58
Installation Interface Unit
Fitting the weatherproof cover on the installation plate
1 2
Detail
3 4
Detail
1 Installation plate
2 Weatherproof cover
3 Screw M8 DIN912
4 Washer A 8,4 DIN125
5 Nut M8 DIN934
4 Also screw the Interface Unit to the installation plate through the four holes of the
weatherproof cover using the supplied assembly material, → Fig. 59.
5
102 FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH
Installation Interface Unit
Fig. 59 Fitting the Interface Unit on the weatherproof cover
1
Fig. 60
1 Holes for fitting the Interface Unit Zone 2
Interface Unit with fitted weatherproof cover
1 2 3
1 Screw M10 DIN912
2 Washer B10.5 DIN125
3 Nut M10 DIN934
FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH 103
Detail
6.4.6
Fig. 61
Installation Interface Unit
Fitting the tag plate (available as option)
Two versions of the tag plate are available:
● As label
The label with the tag number is already glued on at the factory when this variant is selected.
● As label with an additional stainless steel tag plate
The label with the tag number is already glued on at the factory when this variant is selected and the additional stainless steel tag plate then attached after electrical installation. This Section describes fitting the stainless steel tag plate.
NOTICE:
▸
Fit the tag plate after the electrical installation in p. 106, §6.5
.
Overview
1
104
2
1 Label with tag number
2 Stainless steel tag plate
Fitting the stainless steel tag plate
▸
Before fitting the tag plate ensure it is the correct tag plate. Compare the tag plate with the tag number on the Interface Unit.
▸
Fit the tag plate.
The tag plate assembly kit comprises 4 screws with different lengths (2 short, 2 long) and one contact disc:
WARNING: Hazard through electrostatic discharge
Fit the contact disc provided with one of both screws.
The contact disc ensures the stainless steel tag is securely earthed via the screw-on point.
– Use both longer screws for the Interface Unit with NPT cable entries (with flange plate): For fitting the tag plate, first unscrew two screws from the flange plate and replace these with the longer screws. Fit the contact disc with one of the two screws between the screw head and tag plate.
– Use both shorter screws for the Interface Unit with metric cable entries (without flange plate): Fit the contact disc with one of the two screws between the screw head and tag plate.
FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH
Installation Interface Unit
Fig. 62 Tag plate fitted
Interface Unit with metric thread Interface Unit with NPT thread
FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH 105
106
6.5
6.5.1
6.5.2
Installation Interface Unit
Electrical installation
Safety information
All assembly work previously described must be completed (as far as applicable) before starting installation work. Carry out all installation work on-site unless otherwise explicitly agreed with SICK or authorized representatives. This includes laying and connecting the power supply and signal cables and installing switches and power fuses.
WARNING: Electrical hazard
Incorrect cabling can cause device malfunctions, failure of the measurement system or serious injuries.
▸
Observe the relevant safety regulations as well as the safety notices in
during all installation work.
▸
Take suitable protection measures against possible local hazards or hazards arising from the equipment.
▸ All work may only be carried out when the device is disconnected from the power supply.
▸ Before opening the cover, the device must be disconnected from the power supply.
WARNING: Danger due to missing fuse protection of the power supply line
An external line fuse must be provided during installation. Internally, the main power supply lines are designed for an overcurrent protection device up to max.
16 A.
Requirements for the external main power switch:
▸ A main power switch must be provided in the installation.
▸
The main power switch must be located at a suitable position and must be easily accessible.
▸
The main power switch must be marked as disconnecting device for the device.
Cable specification
WARNING: Electrical hazard
▸ The cables and wires must be permanently installed. The plant operator must provide adequate strain relief.
▸
Cables must have a permitted operating temperature of min. 70 °C.
NOTICE: Requirements on cables and installation
▸ Pay attention to the requirements in EN 60079-14 when selecting the cables and during installation!
▸ Further legal requirements must be observed for use in explosive atmospheres.
▸
For devices with Ex approval, the cable inlets must have an Ex approval minimum Ex ec IIC.
▸
All cable inlets or cable sealing plugs must be approved for a temperature range of -40°C ... + 60°C or -40°C ... +65°C, depending on the version.
▸ Only copper wires may be used.
FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH
Installation Interface Unit
6.5.3
Power supply
● DC version
Max. 30 VDC, max. 1 A, recommended cable cross-section: 1 ... 2.5 mm 2
● AC version
Max. 253 VDC, max. 0.5 A, recommended cable cross-section: 0.75 ... 2.5 mm 2
Switching outputs
Max. 30 VDC, max. 70 mA, switching frequency max. 50 Hz, recommended cable crosssection: min. 0.5 mm 2
Digital output
Max. 30 VDC, max. 70 mA, switching frequency max. 10 kHz, recommended cable crosssection: min. 0.5 mm2, twisted pair, shielded
Analog output
Max. 30 VDC, max. 24 mA, recommended cable cross-section: min. 0.5 mm 2 , twisted pair, shielded
Analog input
Max. 30 VDC, max. 24 mA, recommended cable cross-section: min. 0.5 mm 2 , twisted pair, shielded
RS485
EIA -485, max. 57.6 kbit/s, termination 150 Ohm switchable, recommended cable crosssection: min. 0.5 mm 2 . twisted pair, shielded
Ethernet
10/100 Mbit/s, protocol Modbus TCP, recommended cable cross-section: Cat 5 or higher
Cable glands
Depending on the variant, the inputs of the device are installed with certified cable glands or with certified sealing plugs. Use only installation material approved for the hazard zone involved. The user is responsible for correct selection.
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6.5.4
Installation Interface Unit
Requirements for installation in the Ex zone
WARNING: Dangerous voltage
▸
Do not open the enclosure while energized.
▸ Only operate internal switches if the device is not live or the area is safe.
▸
Do not connect or disconnect the circuits unless the power has been turned
▸ off or the area is safe.
It must be ensured that the rated voltage U connected to devices not belonging to the system, in particular external power supply devices, power supply units, etc.; except for the main power supply with U
M
< 253 V.
M
60 V is not exceeded when
▸
A suitable main power switch must be provided.
▸ Do not use the device when cables or terminals are damaged.
WARNING: Ignition hazard through electrostatic discharge
The plastic display surface dimensions of the display door and of the display exceed the allowable value for ignition group IIC. The user must take appropriate precautions to avoid ignition hazards through electrostatic discharge.
Ignition hazards through electrostatic discharges exist when gas flow meters with special paintwork and a layer thickness >0.2 mm are used in applications with ignition group IIC in accordance with ATEX and IECEx.
▸
For installation, the risk of electrostatic charging of the surface must be reduced to a minimum.
Therefore, the device should not be installed in a location where the external conditions are conducive to the build-up of electrostatic charge on such surfaces. change previous text
▸
Use appropriate caution when performing maintenance and cleaning work.
For example, the surfaces should only be cleaned with a damp cloth. The respective devices will be identified by the manufacturer with a warning sign.
General information
● The documentation for zone classification according to EN 60079-10 must be available.
● The devices to be used must be checked for suitability for the application area.
● After installation, an initial test of the device and the plant according to EN/
IEC 60079-17 must be performed.
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Installation Interface Unit
Cables
● Cables must fulfill the requirements according to EN 60079-14.
● Cables must have a permitted operating temperature of min. 70 °C.
● Protect cables especially endangered by thermal, mechanical or chemical stress, e.g. by laying in protective tubes.
● Cables must be flame-retardant according to DIN VDE 0472 Part 804. The fire behavior according to B / IEC 60332-1 must be approved.
● The cross-section of each individual wire must not be smaller than 0.5 mm².
● Observe the clamping range of the cable glands for cable selection.
● Cables for Ex-e cable inlets must comply with the requirements in EN 60079-14 Section
11.3.
● The existing air and creepage paths according to EN 60079-7 or EN 60079-15 may not be reduced by cable connections in the terminal box.
● Protect the wire ends with connector sleeves against fraying.
● Replace unused cable inlets with the enclosed Ex-e sealing plugs.
● Connect or safeguard unused wires to ground so that a short circuit with other conductive parts is excluded.
● Carry out potential equalization in accordance with EN 60079-14 (see also the following
Section).
● Use thread sealant according to EN 60079-14, Section 9.4 for threads with ½" NPT.
Specific requirements for installation in the USA and Canada
● Installations in USA must be carried out according to NEC (ANSI/NFPA70).
● Installations in Canada must be carried out according to CEC part 1.
FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH 109
6.5.5
6.5.5.1
Fig. 63
Installation Interface Unit
Electrical connections of the Interface Unit
Overview of electrical connections
Connection area and inner electronics of the Interface Unit
Connection area
1
2
3
Terminal blocks
6
15
14
13
12
17
16
5
Mainboard
4
7
110
18
1 Mainboard
2 DIN rail
3 Exterior ground terminal (connected with GND)
4 Shielding terminals
5 Terminal blocks
6 Terminal assignment sticker
7 Slots for I/O modules 1-6
8 Field connections for I/O modules P4 - P9 – direct connection to module slots 1-6
9 Field connection for ultrasonic sensors P3 – external serial bus
11 10 9 8
10 Field terminal connector P2 – Ethernet
11 Field terminal connector P1 – Power In 24 V DC
12 Fuse F1
13 Fuse F2
14 Field connection J2 – power supply connection of the internal power supply unit
15 Field connection J1 – 24 V output voltage of the internal power supply unit
16 Memory card (MIcro SD)
17 Backup battery for real-time clock (RTC)
18 Terminal block grounding
FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH
Installation Interface Unit
Fig. 64
The pin assignment is shown on the sticker on the inside of the door:
● Device module configuration
● Connection area for field-side wiring
● Termination resistors of serial RS485 lines
● Identification of fuses and fuse characteristics
Terminal assignment
6.5.5.2
Fig. 65
Device module configuration
The module configuration of the respective device is marked on the sticker on the inside of the enclosure door:
Module configuration (example; the first line designates module slots 1-6)
FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH 111
6.5.6
Fig. 66
Installation Interface Unit
Connection area for field-side wiring
Terminal blocks
Table 10
Terminal
No.
