SICK FLOWSIC100 Flare-XT Operating Instructions Manual Download

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Installation FLSE100-XT

FLOWSIC100 Flare-XT · Operating Instructions · 8023761/V1-0/2020-10 · © SICK Engineering GmbH

5.2.6

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:

Table 1

Device versions

Version

Approval

IECEX

ATEX

NEC/CEC (USA/CA)

F1F-S

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

F1F-M

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

F1F-H

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

F1F-P

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

Summary of Contents for FLOWSIC100 Flare-XT

Page 1: ...OP ER ATIN G IN STRUC TION S Main FLOWSIC100 Flare XT Ultrasonic Mass Flow Measuring Device Installation Operation Maintenance ...

Page 2: ...or your local representa tive in case of doubt Legal information Subject to change without notice SICK Engineering GmbH All rights reserved Warning symbols 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 whic...

Page 3: ...2 4 Applications with wet gas 25 4 2 5 Clearance for fitting and removing the sender receiver units 25 4 3 Determining the installation location of the Interface Unit 26 4 3 1 Installation location requirements 26 4 3 2 Clearance for fitting the Interface Unit 26 5 Installation FLSE100 XT 27 5 1 Intended use 28 5 2 Safety information 28 5 2 1 Hazards due to hot cold cryogenic or aggressive gases o...

Page 4: ...e on 57 5 6 8 Fitting the sender receiver units 62 5 6 8 1 Calculating the wetted part length wL and geometric installation parameters 65 5 6 8 2 Tightening the self cutting ring 68 5 6 8 3 Installing the sender receiver units 71 5 6 8 4 Leak tightness check 74 5 6 9 Pulling the sender receiver units back 75 5 6 10 Fitting the venting valve 76 5 6 11 Fitting the weatherproof cover for the sender r...

Page 5: ...e tag plate available as option 104 6 5 Electrical installation 106 6 5 1 Safety information 106 6 5 2 Cable specification 106 6 5 3 Cable glands 107 6 5 4 Requirements for installation in the Ex zone 108 6 5 5 Electrical connections of the Interface Unit 110 6 5 5 1 Overview of electrical connections 110 6 5 5 2 Device module configuration 111 6 5 6 Connection area for field side wiring 112 6 5 7...

Page 6: ...issioning 136 8 Operation 137 8 1 Operating concept 138 8 2 Display and operating elements 138 8 3 Display in the symbol bar 138 8 4 Menu navigation 139 8 5 Status LEDs on the mainboard 140 9 Maintenance 141 9 1 Safety information 142 9 2 General information 142 9 3 Routine checks 142 9 3 1 Function check on the display 143 9 3 2 Function check with FLOWgateTM 143 9 4 i diagnosticsTM Software Plug...

Page 7: ...ressure resistance 165 12 8 Dimension drawings 167 12 8 1 Dimension drawings of FLSE100 XT sender receiver units 167 12 8 2 Dimension drawings Interface Unit 169 13 Spare parts 171 13 1 Recommended spare parts for FLSE100 XT sender receiver units 172 13 2 Recommended spare parts for Interface Unit 172 14 Accessories optional 173 14 1 Accessories for FLSE100 XT sender receiver units 174 14 2 Access...

Page 8: ...Contents 8 FLOWSIC100 Flare XT Operating Instructions 8023761 V1 0 2020 10 SICK Engineering GmbH ...

Page 9: ...OWSIC100 Flare XT Operating Instructions 8023761 V1 0 2020 10 SICK Engineering GmbH 9 FLOWSIC100 Flare XT 1 About this document Function of this document Scope of application Target groups Data integrity Further information ...

Page 10: ...tions 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 1 3 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 th...

Page 11: ...About this document FLOWSIC100 Flare XT Operating Instructions 8023761 V1 0 2020 10 SICK Engineering GmbH 11 1 5 Further information NOTICE Observe all supplied documents ...

Page 12: ...12 FLOWSIC100 Flare XT Operating Instructions 8023761 V1 0 2020 10 SICK Engineering GmbH About this document ...

Page 13: ...For your safety FLOWSIC100 Flare XT Operating Instructions 8023761 V1 0 2020 10 SICK Engineering GmbH 13 FLOWSIC100 Flare XT 2 For your safety Basic safety information Intended use ...

Page 14: ...empt 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 ...

Page 15: ...tem description FLOWSIC100 Flare XT Operating Instructions 8023761 V1 0 2020 10 SICK Engineering GmbH 15 FLOWSIC100 Flare XT 3 System description System components Functional principle System configuration ...

Page 16: ...s 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 External temperature and pressure transmitters a...

Page 17: ...easuring method changes of the sound velocity due to pressure or temperature variations therefore have no influence on the gas velocity determined Fig 1 Functional principle FLOWSIC100 Flare XT 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 ...

Page 18: ...OWSIC100 Flare XT Zur Interface unit Draufsicht Zur FLSE Frontansicht 4 8 7 6 5 3 2 1 Top view Front view To FLSE XT Master To Interface Unit 1 Sender receiver unit FLSE XT Master 5 Temperature sensor 2 Connection cable 6 Pressure sensor 3 Weatherproof cover for Interface Unit 7 Sender receiver unit FLSE XT Slave 4 Interface Unit 8 Optional spool piece ...

Page 19: ...ned 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 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 meas...

