SM FLOWSIC100 Flare en V2-1 2016-06

Titelseite
SERVICE MANUAL
FLOWSIC100 Flare/Process
Mass Flow Meter
Maintenance
Inspection
Repair
This manual is intended exclusively for trained

and authorized service technicians of SICK
Engineering GmbH and their representatives
Unauthorized intervention voids the
manufacturer's guarantee.
Document Information
Product
Product name: FLOWSIC100 Flare/Process
Document ID
Title: Service Manual FLOWSIC100 Flare/Process
Order No.: 8013520
Version: 2-1
Release: 2016-06
Publisher
SICK Engineering GmbH
Bergener Ring 27 · 01458 Ottendorf-Okrilla · Deutschland
Telefon: +49 35205 52410
Fax: +49 35205 52450
E-mail: info.pa@sick.de
Trademarks
IBM is a trademark of the International Business Machine
Corporation.
MS-DOS is a trademark of the Microsoft Corporation.
Windows is a trademark of the Microsoft Corporation .
Other product names used in this document may also be trade-
marks and are only used for identification purposes.
Guarantee Information
Specified product characteristics and technical data do not serve
as guarantee declarations.
© SICK Engineering GmbH. All rights reserved.
2 FLOWSIC100 Flare/Process · Service Manual · 8013520/V 2-1/2016-06 · © SICK Engineering GmbH

Warning Symbols Information Symbols
Information about use in potentially explosive atmo-

Hazard (general)
spheres.
Hazard by voltage Important technical information for this product
Hazards by explosive or combustible gases Supplementary information
Hazard by noxious substances Link to information in another place
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 personal injury or
property damage.
NOTICE
Hazard which could result in property damage.
FLOWSIC100 Flare/Process · Service Manual · 8013520/V 2-1/2016-06 · © SICK Engineering GmbH 3

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1 Important Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.1 About this document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.2 Main hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.2.1 Hazards due to hot, cold (cryogenic) or aggressive gases, or high pressure . . . . . 11
1.2.2 Hazards with electrical equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.2.3 Hazards due to explosive or combustible gases. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.3 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.3.1 Purpose of the device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.3.2 Correct use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.3.2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.3.2.2 FLSE100 sender/receiver units for use in ex zones . . . . . . . . . . . . . . . . . . . . . . . 12
1.3.2.3 Use depending on temperature class / process temperature. . . . . . . . . . . . . . . 12
1.3.2.4 Permitted gas temperature depending on temperature code of FLSE100 . . . 13
1.3.2.5 Sender/receiver unit with probe retraction mechanism . . . . . . . . . . . . . . . . . . . . 15
1.3.2.6 MCUP control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.3.3 Restrictions of use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.4 Responsibility of user . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.4.1 General information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.4.2 Safety information and protective measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.1 Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.1.1 General information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.1.2 Setting the measuring system to the "Maintenance" mode . . . . . . . . . . . . . . . . . . . . 23
2.2 Maintaining the sender/receiver units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.2.1 Removing sender/receiver units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.2.2 Cleaning the sender/receiver unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.3 Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3 Functional Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.1 Checking the sender/receiver unit(s) - MCUP connection . . . . . . . . . . . . . . . . . . . . . . . . 30
3.1.1 Checking the termination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.1.2 Bus addressing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.2 General tests and diagnosis options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.2.1 Possible checks on the MCUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.2.2 Check cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.2.3 Checking the measured values with two-path measurement . . . . . . . . . . . . . . . . . . 44
3.3 Changing the MCUP parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
3.3.1 Recalibration of analog outputs and inputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
3.4 Periodic field test of FLOWSIC100 Flare/Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3.5 Setting the System Runtime . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3.5.1 Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3.5.2 Additional settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
4 Data Back-up with the SOPAS ET Program . . . . . . . . . . . . . . . . . . . . 53

4.1 Log function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
4.1.1 Saving data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
4.1.2 Output of data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Content
4.2 Data backup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

4.2.1 Saving as a project . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
4.2.2 Saving as a device file . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
4.2.3 Saving as a protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
5 Firmware Update . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
6 Malfunction and Error Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
6.1 Indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
6.1.1 Signaling in the SOPAS ET program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
6.1.2 Display on LC-Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
6.1.3 Signaling with relays in the MCUP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
6.2 Malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
6.2.1 Implausible measured values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
6.2.2 General system malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
6.2.3 Malfunctions of sender/receiver unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
6.2.4 Control unit malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
6.3 Correction of malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
6.3.1 Internal functional sequence, signal processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
6.3.2 Communication fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
6.3.3 "Heavy noise" error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
6.3.4 "No signal" error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
6.3.5 "Measuring range" error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
6.3.6 "Time plausibility" error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
6.3.7 Checking the sender/receiver units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
6.4 Special effects from the gas condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
6.5 Optimization of device-internal parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
6.5.1 Device parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
6.5.2 Overview of standard parameters(default values) . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
6.5.3 "First max" parameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
6.5.4 "Total periods", "Activation periods", "Rel. transmit amplitude" parameters . . . . 111
7 Repair work for sender/receiver unit . . . . . . . . . . . . . . . . . . . . . . . . . . 113

7.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
7.2 Special notes for replacement of electronic unit at sender/receiver units . . . . . . . . 115
7.3 Special notes for replacement of transducer assembly . . . . . . . . . . . . . . . . . . . . . . . . . 116
7.4 Removing of sender/receiver units from installation for repair work . . . . . . . . . . . . . 117
FLOWSIC100 Flare/Process · Service Manual · 8013520/V 2-1/2016-06· © SICK Engineering GmbH 5