Terminal assignment of the terminal blocks
Short name Function Comment
Ground symbol Grounding Connected with GND
Conductor size
0.5 … 2.5 mm 2
7
8
9
10
5
6
3
4
1 L1
2 N
Separator / partition plate
GND
DC power
RS485-A1
RS485-B1
Phase conductor
Neutral conductor
Minus pole - DC
Positive pole - DC
Serial interface
Optional - AC variant
Variant-dependent wiring
DC variant
– Connection of ext. power supply unit
– Routing of external power supply to
FLSE100-XT sender/receiver units
AC variant:
– Internal 24 VDC power supply unit is connected
– Connection of external. FLSE100-XT sender/receiver units for their power supply
0.5 … 2.5 mm 2
GND is connected electrically with the exterior ground terminal
Installation option for connection of two
FLSE100-XT sender/receiver units, connection from P3 to the terminal blocks must be made on-site
112 FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH
Installation Interface Unit
Fig. 67
Overview of field connections mainboard and 115 ... 230 VAC power supply
Field connections
Plug/terminal name
P1
P2
P3
Pin identification
A3
B3 nc
TXD
RTS
RXD
CTS
COM
1
2
TXP – ETH1
TXN – EHT1
RXP - ETH1
RXP - ETH1
TXP – ETH2
TXN – EHT2
RXP – ETH2
RXP – ETH2
A1
B1
A2
B2
Function Comment Conductor size
Minus pole – DC, GND Power supply of electronic
Positive pole - DC unit, prewired at the factory to
Data line of first
Ethernet interface terminal block 3 to 6
100Base-TX or 10Base-T full and halfduplex Ethernet
0.5 … 1.5 mm 2
0.14 … 1.5 mm 2
Data line between of second Ethernet interface
100Base-TX or 10Base-T full and halfduplex Ethernet
Serial RS485
Serial RS485
Serial RS485 internal COM5,
Connection FLSE100-XT internal COM2,
Connection Scada, Service PC or Gas chromatograph internal COM3,
Connection Scada, Service PC or Gas chromatograph
0.5 … 1.5 mm 2
Not connected
Transmit data
Request to send
Receive data
Clear to send
Common Ground – connected electrically with GND
Serial RS232
Internal COM1,
Connection Scada, Service PC or Gas chromatograph
FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH 113
114
Installation Interface Unit
J1
J2
Plug/terminal name
P4 to P9
Pin identification
N nc
L
7
8
5
6
3
4
1
2
9
10
11
12
+24V DC
GND
Function
Directly connected to
I/O module slots 1 to 6, example:
P4 connected to slot 1 etc.
Exact pin assignment depending on the
Comment Conductor size
0.5 … 1.5 mm 2
Positive pole - DC
Minus pole – DC, GND
Neutral conductor
Not connected
Phase conductor
24V output voltage of internal power supply unit
*optionally available
Power supply connection of internal power supply unit, prewired to terminal blocks 1 and 2
*optionally available
0.5 … 2.5 mm 2
0.5 … 2.5 mm 2
6.5.7
Table 11
Pin ident.
1
2
3
24V_1 Auxiliary voltage for
GND_1 up to two current
AO1+/
HART1 loops, max. 60 mA
Analog output;
HART Slave
5
6
7
8
4
9
AO1-/
HART1
AO2+ Analog output
AO2-
24V_2 Auxiliary voltage for
GND_2 up to two current loops, max. 60 mA
AI1+/
HART2
10 GND_2
Analog input;
HART master
12 GND_2
Connection assignment of I/O modules
Signal definition of individual modules
Analog module type 1
(2AI/2AO)
11 AI2+ Analog input
I/O module
Analog module type 2
(2AO)
Digital module type 1
(2DI/6DO)
24V_1 Auxiliary voltage for up
GND_1 to two current loops,
AO1+/
HART1 max. 60 mA
Analog output;
HART Slave
AO1-/
HART1
AO2+ Analog output
AO2-
24V_2 Auxiliary voltage for up
GND_2 to two current loops, max. 60 mA
DO2-
DO5+/
DI1+
DO5 /
DI1-
DO6+/
DI2+
DO6 /
DI2-
DO3+ Digital output
DO3 -
DO4+ Digital output
DO4-
Switching output/ digital input
Switching output/ digital input
Interface module
FOUNDATION Fieldbus
(FF)
DO1+ Digital output FF H1+ FOUNDATION
DO1FF H1-
Fieldbus
DO2+ Digital output
FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH
Installation Interface Unit
6.5.8
Fig. 68
Electronics cover
Electronics cover
BATTERY
RTC BATTERY
BAT 1 use only type:
PANASONIC
BR 2032
SWITCH
DIGITAL
(2DI / 6DO)
FF
LED
Module Com
Module Status
D01
NAMUR
OC
MODULE 1
D02
NAMUR
OC
D03
NAMUR
OC
FF Power
FF Tx
FF Rx
Simulate disable enable
D04
NAMUR
OC
D05
NAMUR
OC
D06
NAMUR
OC
MODULE 2 MODULE 3 MODULE 4 MODULE 5 MODULE 6
PULL PULL
The electronics cover serves to protect the internal electronics from contamination.
The labeling on the electronics cover refers to the module slots.
Fig. 69 Electronics cover labeling
Labeling
Digital
FF
Description
Switch for NAMUR/OC changeover, for digital modules
Simulate switch, only for FOUNDATION Fieldbus
Switching between Open Collector and Namur,
● Disable: Measured and process values available via FOUNDATION Fieldbus
● Enable: Simulated values available via
FOUNDATION Fieldbus
LED
Mobile communication signaling
Module COM
Module Status
FF Power
FF Tx
FF Rx
1) Independent of external communication via FOUNDATION Fieldbus H1
Communication via backplane bus active
● Flashing: I/O module synchronization (once per I/O cycle, e.g. 500 ms)
● Blinking: Short-term I/O or communication error; check I/O module status
● Static on: Permanent I/O or communication error; check I/O module status
Bus line via FOUNDATION Fieldbus H1 available
● Flashing/blinking: Internal communication response of the I/O module 1)
● Static on: No communication
● Flashing/blinking: Internal communication response of the I/O module 1)
● Static on: No communication
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Installation Interface Unit
6.5.9
Figure 70
Switching (Open Collector - Namur) on digital modules
NOTICE:
Electrical parameters, see Technical Data, p. 158, §12.3
“Digital outputs”.
DO circuitry (Open Collector - Namur)
„OPEN COLLECTOR“ „NAMUR“
1 k
10 k
U
S
1 k
6.5.10
Fig. 71
Termination resistors of serial RS485 lines
For all three serial RS485 lines, termination resistors can be optionally connected via switches (Term-1...3).
The termination network is structured as follows:
Termination
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Installation Interface Unit
Fig. 72 Position of termination switches
6.5.11
Internal fuses
WARNING: Danger through power voltage
▸ Disconnect the power supply line before replacing the fuse.
The device has two internal fuses.
● Fuse F1 - protection of the DC supply for the complete electronic unit
Fuse characteristics:
Manufacturer: Eska Fuses
Part No.: 520.521
SICK Order No.: 2104408
D5 * 20; 2.5 A; quick-blow; with extinguishing agent
● Fuse F2 - depending on variant for securing the AC supply line
Fuse characteristics:
Manufacturer: Eska Fuses
Part No.: 522.722
Sick Order No.: 2105350
D5 * 20; 3.15 A; slow-blow; with extinguishing agent
NOTICE:
To prevent the fuse from blowing repeatedly, the user must determine the cause and take appropriate precautions before restarting the device.
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Installation Interface Unit
6.5.12
Table 12
Torque values for screw connections
All screw connections have to be tightened with a specific torque value:
Torque values
Electrical connection
Terminal block
Terminal P1
Terminal P2 ... P9
Terminal J1, J2
Definition of torque value
0.5 - 0.6 Nm
0.5 - 0.6 Nm
0.22 - 0.25 Nm
0.5 - 0.6 Nm
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Installation Interface Unit
6.6
Connecting shielding terminals
1 Strip the cable > 22 mm.
2 Leave a piece of the sheath in place to hold the wires together. As an alternative, use a cable strap.
3 Before securing the cable with the terminal, attach the associated plug-in connector.
Then connect the terminal to the shield.
4 Press the terminal down and slide it onto the rail to secure the cable.
> 22 mm
WARNING: Danger due to incorrect use of the shielding terminal
The insulation of the cable must not be clamped under the shielding terminal.
Otherwise there is no electrical contact and shielding is not guaranteed.
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Installation Interface Unit
5 Ensure the insulation of the cable is not clamped under the shielding terminal.
6 Check that the cable is correctly seated.
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Commissioning FLOWSIC100 Flare-XT
FLOWSIC100 Flare-XT
7
Commissioning FLOWSIC100 Flare-XT
Opening the display protective flap
Commissioning with the FLOWgate TM operating software
Function checks after commissioning
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7.1
7.2
Fig. 73
Commissioning FLOWSIC100 Flare-XT
General information
● Before commissioning, the sender/receiver units and the Interface Unit must be installed and electrically connected.