Page 20: ...oises 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 Fig 3 ASC technology Extended VOG Range is signalled in the path status of FLOWgateTM when the ASC technology is active Fig 4 Signaling Extended VOG Range ...

Page 21: ...erating Instructions 8023761 V1 0 2020 10 SICK Engineering GmbH 21 FLOWSIC100 Flare XT 4 Project planning Overview Determining the measuring and installation location for FLSE100 XT Determining the installation location of the Interface Unit ...

Page 22: ...sy and safe Provide platforms or pedestals as required Installation free of vibrations Acceleration 1 g Avoid reduce vibrations through adequate measures Ambient conditions Limit values in accordance with Technical Data If necessary Provide weatherproof covers sun protection enclose or lag device components Select device components Internal pipe diameter Sender receiver unit type Select components...

Page 23: ...nditions 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 In...

Page 24: ... diameters of inlet pipe and spool piece 1 No welding beads and burs on the flanges of the inlet pipe Gas flow Free from any foreign material dust and liquids Otherwise filters and traps shall be used Seals between spool piece and pipeline 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 Pres...

Page 25: ...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 4 2 5 Clearance for fitting and removing the sender receiver units Calcula...

Page 26: ...ed 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 failur...

Page 27: ...FLSE100 XT FLOWSIC100 Flare XT Operating Instructions 8023761 V1 0 2020 10 SICK Engineering GmbH 27 FLOWSIC100 Flare XT 5 Installation FLSE100 XT Intended use Product description Installation Electrical installation ...

Page 28: ...ved 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 i...

Page 29: ...ed before switching the power voltage back on again 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 p 37 5 3 Observe the information on p 37 5 3 during installation work on running equipment hot tapping method WARNING Ignition hazard through electrostatic discharge Ignition...

Page 30: ...he 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 durin...

Page 31: ... 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 Divisi...

Page 32: ...trinsically 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 dev...

Page 33: ...re may not exceed the specified ambient values NOTICE The pipe wall can separate different hazardous areas zones Table 2 Permitted gas temperature for temperature code Classified tempera ture code in the hazard ous area Case 1 Case 2 Case 3 Ultrasonic sensor outside explosive atmosphere Zone 1 or 2 Electronics in explosive atmosphere Zone 1 or 2 Gas pressure and gas temperature according to specif...

Page 34: ...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 ...

Page 35: ... Ensure the rated voltage UM 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 WARNING Leakage hazard Operation with leakage is not permitted The metallic and hermetically sealed fully welded enclosure and the seal must comply with all sa...

Page 36: ...he 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 ...

Page 37: ...e example FLSE100 XT S Fig 7 Type plate example FLSE100 XT M Product name FLSE100 XT Manufacturer SICK Engineering GmbH Bergener Ring 27 01458 Ottendorf Okrilla Germany Example of marking plate FLSE100 XT S ATEX IECEx Example of marking plate passive SLAVE FLSE100 XT S ATEX IECEx 3 Example of marking plate FLSE100 XT M ATEX IECEx Example of marking plate passive SLAVE FLSE100 XT M ATEX IECEx ...

Page 38: ...ineering GmbH Installation FLSE100 XT Fig 8 Type plate example FLSE100 XT H Fig 9 Type plate example FLSE100 XT P Example of marking plate FLSE100 XT H ATEX IECEx Example of marking plate passive SLAVE FLSE100 XT H ATEX IECEx 3 Example of marking plate FLSE100 XT 3 ATEX IECEx ...

Page 39: ... units Cross duct Fig 10 F1F S Master and slave shown as examples 1 Pressure compensation element 6 Retraction nozzle 2 Electronics unit 7 Duct probe 3 T connector 8 Sensor contour 4 TNC connector connection for Slave 9 Transducer 5 Self cutting ring 10 TNC connector connection for Master 1 7 8 6 4 5 3 2 Sensor length 9 8 6 5 9 7 9 10 ...

Page 40: ...tion element 6 Retraction nozzle 2 Electronics unit 7 Duct probe 3 T connector 8 Sensor contour 4 TNC connector connection for Slave 9 Transducer 5 Self cutting ring 1 7 8 6 4 5 3 2 Sensor length 9 3 7 5 1 4 2 Sensor length 1 Pressure compensation element 5 Retraction nozzle 2 Electronics unit 6 Duct probe 3 Cable gland connection for Slave 7 Sensor contour 4 Self cutting ring 8 Transducer 6 8 ...

Page 41: ...023761 V1 0 2020 10 SICK Engineering GmbH 41 Probe version Fig 13 F1F P 1 Pressure compensation element 6 Retraction nozzle 2 Electronics unit 7 Duct probe 3 T connector 8 Transducer 4 Pressure compensation element 9 Sensor contour 5 Self cutting ring 1 7 8 6 4 5 3 2 9 ...

Page 42: ... 10 8 3 7 6 4 1 Pipe screw fitting 10 Duct probe 2 Threaded ring 11 Connection for optional venting 3 Spring 12 Centering 4 Sealing disc 13 Sensor contour probe version F1F P 5 Sealing profile 14 Adjusting ring 6 Retraction nozzle 15 Thrust ring 7 Retraction flange 16 Probe tube 8 Transducer 17 Transducer pipe screw fitting 9 Sensor contour 18 Transducer and contour holder Cross duct versions F1F ...