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7.5 Electronics unit of device type FLOWSIC100 EX-S and EX-PR . . . . . . . . . . . . . . . . . . . 119
7.5.1 Replacement of electronics unit housing parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
7.5.2 Replacement of complete electronics unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
7.5.2.1 Device type ATEX Zone 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
7.5.2.2 Device type ATEX Zone 1 with Exe junction box . . . . . . . . . . . . . . . . . . . . . . . . . . 123
7.5.2.3 Device type ATEX Zone 1/IECEx without junction box and CSA . . . . . . . . . . . . 123
7.5.3 Replacement of terminal block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
7.5.4 Replacement of cable glands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
7.5.4.1 Device type ATEX Zone 2 and ATEX Zone 1 with junction box . . . . . . . . . . . . . . 132
7.5.4.2 Device type ATEX Zone 1/IECEx without junction box and CSA . . . . . . . . . . . . 133
7.5.5 Replacement of blind plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
7.5.5.1 Device type ATEX Zone 2 and ATEX Zone 1 with junction box . . . . . . . . . . . . . . 133
7.5.5.2 Device type ATEX Zone 1 without junction box and CSA. . . . . . . . . . . . . . . . . . . 134
7.5.6 Rotation of electronics unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
7.5.7 Replacement of pressure compensation element . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
7.6 Electronics unit of device type FLOWSIC100 EX/EX-RE . . . . . . . . . . . . . . . . . . . . . . . . . 138
7.6.1 Replacement of electronics unit housing parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
7.6.2 Replacement of complete electronics unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
7.6.2.1 Device type ATEX Zone 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
7.6.2.2 Device type ATEX Zone 1 with junction box, ATEX Zone 1/IECEx and CSA . . . 143
7.6.3 Replacement of terminal block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
7.6.4.1 Device type ATEX Zone 2 and ATEX Zone 1 with junction box . . . . . . . . . . . . . 149
7.6.4.2 Device type ATEX Zone 1 without junction box and type CSA . . . . . . . . . . . . . . 149
7.6.5.1 Device type ATEX Zone 2 and ATEX Zone 1 with junction box . . . . . . . . . . . . . 149
7.6.5.2 Device type ATEX Zone 1 without junction box and CSA. . . . . . . . . . . . . . . . . . . 149
7.6.6 Rotation of electronics unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
7.6.7 Replacement of pressure compensation element . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
7.7 Sensor assembly of device type FLOWSIC100 EX-S . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
7.7.1 Replacement of sensor assembly FLOWSIC100 EX-S - non-retractable types. . . 151
7.7.2 Replacement of sensor assembly FLOWSIC100 EX-S - retractable types. . . . . . . 153
7.7.2.1 Standard / high temperature version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
7.7.2.2 Low temperature version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
7.7.3 Replacement of sealing set at probe retraction mechanism . . . . . . . . . . . . . . . . . . 162
7.7.3.1 Sender/receiver unit FLSE100-EXS standard/high temperature version. . . . 163
7.7.3.2 FLSE100-EXS low temperature version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
7.7.4 Replacement of sensor contour FLSE100-EXS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
7.8 Sensor assembly of device type FLOWSIC100 EX/EX-RE . . . . . . . . . . . . . . . . . . . . . . . 175
7.8.1 Replacement of sensor assembly FLOWSIC100 EX non-retractable types . . . . . 175
7.8.1.1 Device Type ATEX Zone 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
7.8.1.2 Device type ATEX Zone 1 and CSA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
7.8.2 Replacement of sensor assembly FLOWSIC100 EX-RE retractable types . . . . . . 186
7.8.2.1 Device type ATEX Zone 2 standard / high temperature version . . . . . . . . . . . . 186
7.8.2.2 Device type ATEX Zone 1 and CSA standard /high temperature version . . . . 186
7.8.2.3 Device type ATEX Zone 2 low temperature version . . . . . . . . . . . . . . . . . . . . . . . 193
7.8.3.1 Sender/receiver unit standard /high temperature version . . . . . . . . . . . . . . . . 196
7.8.3.2 FLSE100-EXRE sender/receiver unit low temperature version. . . . . . . . . . . . . 200
7.8.4 Replacement of sensor contour FLSE100-EX/EXRE . . . . . . . . . . . . . . . . . . . . . . . . . 206

Content
7.9 Sensor assembly of device type FLOWSIC100 EX-PR . . . . . . . . . . . . . . . . . . . . . . . . . . . 207

7.9.1 Replacement of sensor assembly FLOWSIC100 EX-PR - non-retractable types. . 207
7.9.2 Replacement of sensor assembly FLOWSIC100 EX-PR retractable types . . . . . . . 211
7.9.4 Replacement of sensor contour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
7.10 Replacement of installation and mounting parts of device type FL100 EX-S . . . . . . 220
7.10.1 Replacement of relief valve (option for retractable S/R units only) . . . . . . . . . . . . 220
7.10.2 Replacement of analog connection cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
7.10.3 Replacement of mounting accessory parts - non-retractable types . . . . . . . . . . . . 222
7.10.4 Replacement of mounting accessory parts - retractable types . . . . . . . . . . . . . . . . 223
7.11 Replacement of installation and mounting parts of device type FL100 EX/EX-RE . 226
7.11.1 Replacement of relief valve (option for retractable S/R units only) . . . . . . . . . . . . 226
7.12 Replacement of installation and mounting parts of device type FL100 EX-PR . . . . . 230
7.12.1 Replacement of relief ball valve (option for retractable S/R units only) . . . . . . . . 230
8 MCUP control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233

8.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
8.2 MCUP control unit - compact housing (non ex-protected) . . . . . . . . . . . . . . . . . . . . . . . 235
8.2.1 Replacement of processor board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
8.2.2 Replacement of optional modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
8.2.3 Replacement of LC-display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
8.2.4 Replacement of power supply unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
8.2.5 Replacement of fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
8.3 MCUP control unit - 19" version (not ex-protected) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
8.3.3 Replacement of display unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
8.3.5 Replacement of fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
8.4 MCUP control unit - medium size housing (non-ex, ATEX Zone 2, CSA Cl I, Div2) . . . 245
8.4.1.1 MCUP non-Ex protected. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
8.4.1.2 MCUP ATEX Zone 2 and CSA CI I, Div2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
8.4.3 Replacement of LC-display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
8.4.6 Replacement of cable glands. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
FLOWSIC100 Flare/Process · Service Manual · 8013520/V 2-1/2016-06· © SICK Engineering GmbH 7

Co n tent
8.5 MCUP control unit - Exd housing (ATEX Zone 1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
8.5.3 Replacement of LC-display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
8.5.4 Replacement of power supply unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
8.5.4.1 Housing type STAHL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
8.5.4.2 Housing type CORTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
8.5.8 Replacement of sealing at Ex-d housing cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
9 Annex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
9.1 Zero Point Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
9.2 Periodic Field Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
9.3 Basic Function test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
9.3.1 Test set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
9.3.2 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
9.3.3 Finalizing the test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297

Important Information
1 Important Information
About this document

Main hazards
Intended use
Responsibility of user
Safety information and protective measures
Subject to change without notice

1. 1 About this document

This Service Manual is part of the FLOWSIC100 Flare/Process device documentation. It
contains the description of all service work (maintenance, troubleshooting, repair) that can
be performed by trained personnel. Since fundamental information on the measuring
system used, the design and function of the measuring system and its components as well
as on the usage of the device are contained in the relevant Operating Instructions (OI),
supplementay information is provided only where necessary in order to understand the
function. The Service Manual is therefore to be used only in conjunction with the relevant
Operating Instructions (Part No. 8013344).
NOTICE:
Always read the Operating Instructions before starting any work! The
observance of all safety and warning notices is imperative.
Abbreviations used in this manual