● The display language can be set directly on the device via the display, p. 122, §7.3
● The field setup wizard in the FLOWgate™ operating software supports commissioning,
Opening the display protective flap
▸
Loosen the screw on the display protective flap.
▸
Swivel the display protective flap down.
NOTICE: Display protective flap
Do not remove the display protective flap.
▸
Always keep the display protective flap closed when the display is not in use!
▸ Screw the display protective flap tight after finishing work.
Display protective flap
7.3
Setting the display language
The display language can be set directly on the display without login.
Available: English, German, Russian
1 Press ESC to go to the main menu.
2 Using the arrow buttons, navigate to the “Language” menu.
3 Press ENTER to open the “Language” menu.
4 Using the arrow buttons, navigate to the desired language.
5 Press ENTER to confirm the language selection.
The display language is changed.
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Commissioning FLOWSIC100 Flare-XT
7.4
7.4.1
Fig. 74
Commissioning with the FLOWgate
TM
operating software
Connect to the device
A data connection can be established with the device using the optical data interface and the infrared/USB adapter HIE-04 (Order No. 6050602).
This interface serves to configure the FLOWSIC100 Flare-XT. The infrared/USB adapter has a USB 2.0 interface. This interface provides the connection to the PC and transfers the
FLOWSIC100 Flare-XT data.
A device driver software must first be installed to operate the adapter on a PC.
The device driver software is on the delivered Product CD.
1 Install the device driver software before connecting the USB plug to the PC.
2 Connect the USB plug to the PC.
3
Fit the infrared/USB adapter to the infrared interface as shown (Fig. 74), a magnet
integrated in the reading head retains the adapter.
Aligning the infrared/USB adapter
Correct alignment
4 Install the FLOWgate TM operating software.
The FLOWgate TM operating software and the associated Manual are to be found on the
Product CD delivered with the FLOWSIC100 Flare-XT and on the SICK website.
5 Click on the FLOWgate TM icon to start FLOWgate TM :
6 Add the FLOWSIC100 Flare-XT to the Device Manager of the FLOWgate TM operating software and create a connection to the device.
Standard settings for connection with the infrared/USB adapter:
● Protocol: Modbus RTU
● Baud rate: 38400
● Modbus address: 1
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Fig. 75
Commissioning FLOWSIC100 Flare-XT
7 Login to the device with the default user “Operator”.
Standard password for the “Operator”: flaregas
8 Start the field setup wizard and follow the step-by-step instructions.
Connection with FLOWgate TM - Overview
7.5
Fig. 76
Field setup wizard
The field setup wizard leads step by step through the necessary parameterization of the
FLOWSIC100 Flare-XT and ensures no important settings are forgotten. The respective parameters are written to the Interface Unit and the FLSE-XT sender/receiver unit after every step.
▸ Switch to Configuration mode to start commissioning.
Starting Configuration mode
124
7.5.1
Path setup
The connected device is automatically recognized for a 1-path installation.
Proceed as follows for a 2-path installation:
▸ Push the slider control to “2 path”.
▸ The assignment of the two paths in the pipe is that the upper path is "Path 1" and the path below it has the number 2.
FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH
Commissioning FLOWSIC100 Flare-XT
Fig. 77
The FLSE100-XT Master always has the lower number and the FLSE100-XT Slave the higher number.
▸
Click “Use path setup”.
The connection to the sender/receiver units is created.
Path setup (2-path installation)
7.5.2
7.5.3
Identification
▸ Compare the serial numbers with the type plates.
▸ Enter a device name: The device name is freely selectable.
▸ Enter the location.
System/archives
Date and time
▸ Enter the date and time or synchronize with the PC.
Units
▸ Select the unit system for the display in FLOWgate TM .
▸ Set whether pressure values are to be shown as absolute or relative pressure.
Data archive settings
▸ Determine the storage intervals for the data archives.
The archives each have a memory of 65,000 entries and are ring buffers.
A typical setting at 1 hour allows saving data for a period of 7 years.
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7.5.4
Fig. 78
Commissioning FLOWSIC100 Flare-XT
Installation
NOTICE:
Systems consisting of Interface Unit, FLSE-XT sender/transmitter/receiver units and spool piece are preconfigured at the factory. Do not change the configurations for these systems and skip the “Installation”.step.
▸
For installations with ball valves, set slider “Path is retractable” to “Yes”.
Installation parameters
▸ Enter the dimensions determined during installation:
– Wall thickness w, circumference U
for the probe versions
– Nozzle length D1; and the length of the second nozzle D2 for cross-duct versions,
– Gasket thickness S, length of ball valve VL
▸ Click “Calculate probe offset”.
The probe offset is calculated.
▸ Click “Calculate parameter values”.
The parameter values are calculated.
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Commissioning FLOWSIC100 Flare-XT
7.5.5
Table 13
Pressure/temperature sensor
▸ Select source of pressure and temperature measured values.
Settings for connected pressure or temperature sensors
Selection pT sensor settings
Parameter Description
Single/dual source
Fall back type
Fixed value
Single
Dual
Last good value
Fixed value
Entry field
One sensor connected
Two sensors connected; an average is created from both measured sensor values
Last valid measured value of connected sensor
Value set under “Fixed value”
Fixed value for pressure or temperature
If “Fixed value” was selected under “Source selection” or when a sensor fails.
pT transmitter A/B
Source selection
External live value
Analog input
Measured value read in via the Modbus register
Pressure value read in via an analog input.
Fixed value
P Absolute/Gauge
P Source Abs Gauge
Absolute
Gauge
Value set under “Fixed value”
The connected sensor is an absolute pressure sensor
The connected sensor is a gauge pressure sensor
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Commissioning FLOWSIC100 Flare-XT
7.5.6
7.5.6.1
7.5.6.2
Table 14
7.5.6.3
Fig. 79
I/O configuration
In the I/O configuration step, the parameters can be set for the interfaces available in accordance with the ordered configuration. Depending on the configuration, several modules of one type may be available.
The designation Px behind the interface designation describes the position of the module,
for arrangement see p. 110, §6.5.5
Ethernet
The MAC address can be read out in this view.
▸ Enter IP address, network mask and gateway.
▸ When no gateway is used, enter “0.0.0.0” as gateway.
Factory settings:
● Ethernet port 1:
– IP address: 192.168.1.100
– Network mask: 255.255.255.0
● Ethernet port 2:
– IP address: 192.168.2.100
– Network mask: 255.255.255.0
RS485/RS232
Define the communication settings for connected devices, e.g., for connected gas chromatographs.
Selection options for connected devices
Selection
Flowgate Modbus Ser
Scada MODBUS Ser
MCU-P compatible
GC
Description
Connection Service PC via RS485-USB Adapter Using
Flowgate over greater distances than with infrared adapter
Connection Interface Unit to higher level control system
Interface Unit MODBUS Register mapping analog to MCUP
Connecting a standardized gas chromatograph
DI/DO (layout depending on the selected configuration)
Digital outputs DO1, DO2 and DO4 can be activated.
DO3 can be configured as status output or pulse output (PO1). The desired measured value can be assigned to the pulse outputs. The desired function can be assigned to the digital output in the “Function” menus.
DO5 and DO6 can be configured as digital inputs DI1 and DI2.
Example for the configuration of a digital output:
DO1 (example)
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Table 15
Fig. 80
Selection options
Selection
Checkcycle active
Warnings active
Alarms active
Flow direction
Description
Check cycle of the sender/receiver units
Warnings are active on the FLOWSIC100 Flare-XT
Alarms are active on the FLOWSIC100 Flare-XT
Flow direction of the gas; positive flow direction (0), return flow (1)
● Invert logic: Inverts the logic of the output signal
● Alarm on error: In case of an error of the digital output, an error is displayed in the system status of the FLOWSIC100 Flare-XT
● Test mode:
– Off: Test mode not active
– Permanently on: Test of digital output, permanently on
– Permanently off: Test of digital output, permanently off
Example for the configuration as pulse output:
PO1 (example)
Fig. 81
● Function: Output values of the pulse output; the following measured values can be output (forward = positive flow direction):
– Indicated volume fwd
– Base volume fwd
– Mass fwd
– CO2 mass fwd
● Factor: The factor indicates how many pulses are output per selected unit; in the
example (→ Fig. 80), 3.2 pulses per measured cubic meter of gas are output in the flow
direction.
● Alarm on error: In case of an error of the pulse output, an error is displayed in the system status of the FLOWSIC100 Flare-XT
● Test mode: Test mode active
● Test value: Impulses per calculation cycle of the application; the default duration of a calculation cycle is 500 ms.
Example for the configuration as digital output:
DI1 (example)
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Commissioning FLOWSIC100 Flare-XT
Table 16
7.5.6.4
Fig. 82
Selection options
Selection
Maintenance
Start check cycle
Start AO check cycle
Start AO check and check cycle
Data valid
Description
Set maintenance condition
Start check cycle of the sender/receiver units
Start check cycle of the analog outputs
Start check cycle of analog outputs and sender/receiver units
Overall status for the measuring point; when the control system signals an incorrect overall status, the Interface Unit increments the error counters, even when there is no error on the FLOWSIC100 Flare-XT
● Invert logic: Inverts the logic of the received signal
● Raw read: Instantaneous value, without debounce
● Debounce: Debounce time (the time a digital input must be constant without status change)
● Alarm on error: In case of an error of the digital input, an error is displayed in the system status of the FLOWSIC100 Flare-XT
● Test mode:
– Off: Test mode not active
– Permanently on: Test of digital input, permanently on
– Permanently off: Test of digital input, permanently off
AI/AO
▸
Determine the output values for the analog outputs.