Page 43: ...nd 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 DT 5 diameter of the thermowell in the outflow area Spool piece extended length with integrated pressure and temperature tapping Fig 15 Spool piece option example Material C...

Page 44: ...at the transducer cannot slip out of the retraction nozzle during transport Fig 16 Transport protection 5 5 2 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 ...

Page 45: ...e 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 th...

Page 46: ... 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 loa...

Page 47: ...on 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 ...

Page 48: ...p 65 5 6 8 1 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 p 65 5 6 8 1 NOTICE To ensure measurement accuracy th...

Page 49: ...nstallation 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...

Page 50: ... Available seals 2 1 1 Welding bevel 2 Marking NOTICE Observe the diagrams on p 165 12 7 Flange connection Material Temperature ranges CL150 LTCS P355 QH1 A350 LF2 46 280 C SS 1 4401 1 4404 ASTM A182 Gr 316 316L 196 280 C CL300 LTCS P355 QH1 A350 LF2 46 280 C SS 1 4401 1 4404 ASTM A182 Gr 316 316L 196 280 C PN25 DN50 LTCS P355 QH1 A350 LF2 46 280 C SS 1 4401 1 4404 ASTM A182 Gr 316 316L 196 280 C ...

Page 51: ...ture Ball valve CL150 2 SS CL150 2 Stainless steel 1 4408 CF08M 46 200 C 50 392 F Ball valve CL300 2 SS CL300 2 Stainless steel 1 4408 CF08M 46 200 C 50 392 F Low temperature Ball valve CL150 2 SS CL150 2 Stainless steel 1 4408 CF08M 196 200 C 320 392 F Ball valve CL300 2 SS CL300 2 Stainless steel 1 4408 CF08M 196 200 C 320 392 F High temperature Ball valve CL150 2 SS CL150 2 Stainless steel 1 44...

Page 52: ...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 Fig 21 Nozzle installation tool 4...

Page 53: ...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 st...

Page 54: ...0 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 NOTICE Note probe offset a and circumference U these values are required to calculate path angle and path length during commissioning with FLOWgateTM 1 path measurement 2 path measurement 5 Draw guide lines 1 for the nozzle positions with the pre...

Page 55: ...strip back around the pipeline and mark the nozzle positions with crossing and marking points by using a metal center punch 7 Take the strip off again and join the additional markings with a line Crossing point marking for the center of the nozzle Marking point aid for aligning the nozzle Path 1 Path 2 Path 1 Path 2 Crossing point marking for the center of the nozzle Marking point aid for aligning...

Page 56: ...surement 2 path measurement 1 Start preparation work as shown in p 53 Fig 22 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 Overlap line U 2 Kink line 90 90 4a Roll the strip out again and mark the kink line 90 90 90 4b Roll the strip out again and mark the lines as follows 2 498 r 2 498 r r U 2 x x x x ...

Page 57: ...trip off again and join the additional markings with a line Crossing point marking for the center of the nozzle Marking point aid for aligning the nozzle Path 1 Path 2 Path 1 Path 2 Marking point aid for aligning the nozzle Crossing point marking for the center of the nozzle Marking lines Marking lines WARNING Hazards through combustible gases or high pressure If hot tapping is not used depressuri...

Page 58: ...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 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 ...

Page 59: ...ing 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...

Page 60: ...as tightness of ball valve installation before you continue 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 p 53 5 6 7 Only once on each nozzle Have this work done by skilled persons specially qualified for this work Nozzle Centering D1 WARNING Hazard through le...

Page 61: ...r receiver unit is installed 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 o...

Page 62: ...e 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 5 1 ...

Page 63: ...ion 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 Fig 32 Using the nozzle insulation set 1 Centering sl...

Page 64: ...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 def...

Page 65: ...ctable 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 nozzl...

Page 66: ...66 FLOWSIC100 Flare XT Operating Instructions 8023761 V1 0 2020 10 SICK Engineering GmbH Installation FLSE100 XT Fig 33 Installation of F1F S F1F M F1F H cross duct versions ...

Page 67: ...Installation FLSE100 XT FLOWSIC100 Flare XT Operating Instructions 8023761 V1 0 2020 10 SICK Engineering GmbH 67 Fig 34 Installation of F1F P probe version ...

Page 68: ... 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...

Page 69: ...od between the threaded bolts screws for countering Ensure that the duct probe and the flange sealing surface are not damaged Fig 36 Securing the sender receiver unit example 4 First tighten the self cutting ring fitting hand tight 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 ...

Page 70: ... 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 ...

Page 71: ...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 self cutting 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 Fig 35 13 For cross duct versions install ...

Page 72: ... Installation FLSE100 XT Fig 37 Marking on probe version F1F P 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 Flow direction ...

Page 73: ...nt 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 ...

Page 74: ...erform 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 NOTICE Proceed as follows when leak tightness is not established Pull the sender receiver units back and disconnect them from the process by closin...

Page 75: ...hrough incorrect use of the retraction mechanism Observe the information on activating the retraction mechanism p 30 5 2 5 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 ...

Page 76: ...l 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 Fig 40 Venting valve connection 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 ...

Page 77: ...rproof 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 5 6 11 1 Overview Fig 41 Weatherproof cover overview 1 2 6 3 5 2 4 4 5 1 Holder 2 Safety splints 3 Weatherproof cover 4 Washers 5 Hexagon nuts 6 Round steel bow ...