AGC Automatic gain control
ANSI American National Standards Institute
ASME American Society of Mechanical Engineers
CSA Canadian Standards Association
DIN Deutsches Institut für Normung (German Standards Institut)
DN Nominal Diameter
EC European Community
EN Euro Norm (European Standard)
Ex Potentially explosive atmosphere
HART Highway Addressable Remote Transducer (Communication Interface)
Act. Actual (operating condition)
IEC International Electrotechnical Commission
Norm. Normalised (standard conditions)
LED Light Emitting Diode
NAMUR Normenarbeitsgemeinschaft für Mess- und Regeltechnik in der
chemischen Industrie …
PC Personal Computer
SNR Signal Noise Ratio
VOG Velocity of Gas
VOS Velocity of Sound

1.2 Main hazards
1.2.1 Hazards due to hot, cold (cryogenic) or aggressive gases, or high pressure
The sender/receiver units are mounted directly at 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 or
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 the
"hot tapping" method may fit devices on running equipment (authorized
personnel  p. 17, §1.4). 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.
1.2.2 Hazards with electrical equipment

The FLOWSIC100 Flare measuring system is equipment used for operation of industrial
high-voltage plants.
WARNING: Mains voltage Danger

 Disconnect mains lines before working on mains connections or parts
carrying mains voltage.
 Refit any contact protection removed before switching the mains voltage on
again.
1.2.3 Hazards due to explosive or combustible gases

The FLOWSIC100 Flare measuring system may be used in potentially explosive
atmospheres according to the respective specifications.
WARNING: Hazards due to explosive or combustible gases

 In potentially explosive atmospheres, only use the version of the
FLOWSIC100 Flare/Process specified for such use ( p. 12, §1.3.2).
 Observe the information on  p. 11, §1.2.1 during installation work on run-
ning equipment ("hot tapping" method).

1. 3 Intended use
1.3.1 Purpose of the device

The FLOWSIC100 Flare measuring system may only be used for measurements of gas
velocity, gas volume, mass flows and molecular weight in pipelines.
1.3.2 Correct use

1.3.2.1 General
 Use the device only as described in these Operating Instructions. The manufacturer
bears no responsibility for any other use.
 Observe all measures necessary for conservation of value, e.g. for maintenance and
inspection and/or transport and storage.
 Do not remove, add to or modify any components on the device unless described and
specified in the official manufacturer information. Otherwise
– the device could become dangerous
– any warranty by the manufacturer becomes void
 Do not use damaged components or parts.
1.3.2.2 FLSE100 sender/receiver units for use in ex zones
The sender/receiver units of the FLOWSIC100 EX-S, EX, EX-RE and EX-PR device versions
are available as options for use in Ex zone 1 and 2 or as versions for use in Ex zone 2 only.
• Sender/receiver units marked ATEX II 2 G IECEx and CSA Class I Division 1

are approved for use for gases in Ex zones 1 and 2.
• Sender/receiver units marked ATEX II 3 G and CSA Class I Division 2 are
suitable for use for gases in Ex zone 2.
1.3.2.3 Use depending on temperature class / process temperature

Installation and use of sender/receiver units FLSE100 where electronic parts and
transducer parts are 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 % v/v. Subject to change without notice

1.3.2.4 Permitted gas temperature depending on temperature code of FLSE100

Case 1 (see table 1 ):
Outside the pipeline an explosive atmosphere exists under normal atmospheric conditions,
which is categorized as area zone 1 or zone 2. Inside the pipeline the process conditions
can be different from atmospheric conditions. Process conditions can be in the range as
specified on the tag of the FLSE100. In this case the gas or gas mixture can be combus-
tible but must not be explosive.
Case 2 and 3 (see table 1):
On both sides of the pipeline an explosive atmosphere exists under normal atmospheric
conditions. The pipe wall separates different zones, i.e. inside the pipe is zone 1 and
outside the pipe is zone 2. This means the gas temperature and the line pressure must not
exceed the specified ambient values.
NOTICE:
Pipe wall acts as a zone-dividing barrier.
Table 1 Permitted gas temperature for temperature code
Case 1 Case 2 Case 3
• Ultrasonic transducer • Ultrasonic transducer in explosive • Ultrasonic transducer in
Requested outside explosive atmosphere Zone 1 or 2 explosive atmosphere zone 0
temp. class atmosphere Zone 1 or 2 • Electronics in explosive • Electronics in explosive
for • Electronics in explosive atmosphere Zone 1 or 2 atmosphere Zone 1 or 2
hazardous atmosphere Zone 1 or 2 • Gas pressure and gas • Gas pressure atmospheric, gas
area • Gas pressure and gas temperature according to temperature max +60 °C
temperature according to ambient specification of device • For type EX-S and EX-PR only
specification on device label
Zone 1 or 2 Non-ex Zone 1 or 2 Zone 1 or 2 Zone 1 or 2 Zone 0

atmosphere
The standard FLSE100 (Temperature Code T4) can be used in the following gas temperatures:
T4 -70 … +130 °C1) -40 … +70 °C2) -20 … +60 °C
T3 -70 … +195 °C 1 3) -40 … +70 °C 2 -20 … +60 °C
T2 -70 … +280 °C1 3 -40 … +70 °C2 -20 … +60 °C
FLSE100 with Option T6 (not available for versions with high temperature range):
T6 -70 … +80 °C1 -40 … +55 °C2 -20 … +55 °C
1) Option low temperature version with minimum temperature -196 °C (not available for EX/EX-RE Zone 1 and CSA)
2) Option minimum temperature -50 °C
3) Limit for FLSE100 Standard temperature +180 °C, limit for FLSE low temperature version +100 °C

NOTICE:
If the real gas temperature in the pipeline is higher than the ignition
temperature marked by the temperature code on the tag of the FLSE100, the
possible explosive atmosphere does not contain gases which are classified in
a temperature code with a lower ignition temperature than the highest gas
temperature respectively the outside surface temperature of the pipeline
itself. The possibility for heating up of the ambient air by the pipeline around
that must be observed. Ambient temperature around the electronic enclosure
must not exceed +70 °C for FLSE100 marked with T4 and must not exceed
+55 °C for FLSE100 marked with T6. The compliance with these
requirements is the sole responsibility of the user. Particularly the FLSE100
marked with temperature code T6 run the risk of non-resettable switch-off due
to the thermal cutoffs inside the electronics enclosure. In this case the
FLSE100 must be repaired by the manufacturer only. Warranty will be expired.
Compliance with the requirements above is in the sole responsibility of the user.