▸
Determine whether an alarm is to be displayed for analog input errors.
Output via analog output (example)
● Lower output value: Minimum output value of the analog output
● Upper output value: Maximum output value of the analog output
● Test mode: Test mode active
● Test value: Test of the output in relation to the selected upper and lower output value
AO check cycle:
A lower and a higher output value can be set for the check cycle. Both values are output at the start of the check cycle for the time specified in the “Duration of steps” field.
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Commissioning FLOWSIC100 Flare-XT
7.5.6.5
Fig. 83
FFBUS
Displays the status of the FOUNDATION Fieldbus (FF) module. To view details of the status, click on the “?” symbol.
Status of the FOUNDATION Fieldbus module
The FF-related configuration is necessary to read values from the device, e.g., node address and communication relationship of the FF blocks. This FF configuration can only be accessed via the Fieldbus not via the FLOWgate TM operating software.
The FF address is set to 248 and the physical device tag to
“FLOWSIC_IU______commMod12345678” for example. Here, 12345678 is an I/O module specific serial number and not the serial number of the Interface Unit.
Please use official FOUNDATION Fieldbus configuration equipment or a field communicator to set these values according to the standards for your application.
Detailed descriptions of the MODBUS, HART and FOUNDATION Fieldbus protocols are available as separate documents on the product CD, at www.sick.de or from SICK Service.
FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH 131
7.5.7
7.5.7.1
Fig. 84
Fig. 85
Commissioning FLOWSIC100 Flare-XT
Molar mass
Algorithm for calculating the molar mass
▸ Select the desired algorithm for the use of the molar mass:
– Basic
– Hydro Carbon
– Carbon number
– MR113
VOG dependency
When the VOG dependency is activated, different algorithms can be selected for higher and lower gas velocities.
The field “VOG Limit” serves to define at which gas velocity the algorithm should switch over.
Basic algorithm
The basic algorithm is suitable for basically flammable gases with a constant composition and low hydrocarbons content. The basic algorithm is based on the following equation, which can be used to determine the molar mass for ideal gases
Basic algorithm formula
Mm = -------------------
VOS
2
Mm= molar mass
κ = adiabatic coefficient
R = universal gas constant
T = temperature
VOS = velocity of sound
The algorithm requires the adiabatic coefficient κ (mean value) as input value, . Velocity of sound and temperature can be measured by FLOWSIC100 Flare-XT. The algorithm is suitable for all ideal gases with pressures < 5 bar with constant gas composition.
Hydrocarbon algorithm
The hydro-carbon algorithm is suitable for typical hydrocarbon mixtures with inert gases proportion < 10%. On the basis of the velocity of sound, the molar mass is calculated with the assumption of a typical hydrocarbon mixture. Changes in the composition of the hydrocarbon fractions can be taken into account.
Hydrocarbon algorithm formula
132
Carbon number algorithm
The carbon number algorithm is suitable for calculating the molar mass for hydrocarbon mixtures. During the calculation, the carbon-number algorithm can compensate the influence of inert gas components CO
2
, N
2
, H
2
O and uncertainty of the molar mass
FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH
Commissioning FLOWSIC100 Flare-XT
Fig. 86 calculation improves. Fixed values of the inert gas components must be entered when the carbon number algorithm is selected. The portions can be configured in operating software
FLOWgate TM as medium constant values.
Carbon number algorithm formula
Fig. 87
Algorithm MR113n
MR113n is an algorithm for calculating the molar mass and other gas characteristics which is widely used for measurement of associated gas in Russia.
The algorithm is adapted better to the typical application conditions of this industry. The calculation of molar mass, compressibility and other characteristics is based on a known gas matrix with 14 components.
Gas matrix for algorithm MR113n
The gas composition can be configured with constant values or read in by a gas chromatograph. Various types can be selected in the operating software.
The algorithm provides the most exact results when a gas chromatograph is available.
Nitrogen compensation
Nitrogen compensation is available when using the carbon number algorithm.
In applications that inject nitrogen before the measuring device in order to ensure permanent purging, these nitrogen quantities are also recorded.
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Fig. 88
Commissioning FLOWSIC100 Flare-XT
If the quantity of flow rate N
2
is known, FLOWSIC100 Flare-XT can subtract this portion from the total quantity. Without this compensation, the purge air share with the measured molar mass of the combustible gases would be added to the total quantity of CO
2
which leads to higher CO
2
emission values.
Function of nitrogen compensation
Fig. 89
In the Setup wizard, you can select whether the nitrogen quantity should be configured as a constant value or read in via an analog input.
Nitrogen compensation
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Commissioning FLOWSIC100 Flare-XT
7.5.7.2
Fig. 90
7.5.8
Fig. 91
Compressibility
In addition to the flow rate, the measured pressure and temperature and the compressibility K under standard conditions and operating conditions are also required for the calculation of a volume flow at base conditions.
Calculation of volume flow at base conditions
Tsc
Tac
Qac = Operating volume flow
Qsc = Volume flow at base conditions
Pac = Pressure at operating conditions
Psc = Pressure at base conditions
Tac = Temperature at operating conditions
Tsc = Temperature at base conditions
K = Compressibility
For applications < 5 bar, compressibility can always be approximated sufficiently well with value 1. In applications with higher process pressures either constant values for the compressibilities can be configured in the Setup wizard or calculated with a suitable algorithm.
Application
CO
2
calculation
In flare gas applications, unlike CEMS measurements, CO
2
emissions cannot be measured directly because the CO
2
is only created directly at the flare during combustion. Typically, the CO
2
emissions are determined according to a calculation model, which has also been directly implemented in the FLOWSIC100 Flare-XT. Since the measuring device provides an important calculation variable, the mass flow, the calculation of CO
2
emissions can take place directly in the FLOWSIC100 Flare-XT.
The oxidation factor is an installation-dependent fixed value and describes the combustion quality and is provided by the flare manufacturer.
The emission factor describes the flare gas. As there is normally no precise information on the composition of the specific flare gas, an application-dependent fixed value is normally used.
But however, as the FLOWSIC100 Flare-XT can compensate for the components CO
2
, N
2 and H
2
O which contribute to the generation of CO
2
, the measuring system can calculate an emission factor. This allows direct calculation of the real, lower CO
2
emissions.
Formula for calculating the CO
2
emission emissionCO 2 = eCO 2 eCO2 =Emission factor CO
2
MFlow = mass flow rate
OxydationFactor = factor for completeness of combustion (ideal = 1; typically 0.94)
Source: Reporting of greenhouse gas emissions under Directive 2003/87/EC of the European Parliament and of the Council
FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH 135
Fig. 92 CO
2
-Emission factor
Commissioning FLOWSIC100 Flare-XT
7.5.9
7.5.10
7.6
User Management
The user management is only available when connected to the FLOWSIC100 Flare-XT via
Ethernet.
NOTICE:
SICK strongly recommends changing the initial password of the device. Please check also your local cyber security requirements, that may apply.
Completion
▸ If desired, reset meter levels, logbooks and archives.
▸ Create a Parameter report and archive the report with the delivery documentation.
▸
Optionally it is possible to create a Validation Certificate, p. 143, §9.4
Function checks after commissioning
▸
Check the device status, p. 143, §9.3.2
.
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Operation
FLOWSIC100 Flare-XT
8
Operation
Display and operating elements
FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH 137
8.1
8.2
Fig. 93
Operation
Operating concept
The Interface Unit display comprises an LCD display for measuring screens and configuring,
4 buttons for menu navigation and an area to attach an infrared/USB adapter (Order No.
6050602) for data communication.
Display and operating elements
Display and operating elements
1
2
Table 17
8.3
Table 18
3
1 Display
2 Buttons
3 Optical data interface (infrared)
Buttons
Esc
In menu
Returns to next higher level of the operator menu.
Toggles between single menu entries on one level.
ENTER Calls up a submenu.
Display in the symbol bar
Symbols
Symbol Significance Description
Device status: Malfunction The device has an error, the measured value is invalid.
Device status: Warning
Configuration mode
The device has a warning, the measured value is still valid.
Configuration mode is active, parameters can be changed on the device.
138 FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH
Operation
8.4
Menu navigation
Path
Start settings
Network
Network status
Network interface IP
Subnet mask
Gateway
Mac of onboard Eth.
Device setup
System time
Start of main measured values
Velocity of sound
Flow rate ac
Flow rate sc
Molar mass
Volume ac total
Volume sc total
Mass total
CO2 total
Pressure
Temperature
Velocity of gas
Start language
English
German
Russian
Format/unit (metric) Format/unit (imperial) m/s m 3 /h sm 3 /h g/mol m 3 sm 3 kg kg bar(a)
°C m/s
Connected/not connected x.x.x.x
x.x.x.x
aa:bb:cc:dd:ee:ff dd.mm.yyyy
time (format: 24 h) acf scf lbs lbs ft/s acf/h scf/h lb/lbmol psi
°F ft/s
FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH 139
8.5
Fig. 94
Operation
Status LEDs on the mainboard
The Status LEDs are located at the bottom left on the mainboard, → Fig. 94.
Status LEDs position
Table 19 Status LEDs description
LED
Pow
OK
Warn
Err
Description
Supply voltage present.
Normal operation, neither warnings nor errors exist.