Page 78: ...nsions mm 5 6 11 2 Fitting the weatherproof cover 186 188 271 225 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 ...

Page 79: ...ation FLSE100 XT FLOWSIC100 Flare XT Operating Instructions 8023761 V1 0 2020 10 SICK Engineering GmbH 79 2 Push the weatherproof cover into the holder 3 Fix the weatherproof cover with the four safety splints ...

Page 80: ...nder 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 mm with reinforced outer sheath from Lappkabel The cable must fulfill the following requirements for function of the device Operating capacity 150 pF m...

Page 81: ...uit 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 NPT The following applies additionally for intrinsical...

Page 82: ...th 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...

Page 83: ...tion of the sender receiver units 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 1 1 Terminal compartment open 2 Grounding terminals 2 Terminals Description Designation in Terminal box Master Slave B A 24 V DC GND MCX connector External connection yellow green white...

Page 84: ...c n o com n c n o com n c n o com n c n o com n c n o RS485b RS485a 24 V DC gnd ge gn ws br Slave Slave FLSE100 Slave Master FLSE100 Master Master MCUP processor board On site cabling in explosion protected version according to p 37 5 3 Terminals FLSE100 XT passive ultrasonic transducer Not for FLSE100 XT P Connection cable Ex zone Safe zone brown white green yellow white brown green yellow A B C ...

Page 85: ... FLOWSIC100 Flare XT Operating Instructions 8023761 V1 0 2020 10 SICK Engineering GmbH 85 FLOWSIC100 Flare XT 6 Installation Interface Unit Intended use Safety information Product description Installation Electrical installation ...

Page 86: ...ective specifications 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 u...

Page 87: ...ns 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 ...

Page 88: ... 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 ma...

Page 89: ...n 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 UM 253 V 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 enclosur...

Page 90: ... 6 3 Product description 6 3 1 Product identification Fig 45 Type plate ATEX example Fig 46 Type plate CSA example Product name Interface Unit Manufacturer SICK Engineering GmbH Bergener Ring 27 01458 Ottendorf Okrilla Germany Type plate The type plate is located on the right side of the device AC version DC version ...

Page 91: ...ating Instructions 8023761 V1 0 2020 10 SICK Engineering GmbH 91 6 3 2 Type code Fig 47 Interface Unit type code example FC F AEC A1A1S TS 1S111F N Product name Application Ex classification Mechanical properties Ambient conditions Electroncis Customized ...

Page 92: ...allation Interface Unit 6 3 3 Device components Fig 48 Overview 1 Type plate 7 Enclosure base 2 Display 8 Pressure compensation element 3 Infrared interface 9 Exterior ground terminal 4 Display cover 10 Cable inlets 5 Screw on tabs 11 Enclosure door 6 Electronics cover 4 2 1 3 5 5 7 8 9 11 10 6 ...

Page 93: ...optionally available with 9 cable glands Fig 50 Sealing plugs NPT optionally available with 9 cable entries 1 Metric cable gland M20 2 Metric cable gland M25 3 Exterior ground terminal 1 1 2 1 1 1 3 3 1 1 1 1 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 4 5 ...

Page 94: ...etric cable glands are available for routing all connection cables depending on device version The internally installed real time 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 ad...

Page 95: ...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 i...

Page 96: ...rds 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 ...

Page 97: ...ons 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 6 4 4 1 Wall fitting Ensure sufficient assembly clearance Dimension drawing see p 169 12 8 2 Maintain a general clearance of 15 cm around the enclosure to ensure better heat circulation The distance between enclosur...

Page 98: ... 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 Fig 53 Fitting the installation plate on the 2 inch pipe dimensions in mm Detail 1 1 Round steel bow DIN3570 2 Washer A13 A4 3 Nut M12 A4 4 Installation plate 45 365 330 Detail 1 1 4 2 3 Ø 60 ...

Page 99: ...ating Instructions 8023761 V1 0 2020 10 SICK Engineering GmbH 99 Fig 54 Fitting the Interface Unit on the installation plate Detail 2 Detail 2 5 Nut M10 DIN934 6 Washer B10 5 DIN125 7 Screw M10 DIN912 8 Holes for fitting the Interface Unit Zone 2 7 6 5 8 ...

Page 100: ...ll 2 Then screw the Interface Unit also to the wall through the four holes in the weatherproof cover as marked in Fig 57 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 ...

Page 101: ...s 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 Fig...

Page 102: ...itting the weatherproof cover on the installation plate 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 Detail Detail 5 4 3 1 2 1 Installation plate 2 Weatherproof cover 3 Screw M8 DIN912 4 Washer A 8 4 DIN125 5 Nut M8 DIN934 ...

Page 103: ...3761 V1 0 2020 10 SICK Engineering GmbH 103 Fig 59 Fitting the Interface Unit on the weatherproof cover Fig 60 Interface Unit with fitted weatherproof cover 1 1 Holes for fitting the Interface Unit Zone 2 Detail 2 1 3 1 Screw M10 DIN912 2 Washer B10 5 DIN125 3 Nut M10 DIN934 ...

Page 104: ...e 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 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...

Page 105: ...stallation Interface Unit FLOWSIC100 Flare XT Operating Instructions 8023761 V1 0 2020 10 SICK Engineering GmbH 105 Fig 62 Tag plate fitted Interface Unit with metric thread Interface Unit with NPT thread ...