1.3.2.5 Sender/receiver unit with probe retraction mechanism

The retraction mechanism serves to remove and fit complete FLOWSIC100 Flare sender/
receiver units for maintenance or replacement without relieving pressure in the pipeline in
which the measuring system is fitted. This allows maintenance work without having to
interrupt the process.
WARNING: Specified temperature and pressure ranges

Only operate probe retraction mechanism in the following ranges for gas
temperature and operating pressure:
• Device types FL100 EX-S, EX and EX-RE:
– Gas temperature range -20°C to +200 °C
– Upper operating pressure 16 bar at 50 °C (see p-T diagrams in 2.2.1.2
- 2.2.1.4) of OI FLOWSIC100 Flare
• Device type FL100 EX-PR
– Gas temperature range -20°C to +200 °C
– Upper operating pressure limit is +0.5 bar at whole temperature range.
WARNING: Hazardous gas (possibly explosive or toxic)

Small gas quantities escape during the removal and installation of the
transducer assemblies. During proper use, the gas crowd locked up in the
retraction space is less than 0.5 dm³ for device type EX-S, EX and EX-RE and
less than 2.5 dm³ for device type EX-PR.
 Staff performing activities at plants with poisonous or other gases
dangerous to health must use suitable safety equipment to prevent
personal injuries.
1.3.2.6 MCUP control unit

The MCUP control unit is optionally available in the versions for use in Ex zone 1 and 2 or
for use only in Ex zone 2 or not for use in Ex zones.
• Control units with marking ATEX II 2 G Ex de II C T6 are approved for use in

Ex zone 1 and 2.
• Control units with marking ATEX II 3 G Ex nA II T4 are approved for use only
in Ex zone 2 or for use in safe areas.
WARNING: Explosion hazard

 Install and operate the MCUP control unit without explosion protection only
outside Ex zones.
 Use the explosion-protected MCUP control unit only according to the
respective Ex marking.

1.3.3 Restrictions of use
WARNING: Pressure/temperature hazard

 Use the measuring system only within the pressure and temperature limits
specified in these Operating Instructions and on the device type plate. The
selected materials must be resistant to the process gases.
WARNING: Dangerous voltage

• With the use of sender/receiver units FLSE100-EXS and EXPR zone 1 the
rated voltage UM used in the safe area may not exceed 125 V. Higher
voltages can jeopardize intrinsic safety of the ultrasonic transducer circuit
when errors occur.
 Ensure that the rated voltage UM used in the safe area does not exceed
125 V.
• The FLOWSIC100 Flare is not equipped with a power switch.
 Plan and install a suitable switching off device.
The ultrasonic transducers/probes are preferably 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 temporarily.
WARNING: Leakage hazard

Operation with leakage is not permitted.
• The metallic and hermetically sealed, fully welded housing 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 housings
must be installed in the pipeline gas-tight and pressure-tight. Depending on
the design, at least one seal with an O-ring according to DIN 3771 or a
standardized sealing flange must be provided.
• 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.
 Regularly check leak-tightness during operation and replace the seal, as
required.
• The sealing effect must be checked with suitable methods after installation
and every removing and re-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.

1.4 Responsibility of user

• Ultrasonic probes can also be operated in zone 0 under atmospheric
conditions (ambient temperature -20°C to 60°C and ambient pressure 0.8
bar to 1.1 bar absolute). The device must be labelled at least with the
information II 1/2 G Ex ia.
• Ultrasonic probes made from titanium may be used in zone 0 only if the
medium does not contain firm parts (e.g. dust and other particles), and the
ultrasonic probes are installed in the zone 0 (e.g. the inside of a pipe) in
such a way that the danger of ignition due to impact or friction is excluded.
The intrinsically safe ultrasonic transducers with their gas-tight and
pressure-proof housings must be installed gas-tight and pressure-tight in
the wall separating the zones to zone 0. The wall must be thicker than 3
mm. The requirements in EN 60079-26 section 4.6 must be adhered to.
1.4.1 General information

Designated users
The FLOWSIC100 Flare/Process measuring system may only be installed, operated and
maintained 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. The named persons must have exact knowledge of operational
hazards caused e.g. by 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.
Due to their professional training, knowledge and vocational experience, as well as their
knowledge of the relevant standards, regulations, health and safety regulations and
equipment conditions, qualified persons shall be assigned by the person responsible for
personal and plant safety to carry out such work.
Qualified persons must be able to identify possible dangers and to take preventive action
in time.
The technicians must be skilled according to DIN VDE 0105 or IEC 364 or directly
comparable standards.
Any service work on the measuring system may be carried out by special trained persons
only. Service training is provided by the manufacturer. The successfully completed SICK
service training must be proved by a certificate.

Specific requirements for use of devices in hazardous areas
 Cabling /installation, device set-up, maintenance and check may be only

carried out by experienced staff which has knowledge about the rules and
regulations for hazardous areas, in particular:
– type of protection
– installation rules
– area definition
 Regulations to be applied:
– IEC 60079-14
– IEC 60079-17
or comparable national regulations.
Special local conditions

 Observe the valid legal regulations as well as the technical rules deriving from imple-
mentation of these regulations applicable for the respective equipment during work
preparation and performance.
 Special caution and attention is required on equipment with increased hazard potential
(pressure pipes, explosion protection zones). Comply with existing special regulations.
 Carry out work according to the local conditions specific for the equipment as well as
operational hazards and regulations.
 Suitable protection devices and safety equipment for persons must be available accord-
ing to the respective hazard potential and be used by the personnel.
Retention of documents
Keep the Operating Instructions belonging to the measuring system as well as equipment
documentation on-site for reference at all times. Pass the respective documentation on to
any new owner of the measuring system.
Selection of materials
The user must check whether the intended materials of the device components are
suitable for the process conditions.

1.4.2 Safety information and protective measures

Protection devices
NOTICE:
Suitable protection devices and safety equipment for persons must be
available according to the respective hazard potential and be used by the
personnel.
Preventive measures for operating safety
NOTICE:
The user must ensure that:
 Neither failures nor erroneous measurements can lead to operational
states that can cause damage or become dangerous
 The specified maintenance and inspection tasks are carried out regularly
by qualified, experienced personnel.
Recognizing malfunctions
Every deviation from normal operation is to be regarded as a serious indication of a
functional impairment. These are, amongst others:
 Warning displays (e.g. heavy contamination)
 Large drifts in measured results
 Increased power input
 Higher temperatures of system parts
 Monitoring devices triggering
 Smells or smoke emission
Avoiding damage
NOTICE:
The operator must ensure the following to avoid malfunctions that can
indirectly or directly lead to injuries to persons or material damage:
 The responsible maintenance personnel are present at any time and as
fast as possible
 The maintenance personnel are adequately qualified to react correctly to
malfunctions of the measuring system and any resulting operational
interruptions (e.g. when used for measurement and control purposes)
 The malfunctioning equipment is switched off immediately in case of doubt
and that switching off does not cause collateral malfunctions.
NOTICE:
Command "Restart MCU", SOPAS menu MCUP Maintenance/Maintenance

mode will delete contents of data archives and counters! After finishing of all
actions (update etc.) please press button "Reset counter", SOPAS menu "MCUP
Parameter/Measuring point X/Measuring point parameter" and check start of
counter function during gas flow in the pipeline.