Device status warning: At least one warning is pending in the device, the measured value is still valid.
Device status error: At least one error is pending in the device, the measured value is invalid.
140 FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH
Maintenance
FLOWSIC100 Flare-XT
9
Maintenance
i-diagnostics TM Software-Plug-in (optional)
FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH 141
142
9.1
9.2
9.3
Maintenance
Safety information
WARNING: Hazard through improper maintenance work
After all maintenance work, make sure the entire measuring system and any accessories installed are in a safe condition.
General information
Maintenance strategy
Just like any other electronic measuring system, the FLOWSIC100 Flare-XT requires regular maintenance. By inspecting the system regularly and observing the scheduled maintenance intervals, the service life of the device can be lengthened significantly and ensures measurements are always reliable.
Even though the FLOWSIC100 Flare-XT is often deployed in harsh environments, its design and measuring principle are such that the device requires only minimal maintenance.
Maintenance tasks
The tasks to be carried out are limited to routine checks and cleaning the surfaces of sender/receiver units and Interface Unit.
The FLOWSIC100 Flare-XT provides the option of carrying out i-diagnostics TM instead of extractive maintenance. This consists of “one-click verification” and time analysis of the most important diagnostic values (license for software plug-in required).
After passing the test, a certificate is provided and it is shown whether a field service will probably be required for extractive maintenance in the next period (1 year).
The prerequisite for this presentation is that the device has been used properly in the past
6 months to record the diagnostic data, as these are necessary for determining the trend.
Maintenance intervals
The maintenance interval depends on specific system parameters such as operation, gas composition, gas temperature, gas moisture as well as ambient conditions. By default, the manufacturer's requirement is that, if a verification interval of one year is observed, the measurement is ensured within the manufacturer's specifications.
An optional software plug-in allows the user to perform verification within the FLOWgate TM operating software based on the diagnostic data. This type of regular annual verification allows the interval between extractive field services to be extended up to 5 years.
The respectively issued Verification Certificates and the Annex must be kept. The activities required locally and their completion must be documented by the operator in a
Maintenance Manual.
Maintenance agreement
Regular maintenance work can be carried out by the plant operator according to the
Service manual when the plant operator has attended an official FLOWSIC100 Flare-XT service training by SICK. These activities must be carried out by qualified persons as described in
and
. If desired, SICK Service or authorized
Service support centers can carry out all maintenance work. Any repairs will be made by specialists on-site whenever possible.
Routine checks
Proper device function can be determined directly on the LC display of the device. The
FLOWgate™ operating software provides a user-friendly option for the performance of routine checks.
FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH
Maintenance
9.3.1
Table 20
9.3.2
Table 21
Function check on the display
If there is a warning or malfunction on the device, the corresponding symbol is shown on the display of the Interface Unit:
Symbols
Symbol Significance Description
Device status: Malfunction The device has an error, the measured value is invalid.
Device status: Warning The device has a warning, the measured value is still valid.
▸ An active error or warning is shown flashing on the LC and details can be retrieved with the FLOWgate™ operating software.
Function check with FLOWgate
TM
▸ Check the device status.
Signaling the device status in FLOWgate TM
Status Description
Normal operation, neither warnings nor errors exist
9.4
9.4.1
Device status warning: At least one warning is pending in the device, the measured value is still valid.
Device status error: At least one error is pending in the device, the measured value is invalid.
▸ Click on the symbol in the Status bar when warnings or errors exist.
The current Status overview opens and shows details and information on how to proceed.
i-diagnostics
TM
Software-Plug-in (optional)
To activate the extended i-diagnostics TM functions, you need an Entitlement ID (Claim ID), which you will receive by e-mail from the manufacturer after ordering the software plug-in.
One-click verification
The system checks itself and protocols its actual status. The one-click verification provides the option of creating a Validation Certificate and generate supporting documentation.
Proceed as follows to create a Validation Certificate:
Click in the Tool bar:
FLOWgate™ checks critical diagnosis parameters according to manufacturers' specifications.
After the end of the diagnosis, FLOWgate™ creates a Validation Certificate confirming compliance with the standards specified by the manufacturer as relevant for ensuring a valid measurement.
FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH 143
Fig. 95 Validation certificate
Maintenance
9.4.2
Fig. 96
Trend analysis – predictive maintenance
It is also possible to carry out a trend analysis. With the trend analysis, evaluations of various measurement and diagnostic values at past observation points can be made.
If the trend analysis suspects a fault in the future, the manufacturer recommends performing another trend analysis after about 2 months, but at least before reaching the predicted date. This serves to validate the trend in order to then initiate appropriate countermeasures.
The predicted date is based on the assumption of a linear trend and therefore only gives a realistic estimate for linear measurement/diagnostic values.
Trend analysis
144 FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH
Maintenance
9.5
9.5.1
9.5.2
9.6
9.6.1
Cleaning
Cleaning the FLSE100-XT sender/receiver units
▸
Only clean the surfaces of the FLSE100-XT sender/receiver units with a damp cloth.
▸
Only use materials for cleaning which do not damage the surface of the FLSE100-XT sender/receiver units.
▸
Do not use solvents for cleaning.
Cleaning the Interface Unit
Cleaning information
▸
Only clean the Interface Unit with a damp cloth.
▸
Only use materials for cleaning which do not damage the surface of the Interface Unit.
▸
Do not use solvents for cleaning.
▸
Only use cleaning agents free from oil, grease and solvents to clean the display.
Exchanging the battery
Battery types
WARNING: Hazard for intrinsic safety due to incorrect spare parts
Only PANASONIC batteries type BR2032 are permitted as RTC battery, otherwise intrinsic safety is endangered.
The battery may only be replaced after a Service training by SICK or by SICK
Service!
NOTICE:
The replaceable RTC battery has been assessed as intrinsically safe for the following potentially explosive atmospheres: Zone 2, Class I Zone 2 and Class I
Div 2.
The exchange may be carried out in these potentially explosive atmospheres.
FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH 145
Maintenance
146 FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH
Troubleshooting
FLOWSIC100 Flare-XT
10
Troubleshooting
Error signaling on the display
FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH 147
148
10.1
10.2
10.3
10.4
Fig. 97
Troubleshooting
Detecting malfunctions
Any deviations from normal operation must be regarded as a serious indication of a functional impairment. These include:
● Warnings displayed (e.g., high contamination)
● Significant drifts in the measuring results.
● Increased power input.
● A rise in system component temperatures.
● Triggering of monitoring devices.
● Smells or smoke emission
● Failure of a measuring path.
NOTICE:
Proceed as follows when a measuring path fails:
Pull the sender/receiver units back and disconnect them from the process
by closing the ball valve, p. 75, §5.6.9
.
Contact SICK Service.
Error signaling on the display
Pending errors or warnings are signaled on the display,
Contacting Customer Service
Contact SICK Customer Service for any malfunctions you cannot clear yourself.
To help Customer Service to understand malfunctions that have occurred, the
FLOWgate TM operating software provides the option to create a diagnostics file
that can be sent to Customer Service, p. 148, §10.4
Starting a diagnostic session
1 Click the icon in the Tool bar to start a diagnostic session.
2 Select the desired data collection duration.
It is recommended to select a data collection duration of at least 5 minutes.
Data collection duration for the diagnostic session
3 Click “Start” to start recording.
The following message with the current storage location of the data collection is shown after successful creation of the diagnostic session.
FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH
Troubleshooting
Fig. 98 Diagnostic recording completed
Fig. 99
4 Click “OK” to confirm the message.
5 Select the storage location for the diagnostic session:
– Click “Close” to leave the file at the standard storage location.
– Click “Save as” to select a storage location for the diagnostic recording.
– Click “E-mail” to send the file per e-mail. The file is appended to an e-mail when an e-mail client is available.
Save the diagnostic session
The diagnostic sessions are saved as files with the ending .sfgsession. The files are saved by default under:
C:\Users\Public\Documents\SICK\FLOWgate
The name of the storage folder consists of device type and serial number of the device.
FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH 149
Troubleshooting
150 FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH
Decommissioning
FLOWSIC100 Flare-XT
11
Decommissioning
FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH 151
11.1
11.1.1
11.1.2
11.2
11.2.1
11.2.2
Decommissioning
Returning
Contact
Please contact your SICK representative for assistance.
Packaging
Make sure the FLOWSIC100 Flare-XT cannot be damaged during transport.
Disposal information
Materials
● The FLOWSIC100 Flare-XT mainly consists of steel, aluminum and plastic materials.
● It does not contain any toxic, radioactive or other environmentally harmful substances.
● Substances from the pipeline can possibly penetrate, or deposit on seals.
Disposal
▸
Dispose of electronic components as electronic waste.
▸
Check which materials having contact with the pipeline must be disposed of as hazardous waste.
152 FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH
Technical data
FLOWSIC100 Flare-XT
12
Technical data
FLSE100-XT sender/receiver units
FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH 153
154
Technical data
12.1
System FLOWSIC100 Flare-XT
NOTICE:
The exact device specifications and performance data of the product may deviate and depend on the respective application and customer specification.
Only the metrological parameters described in the Application Evaluation
Datasheet apply.
If the delivery documentation of your FLOWSIC100 Flare-XT does not include an
Application Evaluation Datasheet, contact your SICK partner!