Page 106: ...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...

Page 107: ...mm2 twisted pair shielded Analog output Max 30 VDC max 24 mA recommended cable cross section min 0 5 mm2 twisted pair shielded Analog input Max 30 VDC max 24 mA recommended cable cross section min 0 5 mm2 twisted pair shielded RS485 EIA 485 max 57 6 kbit s termination 150 Ohm switchable recommended cable cross section min 0 5 mm2 twisted pair shielded Ethernet 10 100 Mbit s protocol Modbus TCP rec...

Page 108: ...er supply with UM 253 V 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 electrosta...

Page 109: ... 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 ...

Page 110: ...nnected with GND 12 Fuse F1 4 Shielding terminals 13 Fuse F2 5 Terminal blocks 14 Field connection J2 power supply connection of the internal power supply unit 6 Terminal assignment sticker 15 Field connection J1 24 V output voltage of the internal power supply unit 7 Slots for I O modules 1 6 16 Memory card MIcro SD 8 Field connections for I O modules P4 P9 direct connection to module slots 1 6 1...

Page 111: ...le configuration Connection area for field side wiring Termination resistors of serial RS485 lines Identification of fuses and fuse characteristics Fig 64 Terminal assignment 6 5 5 2 Device module configuration The module configuration of the respective device is marked on the sticker on the inside of the enclosure door Fig 65 Module configuration example the first line designates module slots 1 6...

Page 112: ... Separator partition plate 3 GND Minus pole DC 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 receiverunitsfortheir power supply GND is connected electrically with the exterior ground terminal 0 5 2 5 mm2 4 ...

Page 113: ...ase TX or 10Base T full and halfduplex Ethernet 0 14 1 5 mm2 TXN EHT1 RXP ETH1 RXP ETH1 TXP ETH2 Data line between of second Ethernet interface 100Base TX or 10Base T full and halfduplex Ethernet TXN EHT2 RXP ETH2 RXP ETH2 P3 A1 Serial RS485 internal COM5 Connection FLSE100 XT 0 5 1 5 mm2 B1 A2 Serial RS485 internal COM2 Connection Scada Service PC or Gas chromatograph B2 A3 Serial RS485 internal ...

Page 114: ...inal name Pin identification Function Comment Conductor size Pin ident I O module Analog module type 1 2AI 2AO Analog module type 2 2AO Digital module type 1 2DI 6DO Interface module FOUNDATION Fieldbus FF 1 24V_1 Auxiliary voltage for up to two current loops max 60 mA 24V_1 Auxiliary voltage for up to two current loops max 60 mA DO1 Digital output FF H1 FOUNDATION Fieldbus 2 GND_1 GND_1 DO1 FF H1...

Page 115: ...ch for NAMUR OC changeover for digital modules Switching between Open Collector and Namur see p 116 6 5 9 FF Simulate switch only for FOUNDATION Fieldbus Disable Measured and process values available via FOUNDATION Fieldbus Enable Simulated values available via FOUNDATION Fieldbus LED Mobile communication signaling Module COM Communication via backplane bus active Module Status Flashing I O module...

Page 116: ...gure 70 DO circuitry Open Collector Namur 6 5 10 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 Fig 71 Termination NOTICE Electrical parameters see Technical Data p 158 12 3 Digital outputs OPEN COLLECTOR NAMUR 1 k 1 k 10 k US ...

Page 117: ...uses 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 WARNING Danger through power voltage Disconnect the power supply line before replacing the fuse NOTICE To prevent the...

Page 118: ...Interface Unit 6 5 12 Torque values for screw connections All screw connections have to be tightened with a specific torque value Table 12 Torque values Electrical connection Definition of torque value Terminal block 0 5 0 6 Nm Terminal P1 0 5 0 6 Nm Terminal P2 P9 0 22 0 25 Nm Terminal J1 J2 0 5 0 6 Nm ...

Page 119: ...n 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 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 electric...

Page 120: ... XT Operating Instructions 8023761 V1 0 2020 10 SICK Engineering GmbH 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 ...

Page 121: ...V1 0 2020 10 SICK Engineering GmbH 121 FLOWSIC100 Flare XT 7 Commissioning FLOWSIC100 Flare XT General information Opening the display protective flap Setting the display language Commissioning with the FLOWgateTM operating software Field setup wizard Function checks after commissioning ...

Page 122: ...y protective flap Swivel the display protective flap down Fig 73 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 de...

Page 123: ...SB 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 Fig 74 Aligning the infrared USB adapter 4 Install the FLOWgateTM operating software The FLOWgateTM 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...

Page 124: ...he 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 Fig 76 Starting Configuration mode 7 5 1 Path setup The connected device is automatically recognized for a 1 path installation Proceed as follows for a 2 path inst...

Page 125: ...re the serial numbers with the type plates Enter a device name The device name is freely selectable Enter the location 7 5 3 System archives Date and time Enter the date and time or synchronize with the PC Units Select the unit system for the display in FLOWgateTM Set whether pressure values are to be shown as absolute or relative pressure Data archive settings Determine the storage intervals for ...

Page 126: ...ross duct versions and p 56 5 6 7 3 for the probe versions Nozzle length D1 and the length of the second nozzle D2 for cross duct versions p 57 5 6 7 4 Gasket thickness S length of ball valve VL p 62 5 6 8 Click Calculate probe offset The probe offset is calculated Click Calculate parameter values The parameter values are calculated NOTICE Systems consisting of Interface Unit FLSE XT sender transm...