Maintenance
2 Maintenance
Basics
Maintaining the sender/receiver units

Maintenance
2. 1 Basics
2.1.1 General information

The maintenance work required consists of:
 cleaning the sender/receiver units and checking for corrosion and damage,
 cleaning the section mechanism of retracable sender/receiver units.
Maintenance intervals
The maintenance interval depends on specific application parameters such as mode of
operation, gas composition, gas temperature and moisture as well as the ambient
conditions. Typical values are approx. 1 year. Shorter maintenance intervals may be
necessary under unfavorable conditions.
The plant operator must specify the specific work to be carried out and its performance in a
Maintenance Manual.
Maintenance contract
Scheduled maintenance work can be carried out by the plant operator. Only qualified
personnel according to Section 1 should be allowed to do the work. If desired, SICK Service
or authorized Service support centers can carry out all maintenance work. Any repairs will
be made by specialists onsite whenever possible.
Required tools and auxiliary means:
 Key for Allen screws SW 5
 Jaw wrench SW 24
 Screw driver
 Possibly blind plug for nozzle for non-retractable version
 Brush, cleaning cloth and cleaning alcohol
WARNING:
 Observe the relevant safety regulations as well as the safety notices (
p. 19, §1.4.2) during all work.
 All work to be performed in hazardous areas requires the written approval
of the plant operator.
 Do not open any electrical equipment in hazardous area while energized
and do not power on opened devices.

Maintenance
2.1.2 Setting the measuring system to the "Maintenance" mode

Switch the FLOWSIC100 Flare/Process to "Maintenance" mode before starting any
maintenance work. The following ways exist:
Using an external maintance switch
Connect the switch to the terminals 17 and 18 on the MCUP processor board (digital input
2).
Figure 1 Connections in the MCUP
17 18
Using the SOPAS ET program

 Connect the measuring system with the SOPAS ET program and click "Network Scan" in
the "Network Scan Assistant" directory.
 Select the "MCUP-P" device file in the "Network Scan Assistant / Detected devices" tab
and move to the "Project Tree" window (see OI FLOWSIC100 Flare/Process, Section
4.1.4).
 Enter the Level 1 password (see OI FLOWSIC100 Flare/Process, Section 4.1.4).
 Switch to the "Maintenance/Maintenance" subdirectory, activate the "Maintenance on/
off" checkbox in the "Maintenance / Operation" group and click "Set State" ( figure 2).
Figure 2 Setting the maintenance mode with the SOPAS ET program


Maintenance
Using the keys on the LC-Display
Figure 3 Setting the maintenance mode with the buttons on the LC display
Set the overall system to the "Maintenance" mode
Set the sender/receiver units to the "Maintenance" mode

Maintenance
2.2 Maintaining the sender/receiver units

• If a malfunction occurs during "Maintenance", it is output at the
"Operation/Malfunction" relay until it is corrected.
• During "Maintenance", a check cycle is not performed.
• The value set for "Maintenance" is output at the analog output (see OI
FLOWSIC100 Flare/Process, Section 4.3.4).
• The "Maintenance" mode is reset when there is a voltage failure. In this
case, the measuring system switches automatically to "Measurement" after
the operating voltage is switched on again.
The sender/receiver units must be cleaned in regular intervals and checked for corrosion
and damage. To do this, the sender/receiver units must be disassembled from the
nozzles/ball valves.
WARNING:
 Observe the relevant safety regulations as well as the safety notices (
p. 19, §1.4.2) during all installation work.
 Take suitable protection measures against possible hazards.
 Carry out maintenance work only when hot parts have cooled sufficiently.
 Before performing maintenance work the FLOWSIC100 Flare must be dis-
connected from the mains and potential-free!

 Key for Allen screws SW 5
 Jaw wrench SW 24
 Screw driver
 Possibly blind plug for nozzle for non-retractable version
 Brush, cleaning cloth and cleaning alcohol
2.2.1 Removing sender/receiver units

Non-retractable sender/receiver units
WARNING: Hazards due to gas and pressure

A small amount of gas escapes uncontrolled into the environment during
disassembly of the sender/receiver unit from nozzle.
 At plants with increased hazard potential (toxic, aggressive,explosive
gasses, health endangering, higher pressure and temperatures), remove
the sender/receiver unit only when the plant is out of operation.
 Take special precautions in the presence of toxic, aggressive, explosive,
hot, or other gases posing a health risk (risk of serious injuries)!
 Loosen the screws on the flange of the sender/receiver unit.

 Carefully pull out the sender/receiver unit and place it in a suitable location.
 Close the nozzle with a blind flange (optionally available).

 If necessary loosen the cable connection at the electronic terminals of the sender/
receiver units carefully.
 Protect the loose cable ends from dirt or moisture.
NOTICE:
Moist or corroded connector contacts will lead to malfunctions.

Maintenance
Retractable sender/receiver units.
Please refer to OI FL100 Flare, chapter 3.5.2, page 96!
WARNING: Hazards due to pressure and gas

 Observe the maximum permitted pressure for operating the retraction
mechanism on retractable sender/receiver units:
– Device types FLSE100-EXS and EXRE: 16 bar at 50°C (OI FL100 Flare
pg. 37, Fig. 9)
– Device type FLSE100-EXPR: 0.5 bar at whole temperature range
 Close the ball valve after removing the sender/receiver unit with a blind
flange.
 Take special precautions in the presence of toxic, aggressive, explosive,
hot, or other gases posing a health risk (risk of serious injuries)!
In principle, the single steps decribed in OI FL 100 Flare are carried out in the reverese
sequence (see OI FL100 Flare pg.98, Fig.47)
 Loosen fastening nuts (8) and take cotter pins (6) out of guide rods (7).
 Hold the sender/receiver unit tight and pull it back to stop slowly.
 Close the 2" (FLSE100-EXS and EXRE) or 3" (FLSE100-EXPR) ball valve (5).
NOTICE:
A small amount of gas remains in the retractable nozzle and can escape
uncontrolled into the environment during disassembly of the sender/receiver
unit from the ball valve.
Controlled venting is possible when using retractable sender/receiver units

with the relief ball valve option.
 To do so, connect the relief ball valve with a suitable hose that ends away
from the measuring point.
 If necessary, loosen the cable connection at the electronic terminals of the sender/
receiver units carefully.
 Protect the loose cable ends from dirt or moisture.
WARNING: Hazards due to gas

 Take special precautions at toxic, aggressive, explosive, health endangering
and/or hot gases (risk or serious injuries) when using retractable sender/
receiver units without the vent device option.
 Screw fastening nuts (8) on and insert the cotter pins in the guide rods.
 Loosen fastening screws (3) and take the sender/receiver unit with seal (6) off the ball
valve 2" (or 3").
 Fit blind flange (2) and seal on the ball valve 2" (or 3") with fastening screws (1).
NOTICE:
The delivered seal may only be used once. Replace it with a new one after
every disassembly/assembly.