Example of an Application Evaluation Datasheet: p. 162, §12.4
Table 22 System FLOWSIC100 Flare-XT
Measuring parameters
Measured values
Number of measuring paths
Nominal pipe size
Measuring principle
Measured medium
Measuring ranges 1)
Repeatability
Resolution
Mass flow, volumetric flow s. c. (standard condition), volumetric flow a. c. (actual con dition), molecular weight, gas volume and mass, gas velocity, gas temperature, sound velocity
1 path, 2 paths
1-path measurement: 4 ″ ... 72 ″
2-path measurement: 12 ″ ... 72 ″
* Other nominal sizes on request
Ultrasonic transit time difference measurement, ASC technology
Typical flare gas
0.03 m/s … 120 m/s
According to ISO 5725-1; JCGM 200:2012): < 0.5% related to the measured value in the range ≥ 1 m/s
(According to JCGM 200:2012): + 0.001 m/s
Volumetric flow a. c.
1% … 5%
Related to the measured value with ultrasonic technology
(in the range ≥ 0.3 m/s to measuring range end value)
Uncertainty of measurement 1, 2) , 3)
0.5% … 1.5% with spool piece and flow calibration
Related to the measured value with ultrasonic technology
(in the range ≥ 1 m/s to measuring range end value) 4)
Mass flow rate
2% … 5.5%
Related to the measured value with ultrasonic technology
(in the range ≥ 0.3 m/s to measuring range end value)
1.5% … 2% with spool piece and flow calibration
Related to the measured value with ultrasonic technology
(in the range ≥ 1 m/s to calibration range end value) 4
Uncertainty of measurement ASC technology 1),2), 5)
Resolution
Ambient humidity
Compliances
Electrical safety
Volumetric flow a. c.: 1% … 8%
+ 0.001 m/s
≤ 95% relative humidity
ATEX: 2014/34/EU
EMC: 2014/30/EU
RoHS: 2011/65/EU
PED: 2014/68/EU
IEC 61010-1 (Non-Ex Interface Unit)
2)
3)
4)
5)
1) Depending on application conditions such as gas composition, process temperature, device type, pipe diameter, etc.
For mass flow rate, additional selection and configuration of the conversion algorithm as well as uncertainty of the pressure and temperature sensors. To be evaluated by SICK.
With fully developed turbulent flow profile. Typically 20D straight inlet and 5D straight downstream piping is required .
Below a specific threshold Reynolds number, only run time effects and uncertainties of geometry, excluding contributions from the flow profile are considered.
Depending on the capabilities of the selected flow lab.
Additional uncertainty. In the range 100% ... 130% of the last gas velocity measurable with ultrasonic transit time difference measurement.
FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH
Technical data
12.2
FLSE100-XT sender/receiver units
Table 23 Technical data FLSE100-XT
Power supply
Power supply
Power input
Inputs/outputs
Digital data interfaces
Approvals
Ex approvals
Ambient conditions
Temperature range
12…24 V DC, max. 500 mA
< 1 W
1 x RS485, optically isolated
ATEX, IECEx, US/C
Storage temperature
Degree of protection
Dimensions
Dimensions (W x H x D)
Ignition group IIC T4:
–40 °C ... +70 °C
–50 °C ... +70 °C (optional)
Ignition group IIC T6:
–40 °C ... +55 °C
–50 °C ... +55 °C (optional)
–40 °C ... +70 °C
–50 °C ... +70 °C (optional)
IP 66 / 67
Details, see dimension drawings
12.2.1
F1F-S
Table 24
Gas temperature
Ex approvals
IECEx
Technical data F1F-S
Measuring conditions
Operating pressure: 1) CL150 device flange: 20 bar (g)
PN25 device flange (optional): 20 bar (g)
CL300 device flange (optional). 20 bar (g)
–196 °C ... +280 °C
ATEX
NEC/CEC (US/CA)
Ex db [ia Ga] IIA T4 Ga/Gb
Ex db [la Ga] IIB T4 Ga/Gb
Ex db [ia Ga] IIC T6/T4 Ga/Gb
Ex ia IIC T6/T4 Ga
II 1/2G Ex db [ia Ga] IIA T4 Ga/Gb
II 1/2G Ex db [la Ga] IIB T4 Ga/Gb
II 1/2G Ex db [ia Ga] IIC T6/T4 Ga/Gb
II 1G Ex ia IIC T6/T4 Ga
Class I, Division 1, Group D, T4;
Class I, Zone 1, Ex/AEx d[ia] IIA, T4;
Class I, Division 2, Group D, T4;
Class I, Zone 2, Ex/AEx nA[ia] IIA, T4
Class I, Division 1, Groups C and D, T4;
Class I, Zone 1, Ex/AEx d[ia] IIB, T4;
Class I, Division 2, Groups C and D, T4;
Class I, Zone 2, Ex/AEx nA[ia] IIB, T4
Class I, Division 1, Groups B, C and D, T4;
Class I, Zone 1, Ex/AEx d[ia] IIB + H2, T4;
Class I, Division 2, Groups A, B, C and D, T4;
Class I, Zone 2, Ex/AEx nA[ia] IIC, T4
Installation
Weight ≤ 12 kg (sensor pair)
1)
Temperature-dependent, for details see p. 165, §12.7
»Derating pressure resistance«
FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH 155
156
Technical data
12.2.2
F1F-M
Table 25
Gas temperature
Ex approvals
IECEx
Technical data F1F-M
Measuring conditions
Operating pressure: 1) CL150 device flange: 20 bar (g)
PN25 device flange (optional): 20 bar (g)
CL300 device flange (optional). 20 bar (g)
–196 °C ... +280 °C
ATEX
NEC/CEC (US/CA)
Ex db [ia Ga] IIA T4 Ga/Gb
Ex db [la Ga] IIB T4 Ga/Gb
Ex db [ia Ga] IIC T6/T4 Ga/Gb
Ex ia IIC T6/T4 Ga
II 1/2G Ex db [ia Ga] IIA T4 Ga/Gb
II 1/2G Ex db [la Ga] IIB T4 Ga/Gb
II 1/2G Ex db [ia Ga] IIC T6/T4 Ga/Gb
II 1G Ex ia IIC T6/T4 Ga
Class I, Division 1, Group D, T4;
Class I, Zone 1, Ex/AEx d[ia] IIA, T4;
Class I, Division 2, Group D, T4;
Class I, Zone 2, Ex/AEx nA[ia] IIA, T4
Class I, Division 1, Groups C and D, T4;
Class I, Zone 1, Ex/AEx d[ia] IIB, T4;
Class I, Division 2, Groups C and D, T4;
Class I, Zone 2, Ex/AEx nA[ia] IIB, T4
Class I, Division 1, Groups B, C and D, T4;
Class I, Zone 1, Ex/AEx d[ia] IIB + H2, T4;
Class I, Division 2, Groups A, B, C and D, T4;
Class I, Zone 2, Ex/AEx nA[ia] IIC, T4
Installation
Weight ≤ 12 kg (sensor pair)
1) Temperature-dependent, for details see
»Derating pressure resistance«
12.2.3
F1F-H
Table 26 Technical data F1F-H
Measuring conditions
Operating pressure: 1) CL150 device flange:
ATEX/IECEx: 20 bar(g)
CSA: 16 bar(g)
PN25 device flange (optional):
ATEX/IECEx: 20 bar(g)
CSA: 16 bar(g)
CL300 device flange (optional):
ATEX/IECEx: 20 bar(g)
CSA: 16 bar(g)
–70 °C ... +280 °C Gas temperature
Ex approvals
IECEx
ATEX
NEC/CEC (US/CA)
Ex db IIC T6/T4 Gb
II 2G Ex db IIC T6/T4 Gb
Class I, Division 1, Groups B, C and D, T4;
Class I, Zone 1, Ex/AEx d IIB + H2, T4;
Class I, Division 2, Groups A, B, C and D, T4;
Class I, Zone 2, Ex/AEx nA IIC, T4
Installation
Weight ≤ 14 kg (sensor pair)
1) Temperature-dependent, for details see
»Derating pressure resistance«
FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH
Technical data
12.2.4
F1F-P
Table 27
Gas temperature
Ex approvals
IECEx
Technical data F1F-P
Measuring conditions
Operating pressure: 1) CL150 device flange:
ATEX/IECEx: 20 bar(g)
CSA: 16 bar(g)
PN25 device flange (optional):
ATEX/IECEx: 20 bar(g)
CSA: 16 bar(g)
CL300 device flange (optional):
ATEX/IECEx: 20 bar(g)
CSA: 16 bar(g)
–196 °C ... +280 °C
ATEX
NEC/CEC (US/CA)
Ex db [ia Ga] IIA T4 Ga/Gb
Ex db [ia Ga] IIB T4 Ga/Gb
Ex db [ia Ga] IIC T6/T4 Ga/Gb
II 1/2G Ex db [ia Ga] IIA T4 Ga/Gb
II 1/2G Ex db [ia Ga] IIB T4 Ga/Gb
II 1/2G Ex db [ia Ga] IIC T6/T4 Ga/Gb
Class I, Division 1, Group D, T4;
Class I, Zone 1, Ex/AEx d[ia] IIA, T4;
Class I, Division 2, Group D, T4;
Class I, Zone 2, Ex/AEx nA[ia] IIA, T4
Class I, Division 1, Groups C and D, T4;
Class I, Zone 1, Ex/AEx d[ia] IIB, T4;
Class I, Division 2, Groups C and D, T4;
Class I, Zone 2, Ex/AEx nA[ia] IIB, T4
Class I, Division 1, Groups B, C and D, T4;
Class I, Zone 1, Ex/AEx d[ia] IIB + H2, T4;
Class I, Division 2, Groups A, B, C and D, T4;
Class I, Zone 2, Ex/AEx nA[ia] IIC, T4
Installation
Weight ≤ 10 kg
1)
Temperature-dependent, for details see p. 165, §12.7
»Derating pressure resistance«
FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH 157
158
Technical data
12.3
Interface Unit
Table 28 Technical data of Interface Unit
Ambient conditions
Ambient temperature
Storage temperature
Ambient pressure
Geographic altitude
Relative humidity
–40 °C … +60 °C
–40 °C … +65 °C optional (number of maximum available I/O interfaces is limited)
–40 °C ... +70 °C
80 kPa (0.8 bar) ... 110 kPa (1.1 bar)
Up to 2000 m (above sea level)