Page 127: ... Last good value Last valid measured value of connected sensor Fixed value Value set under Fixed value Fixed value Entry field 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 Measured value read in via the Modbus register Analog input Pressure value read in via an analog input ...

Page 128: ...ions for connected devices 7 5 6 3 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...

Page 129: ...ction 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 I...

Page 130: ...utput 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 cyc...

Page 131: ...s This FF configuration can only be accessed via the Fieldbus not via the FLOWgateTM 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...

Page 132: ...he 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 ...

Page 133: ... 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 Fig 87 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 s...

Page 134: ...om 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 CO2 which leads to higher CO2 emission values Fig 88 Function of nitrogen compensation 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 Fig 89 Nitroge...

Page 135: ...t calculation variable the mass flow the calculation of CO2 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 ap...

Page 136: ...a Ethernet 7 5 10 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 7 6 Function checks after commissioning Check the device status p 143 9 3 2 NOTICE SICK strongly recommends changing the initial password of the device Please check al...

Page 137: ...eration FLOWSIC100 Flare XT Operating Instructions 8023761 V1 0 2020 10 SICK Engineering GmbH 137 FLOWSIC100 Flare XT 8 Operation Operating concept Display and operating elements Display in the symbol bar ...

Page 138: ...Display and operating elements 8 3 Display in the symbol bar 1 3 2 1 Display 2 Buttons 3 Optical data interface infrared Table 17 Buttons In menu Esc Returns to next higher level of the operator menu Toggles between single menu entries on one level ENTER Calls up a submenu Table 18 Symbols Symbol Significance Description Device status Malfunction The device has an error the measured value is inval...

Page 139: ...ce IP x x x x Subnet mask Gateway x x x x Mac of onboard Eth aa bb cc dd ee ff Device setup System time dd mm yyyy time format 24 h Start of main measured values Velocity of sound m s ft s Flow rate ac m3 h acf h Flow rate sc sm3 h scf h Molar mass g mol lb lbmol Volume ac total m3 acf Volume sc total sm3 scf Mass total kg lbs CO2 total kg lbs Pressure bar a psi Temperature C F Velocity of gas m s...

Page 140: ... the mainboard Fig 94 Fig 94 Status LEDs position Table 19 Status LEDs description LED Description Pow Supply voltage present OK Normal operation neither warnings nor errors exist Warn Device status warning At least one warning is pending in the device the measured value is still valid Err Device status error At least one error is pending in the device the measured value is invalid ...

Page 141: ... Operating Instructions 8023761 V1 0 2020 10 SICK Engineering GmbH 141 FLOWSIC100 Flare XT 9 Maintenance Safety information General information Routine checks i diagnosticsTM Software Plug in optional Cleaning Exchanging the battery ...

Page 142: ...ce 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...

Page 143: ... software plug in 9 4 1 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 ...

Page 144: ...ostic 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 therefor...

Page 145: ...ning 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 9 6 Exchanging the battery 9 6 1 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 batte...

Page 146: ...146 FLOWSIC100 Flare XT Operating Instructions 8023761 V1 0 2020 10 SICK Engineering GmbH Maintenance ...

Page 147: ...Flare XT Operating Instructions 8023761 V1 0 2020 10 SICK Engineering GmbH 147 FLOWSIC100 Flare XT 10 Troubleshooting Detecting malfunctions Error signaling on the display Contacting Customer Service Starting a diagnostic session ...

Page 148: ...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 Fig 97 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 se...

Page 149: ...tandard 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 Fig 99 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 ...

Page 150: ...150 FLOWSIC100 Flare XT Operating Instructions 8023761 V1 0 2020 10 SICK Engineering GmbH Troubleshooting ...

Page 151: ...Decommissioning FLOWSIC100 Flare XT Operating Instructions 8023761 V1 0 2020 10 SICK Engineering GmbH 151 FLOWSIC100 Flare XT 11 Decommissioning Returning Disposal information ...

Page 152: ... during transport 11 2 Disposal information 11 2 1 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 11 2 2 Disposal Dispose of electronic components as electronic waste Check which materials having con...

Page 153: ...OWSIC100 Flare XT Operating Instructions 8023761 V1 0 2020 10 SICK Engineering GmbH 153 FLOWSIC100 Flare XT 12 Technical data System FLOWSIC100 Flare XT FLSE100 XT sender receiver units Interface Unit Dimension drawings ...

Page 154: ...easured value with ultrasonic technology in the range 0 3 m s to measuring range end value 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 f...

Page 155: ...ice flange 20 bar g PN25 device flange optional 20 bar g CL300 device flange optional 20 bar g Gas temperature 196 C 280 C Ex approvals 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 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 US CA Class I Divisio...

Page 156: ...x 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 Table 26 Technical data F1F H Measuring ...

Page 157: ...a Ga IIC T6 T4 Ga Gb ATEX 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 NEC CEC US 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 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...

Page 158: ...x Ex ec ia IIC T4 Gc 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 Degree of protection IP66 and NEMA 4X Interfaces Serial RS485 Quantity 3 Galv isolated termination switchable Data protocol TCP RTU RS 485 ASCII RS 485 Baud rate 2400 57600 Ethernet Quantity Up to 2 variant dependent Speed 10 or 100 Mbit s ...