Maintenance
2.2.2 Cleaning the sender/receiver unit

Clean the outside of the sender/receiver unit after it has been removed. Inspect the probe
tube and transducers for signs of corrosion and replace them if necessary. Dust deposits
and caked dust can generally be removed without disassembling the transducer.
WARNING:
 Clean the transducer with extreme care.
 Do not damage the transducer diaphragm.
 Do not use strong corroded sender/receiver units any further. Repair or
replace them with identical units (for repair please consider notes in
chapter 7).
Depending on the conditions at the installation, the probe tube and

transducers may initially require maintenance more frequently (approx. every 2
weeks or less, if necessary). If soiling is limited, the cleaning intervals can be
gradually extended to a maximum of 6 months.
Reinstall the sender/receiver unit after completion of the work.
The activites required to replace the components (probe tube, transducers) are
listed in Chapter 7.
Additional maintenance at retractable sender/receiver units

Clean the retraction mechanism and the outside connection of ball valve after the sender/
receiver unit has been removed. Inspect the retraction flange, guiding rods and ball valves
for signs of corrosion (see figure 48 in OI FL100 Flare).

Maintenance
2. 3 Shutdown
The measuring system must be shut down if the plant is put out of operation for a longer
period of time (after approx. 1 week). In this case, the sender/receiver units must also be
removed from the pipeline to prevent the temperature from reaching a value below the dew
point.
Work to be performed
WARNING:
 Observe the relevant safety regulations as well as the safety notices on 
Page 9, »Important Information« during dismantling work.
 Removals from equipment with hazard potential (higher internal pressure in
duct, hot, aggressive or explosive gases) may only be performed when the
plant is out of operation.
 Take suitable protection measures against possible local hazards or
hazards arising from the equipment.
 Secure switches that should not be switched on again for safety reasons
with signs and safeguards to prevent unintentional switching.
 Loosen the connection cable to the MCUP.
 Remove the sender/receiver units from the duct (p. 25, §2.2).
 Close the nozzles with a blind flange.
 Disconnect the control unit from mains voltage.
Storage
 Store the dismantled device parts in a clean, dry location.
 Use suitable auxiliary means to protect the connection cable ends against dirt and
moisture (plug-in connectors at non-ex-protected devices).

Functional Check
3 Functional Check
Checking the sender/receiver unit(s) - MCUP connection

General tests and diagnosis options
Type FLSE100-EXS/EXPR

Functional Check
3. 1 Checking the sender/receiver unit(s) - MCUP connection
3.1.1 Checking the termination

The RS485 connection between the sender/receiver units and the MCUP must be
terminated at the begin and end as shown in the following figures. The termination can be
changed by plugging/removing the jumpers on the pins marked "term" on the processor
boards of sender/receiver unit (only not ex-protected types) and MCUP.
For ex-protected sender/receiver units termination is set in delivery condition

and cannot be changed in the field.
Figure 4 MCUP not ex-protected, MCUP for use according to ATEX zone 2 and CSA cl I, div 2
MCUP at the begin of the bus
MCUP
Processor board
AB x= Option junction box

Jumper T = Termination
n = no termination
T
n n T
FLSE100 FLSE100 FLSE100

Master Master Master
MCUP in the middle of the bus
MCUP
Jumper
n
T k T


Functional Check
Figure 5 19" MCUP

MCUP at the begin of the bus Processor board
A
A
MCUP
A
Switch
n T
T
n n T

AB x= Option junction box

T = Termination
n = no termination
MCUP in the middle of the bus
MCUP
Jumper
T k T

NOTICE:
The sender/receiver units are delivered without a termination in the electronics. In this con-
dition, no problems are expected between both sender/receiver units and the MCUP.
Should communication problems arise (caused, for example by not using the optimal cable
type), the following measures are recommended:
– Zone 1 devices: Set termination jumper at master s/r unit
– Zone 2 devices: Set a resistor 100 ...150 ohms parallel to terminals A and B in the junc-
tion box

Functional Check
3.1.2 Bus addressing

On bus systems (several sender/receiver units on one MCUP), the required bus address of
a sender/receiver unit (master only) can be assigned by the hardware (non ex-protected
sender/receiver only) units or software. In delivery condition the bus address for every
sender/receiver unit is set in the hardware to adress "0". Hardware addressing is read in
with the start of the SOPAS ET program.
WARNING:
At ex-protected sender/receiver units opening and any work at electronics has
to be performed under strict consideration of the instructions in chapter 7!
NOTICE:
• After a possibly required change of addressing, the respective sender/
receiver units must be started a new (disconnect and reconnect supply
voltage). The output assignments in the MCUP then have to be reconfigured
(see OI FLOWSIC100 Flare/Process, Section 4.2.2).
• The sender/receiver units must have different addresses. Identical
addresses of several units cause the aborting of the communication with
the MCUP!
Software addressing (all sender/receiver units)

As standard, the address can be assigned using the SOPAS ET program. The prerequisite
for this addressing is that hardware address 0 is set (delivery condition). To change it, do
the following:
 Connect the measuring system to a PC/laptop, start the SOPAS ET program establish a
connection with the device (see OI FLOWSIC100 Flare/Process, Section 4.1.4).
 Select the sensor type (e.g. "FL100 EX-S") in the "Network Scan Assistant / Detected
devices" tab and move to the "Project Tree" window.
 In the "Login" menu, select the "Service" user level and enter "service" under Password
(see OI FLOWSIC100 Flare/Process, Section 4.1.4.).
 Set the measuring system to the "Maintenance" mode (  p. 22, §2.1) and select to the
"Configuration/Device Parameters" directory ( p. 33, Fig. 6).

Functional Check
Figure 6 "Configuration / Device Parameters" menu
The default value for the bus address is always 1. Before further sender/
receiver units are connected to the bus, the already connected ones must first
be assigned a higher address.

Functional Check
Hardware addressing (non-ex-protected sender/receiver units only)

As an alternative to software addressing, the address can also be set by means of a
miniature switch on the digital board in the sender/receiver unit (3 switches for
hexadecimal addressing of address 1 to 7;  figure 7).
Figure 7 Hardware addressing of sender/receiver unit
Digital board Switch
4
3
2
1
Position
Miniature switch OFF
ON
Switch 4 serves for master -
slave switch-over
(the switch position for
address 1 is shown)
Address 1 2 3 4 5 6 7
Switch 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3
ON x x x x x x x x x x x x
NOTICE:
Only address 1 or for two-path operation, addresses 1 and 2, may be selected
for the FLOWSIC100 Flare/Process.
 Dismount the electronic unit according to the description in chapter 7on page 113.