Installation
≤ 95%
Relative humidity
Vertical wall or tube installation
Transient overvoltage Overvoltage category II
Environmental conditions Degree of contaminatiion 2
Installation location
Approvals
Indoor, outdoor
Ex approvals IECEx
Ex ec ia IIC T4 Gc
Degree of protection
Interfaces
Serial RS485
ATEX
II 3G Ex nA ia IIC T4 Gc
NEC/CEC (US/CA)
Ex ec ia IIC T4 Gc
Class I Zone 2, AEx ec ia IIC T4 Gc
Class I Division 2, Groups A, B, C and D, T4
IP66 and NEMA 4X
Quantity: 3
Galv. isolated, termination switchable
Data protocol: TCP, RTU RS-485, ASCII RS-485
Baud rate: 2400...57600
Ethernet
Serial RS232
HART ®
Quantity: Up to 2, variant-dependent
Speed: 10 or 100 Mbit/s
Full duplex
Data protocol: Mobus TCP
Auto MDI-X
✔
Quantity: 1
For firmware updates
Supported signals: TXD, RTS, RXD, CTS, COM
Data protocol: Modbus RTU/ASCII
Baud rate: 2400…57600 (default: 9600)
✔
HART ® -compatible master (for connection of external pressure and temperature sensors)
HART ® slave (for communication with control system)
FOUNDATION Fieldbus
Terminal voltage: 9 … 32 V DC
Power input: 18 mA
Optical interface
FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH
Technical data
Inputs and outputs
Analog auxiliary voltage supply
Analog outputs
Analog inputs
Up to two auxiliary voltages per analog module
Variant-dependent galvanically isolated (
Output voltage: Approx. 24 VDC, ± 5%
Max. output voltage: 60 mA
Short-circuit proof, through active current limitation > 60 mA
Up to 6 outputs when using I/O modules (option)
4 … 20 mA
According to NAMUR NE43, configurable fault current: high 21 mA and low 3.6 mA
Terminal voltage: 7 … 30 V DC
Precision: ± 0.07% of fullscale @ 23°C
Temperature drift: 7 ppm/K @ 23°C
Resolution: 16 bits
Reverse polarity protection
Galvanically isolated
Passive
Internal update rate 2 Hz
Up to 6 outputs when using I/O modules (option)
Configurable as voltage or current input
24 bits
Reverse polarity protection
The analog inputs per module and the second auxiliary voltage (→ Table 11 - 24V_2/GND_2)
are referred to a ground, they are galvanically isolated from the rest of the circuit.
Internally supplied
Internal update rate 2 Hz
Current measurement:
4 ... 20 mA, according to NAMUR NE43
With error evaluation for < 3.6 (low error) and > 21 mA (high error)
Precision:
± 0.07% of fullscale @ 23°C
Temperature drift: 7 ppm/K @ 23°C
Input impedance: 290 Ω
Single-ended voltage input:
0 … 5 V DC
Precision: ± 0.002% of fullscale @ 23°C
Temperature drift: 45 ppm/K @ 23°C
Input impedance: > 100 kΩ
FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH 159
Technical data
Digital outputs
Digital inputs
Display
Operation
Installation
Dimensions (W x H x D)
Weight
Electrical connection
Operating voltage
Power supply (nominal)
Frequency
Power
Power input
Switching output
Optionally configurable as digital input
2 per module, up to 6 available when using I/O modules
Galvanically isolated
Max. current: 70 mA
Max. switching frequency: 50 Hz
Max. input voltage: 30 V DC
Switchable Namur/Open Collector
Reverse polarity protection
In Open Collector configuration: Max. switching voltage: 0.5 V DC
In Namur configuration at 8.2 V Us supply voltage:
Power switch state “On”: 4.2 mA
Power switch state “Off”: 0.5 mA
Digital output/frequency output:
4 per module, up to 12 available when using I/O modules thereof 3 as frequency output
Galvanically isolated
Max. current: 50 mA
Max. switching frequency: 10 kHz
Switching frequency: 0 ... 10 kHz
Max. input voltage: 30 V DC
Switchable Namur/Open Collector
Reverse polarity protection
In Open Collector configuration: Max. switching voltage: 1.8 V DC
In Namur configuration at 8.2 V Us supply voltage:
Power switch state “On”: 3.7 mA
Power switch state “Off”: 0.7 mA
2 per module, up to 6 available when using I/O modules
Optionally configurable as digital output (switching output)
Galvanically isolated
For connection of potential-free contacts or active switching outputs
Min. switch-on threshold 2 V DC
Max. switch-off threshold 2.85 V DC
Max. terminal voltage: 30 V DC
Reverse polarity protection
LCD: Measured variables, system information, warnings, maintenance requests, alarms
Software FLOWgate ™ or control panel at LCD
See dimension drawings
Non-Ex / zone 2: 8 kg
Weatherproof cover: 8.75 kg
AC version
115 ... 230 V AC ± 10%
50 ... 60 Hz
0.33 A
A higher switch-on current must be expected
≤ 18 W
DC version
12 ... 24 V DC -10/+20%
For installation in system with FLSE100-XT:
-
15 ... 28 V DC
1 A
A higher switch-on current must be expected
≤ 12 W
160
Output supply voltage - 24V-OUT (to supply external sensors)
FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH
Technical data
Output voltage
Max. power output
General
Options
AC version
24 V DC ± 5%
≤ 2 W
DC version
Equivalent to supply voltage of the Interface
Unit, no internal filtering
Depending on external supply ≤ 4 W
Offshore design, sun and weatherproof cover, tag plate
FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH 161
162
Technical data
12.4
Fig. 100
Application Evaluation Datasheet (example)
Application Evaluation Datasheet (example)
FLARE Gas Application Evaluation Datasheet
FLOWSIC100 Flare / FLOWSIC100 Flare-XT
General Information
Project Name
Reference (CRM/ZTA)
TAG No.
Device Type
Path Configuration
Nominal pipe size in "
Type of installation
Testprojekt
12345
654
EX-S 135 kHz
1-path
12
Hot Tapped
Process data pressure in bar(a)
Temperature in K
Speed of sound in m/s
Specified uncertainty by customer
20
5
1
300
400 min norm
% up to
% above
0.3
m/s max
Ex-zone Zone 2
Results
Molecular weigth in g/mol
Max. velocity in m/s
Max. flow rate in m³/h
Max. velocity ASC in m/s
Max. flow rate ASC in m³/h
21.82
100.96
26520
131.25
34476 vog in m/s
0.03
0.10
Flow rate in m³/h
7.9
26.3
Measurement Uncertainty of Flow
1) in %
18.72
6.94
0.30
1.00
78.8
262.7
4.65
4.31
3.00
10.00
788.0
2626.8
4.28
4.28
v_max Q_max 4.26
5.49
v_max,AS Q_max,AS 9.14
2), 3) 2), 3)
1) for fully developed flow profiles; based on
2) extended measurement range based on Active Sound Correlation technology
3) in the range of 100-130% of last ultrasonic
2), 3)
25
20
15
10
5
0
10
-2
10
-1
10
0
10
1 vog in m/s min norm max
10
2
FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH
Technical data
12.5
12.6
Fig. 101
Fig. 102
Applications of FLOWSIC100 Flare-XT in a regulated environment
The gas flow meter can be used for emission measurements, which may be subject to one or more regulations in some jurisdictions. Compliance with all emission regulations applicable at the site of the installation remains the responsibility of the owner / operator.
When correctly designed and applied, SICK's ultrasonic flow technology meets or exceeds most regulatory performance requirements. Please contact your SICK representative to find out about the right flare measurement solution that meets the currently applicable regulatory requirements.
Application ranges
Exemplary V max
of 1-path and 2-path solutions dependent on the sound velocity (SOS)
130
120
110
100
90
80
70
60
50
40
0 10 20 30 40 50 60 70 80
1-path sos = 340 m/s
2-path SOS = 340 m/s
1-path sos = 430 m/s
2-path SOS = 450 m/s
1-path sos = 650 m/s
2-path SOS = 650 m/s
V min
with 20% uncertainty of 1-path and 2-path solutions depending on the speed of sound (SOS)
Welded / dry calibrated / flow calibrated
0.07
0.06
0.05
0.04
0.03
0.19
0.18
0.17
0.16
0.15
0.14
0.13
0.12
0.11
0.10
0.09
0.08
0 10 20 30 40 50 60 70 80
1-path sos = 340 m/s
2-path SOS = 340 m/s
1-path sos = 450 m/s
2-path SOS = 450 m/s
1-path sos = 650 m/s
2-path SOS = 650 m/s
FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH 163
Technical data
Fig. 103 Uncertainty of flow rate as function of the velocity of gas (VOG)
Ultrasound measurement
12
ASC technology
(Additional uncertainty compared to ultra sound measurement.)