Page 159: ...ft 7 ppm K 23 C Resolution 16 bits Reverse polarity protection Galvanically isolated Passive Internal update rate 2 Hz Analog inputs 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 ...

Page 160: ... 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 Digital inputs 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 o...

Page 161: ...20 10 SICK Engineering GmbH 161 AC version DC version Output voltage 24 V DC 5 Equivalent to supply voltage of the Interface Unit no internal filtering Max power output 2 W Depending on external supply 4 W General Options Offshore design sun and weatherproof cover tag plate ...

Page 162: ...sheet 1 FLOWSIC100 Flare FLOWSIC100 Flare XT General Information Project Name Reference CRM ZTA TAG No Device Type Path Configuration Type of installation 12345 654 Process data Specified uncertainty by customer Results 0 03 0 10 0 30 1 00 3 00 10 00 18 72 6 94 4 65 4 31 4 28 4 28 v_max 4 26 in Ex zone 1 2 3 1 2 3 for fully developed flow profiles based on extended measurement range based on Activ...

Page 163: ...ary Vmax of 1 path and 2 path solutions dependent on the sound velocity SOS Fig 102 Vmin with 20 uncertainty of 1 path and 2 path solutions depending on the speed of sound SOS 50 60 70 80 90 100 110 0 10 20 30 40 50 60 70 80 130 40 v max in ft s Nominal pipe size in 120 1 path sos 340 m s 1 path sos 430 m s 1 path sos 650 m s 2 path sos 340 m s 2 path sos 430 m s 2 path sos 650 m s V max m s 1 pat...

Page 164: ...d Dry Calibration Flow Calibration Ultrasound measurement ASC technology Additional uncertainty compared to ultra sound measurement Welded Dry calibrated Flow calibrated Uncertainty Uncertainty 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 temperatu...

Page 165: ... Deviations for other device versions are possible The maximum design values stated on the type plates of the devices shall be respected 11 12 14 15 16 17 200 150 100 50 50 100 150 10 Pressure bar g Temperature C 200 250 13 0 300 18 19 20 21 38 C F1F P CSA F1F S M Pressure bar g Temperature C 11 12 13 14 15 16 100 50 0 50 100 200 250 10 Pressure bar g Temperature C 17 150 300 18 19 20 21 F1F H ATE...

Page 166: ...61 V1 0 2020 10 SICK Engineering GmbH Technical data Fig 106 F1F P 11 12 14 15 16 17 200 150 100 50 50 100 150 10 Pressure bar g Temperature C 200 250 13 0 300 18 19 20 21 38 C F1F P ATEX 100 C F1F P CSA F1F P ATEX F1F P CSA Pressure bar g Temperature C ...

Page 167: ...H Table 29 Extended version Table 30 Compact version A B C C E D 90 F G 150 150 92 92 Inserted position Retracted position FLSE100 XT Dimensions of extended version A B C D E F G F1F S 983 583 400 871 471 1055 5 944 F1F M 980 582 398 869 471 984 873 F1F H 846 448 398 919 518 851 917 FLSE100 XT Dimensions of compact version A B C D E F G F1F S 883 583 300 771 471 955 5 844 F1F M 880 582 298 769 471...

Page 168: ...LOWSIC100 Flare XT Operating Instructions 8023761 V1 0 2020 10 SICK Engineering GmbH Technical data Dimensions for F1F P CL150 2 Fig 108 F1F P 1527 150 92 90 1508 893 615 Inserted position Retracted position ...

Page 169: ...ng GmbH 169 12 8 2 Dimension drawings Interface Unit Fig 109 Interface Unit Zone 2 dimensions in mm in Fig 110 Interface Unit Cl 1 Div 2 dimensions in mm in 358 14 09 334 13 15 306 12 05 203 7 99 363 14 29 322 12 68 258 10 16 358 14 09 334 13 15 306 12 05 203 7 99 352 13 86 322 12 68 258 10 16 ...

Page 170: ...170 FLOWSIC100 Flare XT Operating Instructions 8023761 V1 0 2020 10 SICK Engineering GmbH Technical data ...

Page 171: ...100 Flare XT Operating Instructions 8023761 V1 0 2020 10 SICK Engineering GmbH 171 FLOWSIC100 Flare XT 13 Spare parts Recommended spare parts for FLSE100 XT sender receiver units Recommended spare parts for Interface Unit ...

Page 172: ...9 Replacement cover for stainless steel EXD M20 housing Contents Cover cover lock cover insulation O ring spring washer screws assembly paste sealing plugs X 2110151 Replacement cover for aluminum EXD NPT housing Contents Cover cover lock cover insulation O ring spring washer screws assembly paste sealing plugs X 2110152 Replacement cover for stainless steel EXD NPT housing Contents Cover cover lo...

Page 173: ...761 V1 0 2020 10 SICK Engineering GmbH 173 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 ...

Page 174: ...ver for electronics of the Master ultrasonic sensor 2108210 Venting drain valve for ultrasonic sensor 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 Weather and sun protective cover Interface Unit for wall installation 2109217 Weather and sun protective cover Interface Unit Incl mounting kit ...

Page 175: ...Annex FLOWSIC100 Flare XT Operating Instructions 8023761 V1 0 2020 10 SICK Engineering GmbH 175 FLOWSIC100 Flare XT 15 Annex Compliances Wiring examples Control drawings Gasket installation ...