Functional Check
3.2 General tests and diagnosis options
3.2.1 Possible checks on the MCUP

The following table lists the values that can be measured on the terminals of the MCUP
processor board if it is functioning correctly (  figure 9).
Terminal Connection for Type of check/measured value

31, 32 and 36, 37 Probe voltage 24 V d.c.
33, 34 and 38, 39 Probe RS485 Offset approx. 0.5 V with probe, approx. 0.7 V without
probe
Oscillograph:
Zero-symmetrical data signal packets > 2 Vpp
Impedance measurement (values in voltage-free state)
approx. 55  with one probe
approx. 37  with two probes (bus-type wiring only on ter-
minals 17, 18)
approx. 110  without probes
Figure 8 Connections in the MCUP compact and medium size housing (non-ex, ATEX Zone 2 CSA CII, Div2)
Figure 9 Connections in the MCUP Zone 1 Stahl housing


Functional Check
Figure 10 Connections 19inch MCUP

Functional Check
The correct function of the standard inputs/outputs of the MCUP and the EEPROMs can be
checked in the following manner:
 Connect the measuring system to a PC/laptop, start the SOPAS ET program and estab-
lish a connection with the device (see OI FLOWSIC100 Flare/Process, Section 4.1.4).
and move to the "Project Tree" window.
 In the "Login" menu, select the "Service" user level and enter "service" under Password
(see OI FLOWSIC100 Flare/Process, Section 4.1.4.).
 Set the measuring system to the "Maintenance" mode (  p. 22, §2.1) and switch to the
"Maintenance /System Test" menu.
 Click the "Activate system test" checkbox in the "System Test" window to start the sys-
tem test. The following window is displayed:
Figure 11 "Maintenance /System Test" subdirectory


Functional Check
 Check the system components according to the following table:

MCUP component Check
Analog Output Select "AO1" in the "AO test port select" window, enter a value between live zero and 22 mA in the "Analog
Output / AO test current" window and measure with the digital multimeter on terminals 22 (+) and 23 (-) on
the processor board in the MCUP ( p. 35, Fig. 9) whether this value is output.
Carry out the same procedure for further analog outputs if available (I/O module option, connections see OI
FLOWSIC100 Flare/Process section 3.4.6).
Analog Input Enter a direct current between live zero and 20 mA on the analog input AI1 (terminals 25 (+) and 26 (gnd) on
the processor board in the MCUP,  p. 35, Fig. 9) and on the analog input AI2 (terminals 27 (+) and 28
(gnd)) and check in the "Analog Input / Actual current on AI 1" and "Analog Input / Actual current on AI 2"
windows whether the entered current is displayed.
Carry out the same procedure for further analog inputs if available (I/O module option, connections see OI
FLOWSIC100 Flare/Process section 3.4.6).
Digital Output Successively activate the "Relay 1" to "Relay 5" fields and check on the respective connection (terminals 1
to 15 on the processor board in the MCUP,  p. 35, Fig. 9) whether the relay switches.
The "On/Off" and "DO Number" fields serve to check more optional relay outputs.
Digital Input Successively close digital inputs 1 to 4 (terminals 16 to 21 on the processor board in the MCUP,  p. 35,
Fig. 9) by means of a potential-free contact and check in the "Digital Inputs" window whether the respective
input is activated.
Pulse Output The pulse output is a potential-free contact. For testing the pulse output, a voltage must be connected. To
avoid a short-circuit, a pull-down resistor must be used to limit the current to 100mA.
Test functions for Click the "Test EEPROM" , "Test FRAM" and "Test FRAM" buttons sequentially. If the memory function is
Internal Memories correct, the "Successful" indicator must light up.
If the tests are not successful, replace the processor board ( p. 235, §b).
Incorrect analog values at output and input can possibly be recalibrated ( p. 46, §3.3.1).

Functional Check
3.2.2 Check cycle

The correct device functioning can be checked by initiation of a check cycle. Any incorrect
deviations from normal behavior that may occur are signaled as errors.
Checking the settings
 Connect the measuring system via PC/Laptop with the SOPAS ET program and click
"Network Scan" in the "Network Scan Assistant" directory.
and move to the "Project Tree" window (  p. 22, §2.1).
 Enter the level 1 password, set the measuring system to "Maintenance" mode and
switch to the "Diagnosis/Errors & Warnings" directory and check whether errors or
warnings are displayed.
Figure 12 "Diagnosis/Errors & Warnings" subdirectory in "Maitenance mode"


Functional Check
 Click "Start function check manually" to initiate a check cycle.
Figure 13 Function check subdirectory
 Switch to "Diagnosis / Errors & Warnings" directory and check whether errors or warn-
ings are displayed ( p. 75, §6)
Figure 14 "Diagnosis/Errors & Warnings" subdirectory

Functional Check
Checking the transducer function

 Select the "FLOWSIC100 EX-xx " device file in the "Network Scan Assistant / Detected
devices" tab and move to the "Project Tree" window
 Enter the level 1 password, set the measuring system to "Maintenance" mode ( p. 23,
§2.1.2) and change to the "Adjustment / Function Check-Manual" directory.
 Deselect the "Resonance cycle" input window and click the "Start check cycle" button.
 After expiration of the check cycle, the signal forms for transducer A and transducer B
are displayed.
 Select the "Resonance Cycle" input window and click the "Start check cycle" button.
After expiration of the check cycle, the system frequency response is shown.
Figure 15 "Adjustment / operational check manual" menu
Possible defects of the transducers or in the transducer circuity can be determined by

visual assessment of the signal forms and system frequency responses ( p. 42, Fig. 16 to
 p. 44, Fig. 18).
Check criteria for a correct transducer function are:
 Signal form
Approximately identical signal forms at all amplification levels must occur on both trans-
ducers.
 Signal amplitude
The signal amplitudes must have approximately the same size for both transducers. A
clearly smaller amplitude of a transducer can be caused by incorrect connection
between the transducer and the probe electronics or a transducer defect.
 System frequency response
The frequency response must be essentially identical for both transducers.

Functional Check
Type FLSE100-EX/EX-RE
Figure 16 FLSE100-EX/EXRE signal form

Functional Check
Figure 17 FLSE100-EX/EXRE system frequency response


Functional Check
Type FLSE100-EXS/EXPR
Figure 18 FLSE100-EXS/EXPR signal form
3.2.3 Checking the measured values with two-path measurement

The path-related measured values can be checked in the following manner:
 Connect the measuring system to a PC/laptop, start the SOPAS ET program and make
contact with the device,

and move to the "Project Tree" window (  p. 22, §2.1).
 Enter the level 1 password, set the measuring system to "Maintenance" mode and
switch to the "Diagnosis / Overview - Measuring Poin 1" directory.