12
10
8
6
10
8
6
4
2
0
0.01
0.1
1 10 100 90 100 110 120 130
0
4
2
The exemplary expression of uncertainty according to GUM (Guide to the Expression of Uncertainty in Measurement):
ISO/IEC Guide 98-3:2008-09 shows an F1F-S in 1-path, 16" nominal size and assumes a gas temperature of 20 °C, ambient pressure and a typical molecular weight greater than 27 g/mol.
164 FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH
Technical data
12.7
Fig. 104
Derating pressure resistance
NOTICE:
The diagrams are valid for the standard versions of the sender-/receiver units
FLSE100-XT only. Deviations for other device versions are possible.
The maximum design values stated on the type plates of the devices shall be respected.
F1F-S/-M
21
20
19
18
17
16
15
14
13
12
11
10
-200 -150 -100 -50 0
38 °C
50 100 150 200 250 300
Fig. 105 F1F-H
21
20
19
18
17
16
15
14
13
12
11
10
-100 -50 0
0°C 100 °C
50 100 150 200 250 300
FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH 165
Technical data
Fig. 106 F1F-P
21
20
19
18
17
16
15
14
13
12
11
10
-200 -150 -100
38 °C
-50 0 50 100
Temperature [°C]
Temperature [°C]
100 °C
150 200 250 300
166 FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH
Technical data
12.8
12.8.1
Fig. 107
Dimension drawings
Dimension drawings of FLSE100-XT sender/receiver units
Dimensions for F1F-S/-M/-H CL150, 2"
F1F-S/-M/-H
A
B C C
D
E
90
Inserted position
F
150
92
150
92
G
Retracted position
Table 29
Table 30
Extended version
FLSE100-XT
F1F-S
F1F-M
F1F-H
Compact version
FLSE100-XT
F1F-S
F1F-M
F1F-H
Dimensions of extended version
A B C D
983
980
583
582
400
398
871
869
846 448 398 919
Dimensions of compact version
A
883
880
746
B
583
582
448
C
300
298
298
D
771
769
819
E
471
471
518
F G
1055.5 944
984
851
873
917
E
471
471
518
F G
955.5
844
884
751
773
817
FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH 167
Fig. 108
Dimensions for F1F-P, CL150, 2"
F1F-P
150
92
893
Technical data
1508
615
90
Inserted position
1527
Retracted position
168 FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH
Technical data
12.8.2
Fig. 109
Dimension drawings Interface Unit
Interface Unit Zone 2 (dimensions in mm (in))
358 (14.09)
334 (13.15)
306 (12.05) 203 (7.99)
Fig. 110 Interface Unit Cl. 1 Div. 2 (dimensions in mm (in))
358 (14.09)
334 (13.15)
306 (12.05) 203 (7.99)
FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH 169
Technical data
170 FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH
Spare parts
FLOWSIC100 Flare-XT
13
Spare parts
Recommended spare parts for FLSE100-XT sender/receiver units
Recommended spare parts for Interface Unit
FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH 171
13.1
13.2
Spare parts
Recommended spare parts for FLSE100-XT sender/receiver units
Order No.
Description
2108048 Assembly kit ANSI150 2Z SS ET
2108049 Assembly kit ANSI300 2Z SS ET
2108050 Assembly kit DN50 PN16 M16 SS ET
2107288
2107289
Replacement cover for aluminum EXD M20 housing
Contents: Cover, cover lock, cover insulation, O-ring, spring washer, screws, assembly paste, sealing plugs
Replacement cover for stainless steel EXD M20 housing
Contents: Cover, cover lock, cover insulation, O-ring, spring washer, screws, assembly paste, sealing plugs
2110151
2110152
Replacement cover for aluminum EXD NPT housing
Contents: Cover, cover lock, cover insulation, O-ring, spring washer, screws, assembly paste, sealing plugs
Replacement cover for stainless steel EXD NPT housing
Contents: Cover, cover lock, cover insulation, O-ring, spring washer, screws, assembly paste, sealing plugs
1)
2)
Recommended spare parts for commissioning
Recommended spare parts for 2 years operation
1 1) 2 2)
X X
X X
X X
X
X
X
X
Recommended spare parts for Interface Unit
Order No.
Description
2104408 Fuse kit 2A5 250V D5*20
2105349 Small parts kit (screws, washers, etc.)
2105350 Fuse kit 3A15 250V D5*20
2105364
Electric installation kit
“Ground” marking
End holder
1-10 marking
Terminals
End cover
Separator plate
1)
2)
Recommended spare parts for commissioning
Recommended spare parts for 2 years operation
1 1) 2 2)
X X
X X
X X
X
172 FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH
Accessories (optional)
FLOWSIC100 Flare-XT
14
Accessories (optional)
Accessories for FLSE100-XT sender/receiver units
Accessories for Interface Unit
Further accessory parts (cable screw fittings, ball valves, nozzles, etc.) are available on request from SICK
FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH 173
14.1
14.2
Accessories (optional)
Accessories for FLSE100-XT sender/receiver units
Order No.
Description
2105581
Weather/sun protective cover for electronics of the Master ultrasonic sensor
2108210 Venting/drain valve for ultrasonic sensor
Accessories for Interface Unit
Order No.
Description
2109763
Mounting kit 2-inch pipe assembly, for Interface Unit
Only for Zone 2 and Div 2, incl. adapter plate for 90° Upgrade Kit
2108970
2109217
Weather and sun protective cover Interface Unit, for wall installation
Weather and sun protective cover Interface Unit
Incl. mounting kit 2-inch pipe mounting
6050602 Infrared/USB adapter HIE-04
174 FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH
Annex
FLOWSIC100 Flare-XT
15
Annex
FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH 175
15.1
15.1.1
15.1.1.1
15.1.1.2
15.1.2
15.1.2.1
Annex
Compliances
NOTICE:
Applied European standards and harmonized standards are listed in the valid version of the manufacturer‘s CE conformity declaration.
Compliances of FLSE100-XT sender/receiver units
CE declaration
The FLSE100-XT sender/receiver units have been developed, built and tested according to the following EU Directives:
● ATEX Directive 2014/34/EU
● EMC Directive 2014/30/EC
Conformity with the above Directives has been determined and the CE label attached to the device.
Standards compatibility and type approval
The FLSE100-XT sender/receiver units comply with the following Norms, Standards or recommendations:
● IEC 60079-0: 2015, IEC 60079-1: 2014, IEC 60079-7: 2015,
● IEC 60079-11: 2011 + Cor. 2012, IEC 60079-15: 2010, IEC 60079-26: 2014,
● IEC 61010-1: 2010 + Corr. 2011 and comparable European Standards and comparable
ANSI/UL or CSA Standards
● EN 60079-0:2012, EN 60079-1:2014, EN 60079-7:2015, EN 60079-11:2012,
EN60079-15:2010
● EN 60079-26:2015, EN 60079-28:2015, EN 61326-1:2013
● EN 61010-1 (Safety requirements for electrical equipment)
● EN 60529: 1991/A1:2000/A2:2013 (IP)
Compliances of Interface Unit
CE declaration
The Interface Unit has been developed, manufactured and tested in accordance with the following EU Directives:
● ATEX Directive 2014/34/EU
● EMC Directive 2014/30/EC
Conformity with the above Directives has been determined and the CE label attached to the device.
176 FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH
Annex
15.1.2.2
Standards compatibility and type approval
The Interface Unit conforms to the following standards or recommendations:
● C22.2 No. 60079-0:2019
● C22.2 No. 60079-11:2014
● C22.2 No. 61010-1-12
● C22.2 No. 60079-7:2016
● CSA C22.2 No 94.2-15
● UL 61010-1: 2012
● UL 60079-0: 2019
● UL 60079-11: 2014
● UL 60079-7: 2017
● UL 50E, 2ND Ed
● IEC 60079-0: 2017 Edition:7.0
● IEC 60079-11: 2011 Edition:6.0
● IEC 60079-7: 2015 Edition:5.0
● EN 61010-1:2010
● EN IEC 60079-0: 2018
● EN 60079-7:2015
● EN 60079-11:2012
FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH 177
15.2
Fig. 111
Wiring examples
Interface Unit Zone 2 AC version (example)
Annex
mA 4..20
4..20 mA
mA 4..20
0 mA 4..2
m 250 Oh
Bus Hart Bus Hart
178 FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH
Annex
Fig. 112 Interface Unit Zone 2 DC version (example)
Bus Hart Bus Hart
mA 4..20
4..20 mA
FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH 179
15.3
Fig. 113
Control drawings
Control Drawings FLSE-XT (page 1 of 5)
Annex
180 FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH
Annex
Fig. 114 Control Drawings FLSE-XT (page 2 of 5)
FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH 181
Fig. 115 Control Drawings FLSE-XT (page 3 of 5)
Annex
182 FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH
Annex
Fig. 116 Control Drawings FLSE-XT (page 4 of 5)
FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH 183
Fig. 117 Control Drawings FLSE-XT (page 5 of 5)
Annex
184 FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH
Annex
15.4
Fig. 118
Gasket installation
Gasket installation (designed by ”pikotek”)
FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH 185
Annex
Fig. 119 Gasket installation (designed by ”pikotek”), bolt torque values for grooved metal gasket B9A and polymer gasket GYLON
186 FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH
Annex
FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH 187
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Key features
- High accuracy and reliability even under harsh conditions
- Non-intrusive measurement, no pressure loss
- Suitable for large diameter pipes
- Wide temperature range
- Compact design, easy installation and maintenance
- Optional spool piece for easy installation and removal