Page 176: ... 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 15 1 2 C...

Page 177: ... 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 ...

Page 178: ... diagram Drawing E240654 Voltage Type key Modul configuration Part number 115 230V AC 2 Path 2 AO 2 Ethernet Hartbus 250 Ohm PE N L Loop powered installation for external powered transmitter see instruction manual x2 PE N L 3 4 5 6 7 8 9 10 P2 RXN RXP TXN TXP RXN RXP TXN TXP Gnd 24V P1 J1 N L J2 1 2 3 12 11 10 9 8 7 6 5 4 PE PE Ethernet Ethernet ADL 4 4 20 mA 4 20 mA 4 20 mA 4 20 mA B A Path 2 B A...

Page 179: ...tion Part number 24V DC 2 Path 2 Status Pulse FF U Gnd Status Status Pulse Loop powered installation for external powered transmitter see instruction manual Fieldbus Foundation x1 3 4 5 6 7 8 9 10 Com Cts Rxd Rts Txd B3 A3 B2 A2 B1 A1 P3 P4 Gnd 24V P1 1 2 3 12 11 10 9 8 7 6 5 4 1 2 3 12 11 10 9 8 7 6 5 4 PE PE DO6 DO6 DO5 DO5 DO4 DO3 DO3 DO2 DO2 DO1 DO1 1 2 3 12 11 10 9 8 7 6 5 4 P5 4 20 mA 4 20 m...

Page 180: ...ted version FLOWSIC100 Flare XT H 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 FLOWSIC100 Flare XT S R M P 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 50 C Tamb 70 C Ambient Pressure Division...

Page 181: ...a Um 125 V 50 C to 70 C 196 C to 280 C P 15 28 Vdc 500 mA CL2 SELV Type 4 IP 65 MWP 1600 kPa 16 bar Ex ia Um 125 V 50 C to 70 C 196 C to 280 C Division 2 Zone 2 Installations This equipment is suitable for installation in Class I Division 2 Group A B C D hazardous locations or nonhazardous locations only Cet équipement est conçu pour être installé dans des zones dangereuses de classe I division 2 ...

Page 182: ...e Name D 01458 Ottendorf Okrilla Repl for Repl by Sh 3 5 04 FLOWSIC100 XT H 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 Power Supply Terminals 24 V GND 15 28 VDC max 500 mA Data Interface Terminals RS485a RS485b 5 V max 500 mA Flameproof field wiring Flameproof transducer wiring Zone separating wa...

Page 183: ... A B C and D T4 Class I Zone 2 Ex AEx nA ia IIC T4 Power Supply Terminals 24 V GND 15 28 VDC max 500 mA Data Interface Terminals RS485a RS485b 5 V max 500 mA Install device in accordance with NEC ANSI NFPA 70 in USA or CEC Part 1 in Canada Ex ia WARNING Substitution of components may impair intrinsic safety AVERTISSEMENT La substitution de composants peut nuire à la sécurité intrinsèque Maximum no...

Page 184: ...ivision 2 Groups A B C and D T4 Class I Zone 2 Ex AEx nA ia IIC T4 Power Supply Terminals 24 V GND 15 28 VDC max 500 mA Data Interface Terminals RS485a RS485b 5 V max 500 mA Install device in accordance with NEC ANSI NFPA 70 in USA or CEC Part 1 in Canada Ex ia WARNING Substitution of components may impair intrinsic safety AVERTISSEMENT La substitution de composants peut nuire à la sécurité intrin...

Page 185: ...Annex FLOWSIC100 Flare XT Operating Instructions 8023761 V1 0 2020 10 SICK Engineering GmbH 185 15 4 Gasket installation Fig 118 Gasket installation designed by pikotek ...

Page 186: ...ket B9A and polymer gasket GYLON Tightening torques Default Grooved metal gasket B9A Option Polymer gasket GYLON Grooved metal gasket B9A Polymer gasket GYLON Bolts 2 DN50 3 DN80 2 DN50 3 DN80 M16 A2 A4 70 126 Nm 126 Nm 126 Nm 126 Nm 5 8 A193 gr B8m 84 Nm 84 Nm 118 Nm 118 Nm 5 8 A320 gr L7m A193 gr B8m 77 Nm 77 Nm 118 Nm 118 Nm Thickness of gasket 4 25 mm 4 6 mm No of bolts 4 4 4 8 4 ...

Page 187: ...Annex FLOWSIC100 Flare XT Operating Instructions 8023761 V1 0 2020 10 SICK Engineering GmbH 187 ...

Page 188: ... 3KRQH 0DLO LQIR VLFN LW Japan 3KRQH 0DLO VXSSRUW VLFN MS Malaysia 3KRQH 0DLO HQTXLU P VLFN FRP Mexico 3KRQH E Mail mexico sick com Netherlands 3KRQH 0DLO LQIR VLFN QO New Zealand 3KRQH WROOIUHH E Mail sales sick co nz Norway 3KRQH E Mail sick sick no Poland 3KRQH 0DLO LQIR VLFN SO Romania 3KRQH 0DLO RIILFH VLFN UR Russia 3KRQH 0DLO LQIR VLFN UX Singapore 3KRQH 0DLO VDOHV JVJ VLFN FRP Slovakia 3KR...

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