Functional Check
Figure 19 "Diagnosis / FLOWSIC100 Diagnosis" directory
NOTICE:
The measuring system must previously have been set in the "Configuration /
Application Selection" directory to two-path measurement (see OI Section
4.3.1).

Functional Check
3. 3 Changing the MCUP parameters
3.3.1 Recalibration of analog outputs and inputs

In certain circumstances (e.g. after exchanging the printed circuit boards or to eliminate
long-term drifts) it can be necessary to correct the calibration parameters of the analog
output and analog inputs. The following steps must be performed:
 Enter a test current and check the output value (see previous Section).
 If the values don‘t agree, change to the "Parameter / I/O Configuration / AI/AO Calibra-
tion" directory and correct the coefficients for cc0 (absolute value/offset) and cc1 (lin-
ear factor) as long as input and output value agree.
Figure 20 "Configuration / I/O Calibration" directory

Functional Check
3.4 Periodic field test of FLOWSIC100 Flare/Process

In order to ensure continuously high device performance in the application, a special
procedure for periodic field verification was developed. The field verification consists of two
types of tests. They differ according to the availability of the installation in operation during
the test:
1 Verification test with sender/receiver units installed in the plant (ongoing plant opera-
tion). This test is carried out if the sender/receiver units cannot be removed from the
plant.
2 Verification test with sender/receiver units removed from the installation in the plant.
This test is performed if sender/receiver units can be removed from the installation. In
this case, the testing of the sensor can function additionally as a zero-point check.
A detail detailed description of the periodic field verification procedure can be found in the
annex  p. 263, §9.2.
3.5 Setting the System Runtime

An adjustment procedure, which has to be performed after
 replacement of transducer assembly
or
 replacement of a complete FLSE100
After replacement of an electronic unit the described steps don‘t have to be done. It is
sufficient to update the old to the new electronic circuit.
3.5.1 Conditions
Initially the defect assembly had to be fixed according to the steps specified in this Service
Manual. For the adjustment procedure both sensors of the measuring path need to be
assembled into the Zero Flow Test Box (Option, Part No. 2058832, see OI FL100 Flare
chapter 3). For this reason the second sensor has to be disassembled from the conduction,
too.
Subsequently the working steps according to part 3.4 have to be performed.
3.5.2 Additional settings

1 Using the program SOPAS ET, check if both sensors got equal parameters.
Figure 21 Additional settings for sender/receiver unit


Functional Check
2 When no parameters are available use the following values:
Figure 22 Standard settings for sender/receiver unit
3 After proving settings, check the parameter Zero phase.

4 Activate the option "View envelope" on the page "Sensor value".
5 Proof the signal exposition on the page "Sensor value" if the red and green cursor are
superposed at the Zero point of the third period.

Functional Check
Figure 23 Signal exposition of Hilbert Algorithm
If this isn‘t the case, modify the parameter Zero phase A and Zero phase B so that the
signal cursors are superposed in the third period (demonstrated in the picture).
6 Subsequently the Zero point check can be done like described in part 3.5.
Adjustment of the sensors system runtime
Adjust Hilbert Algorithm
1 When the speed of sound or gas velocity is out of range, configure the system runtimes
A and B of the device.
Configure the values from Cells <C145> and <C146> (see figure 24).
2 For this purpose close the FAD tool and connect the SOPAS ET to the device again.
Figure 24 System runtimes


Functional Check
Figure 25 Receive parameters of device in SOPAS ET
3 Subsequently check if the figured gas velocity is <20mm/s and the deviation of the
speed of sound to the speed of sound of the EXCEL sheet is <0,3%.
4 If this isn‘t the case, perform another data recording with the FAD Toll. Parameterize the
system runtimes in the SOPAS ET again.
Adjust cross-correlation algorithm
For high velocities change the signal processing to a cross-correlation algorithm.
To perform the runtime measuring, the CCR algorithm needs an educated example signal
(reference signal). This signal needs to be educated.
1 Adjust parameter "CCR active" on page "Device parameter" on 80 dB, to force the algo-
rithm under terms of the Zero Flow Box.
2 For that purpose activate the button "Learn signal pattern" in the menu "Function
check".
Figure 26 Menu "Function Check"
3 Now the SOPAS ET shows the multi burst signal. The signal education ends, when the
standard burst will be shown again. The number of notifications should amount at least
5.
4 As the actual result of the example signal education for the signal pictures of the multi
burst should be shown as following:

Functional Check
Figure 27 Signal exposition of cross-correlation algorithm
5 Subsequently a data recording has to be done again with the FAD Tool, but this time the
CCR Algorithm stays activated.
6 After ending of data recording configure the values from the cells <E145> and <E146>
with the SOPAS ET menu "Device Parameter".
Figure 28 System runtimes
Figure 29 CCR algortihm runtime
7 Adjust parameter "CCR aktiv" on 18 dB.

8 Subsequently the signals for standard burst should be shown as figured (see figure 30).

Functional Check
Figure 30 Signal exposition of standard burst
9 Configure the old path length from the application again.

10 Switch the device in measuring mode.

Data Back-up with the SOPAS ET Program
4 Data Back-up with the SOPAS ET

Program
Log function
Data backup

4. 1 Log function
A data recorder is integrated into the SOPAS ET program. This allows the recording of
measured values, system states and device parameters over a longer period. For
recording, the SOPAS ET program must be connected with the FLOWSIC100 Flare/Process
over the complete recording period.
The values that are saved in a file can be displayed offline later in SOPAS ET, analyzed or
processed in a different way.
Figure 31 "Tools / Data recorder" menu
4.1.1 Saving data

Various setting options allow for the adapting of data recording to the special task. For
example, the maximum file size, the number of files to be saved, storage location, value to
be saved with storage rate and others can be determined.
Saving data of a measuring system
contact with the device (see OI FLOWSIC100 Flare/Process, Section .4.1.3).
 Call up the "Tools / Data recorder / Configuration" menu ( p. 54, Fig. 31).
The following window is displayed of the monitor screen:
Figure 32 "Data Recorder" submenu

 Specify the storage location with the folder symbol - it will be opened the window "Select
a Data Recorder file".
Figure 33 "Recorder file" submenu
 Determine folder and name of the to record data and press "Open/Save".
Figure 34 "Settings Data Recorder".
Select "Settings"

 "Data recorder configuration" will be opened.
Figure 35 "Data Recorder configuration"
to select
 Choose settings like recording time and sample rate and select the devices which
should be saved/recorded (Diagnosis log must be selected).
Figure 36 "Data Recorder"
record button
 Press the red button to record data.

 Stop the record by the "Stop" button (no "Max. Recording time" selected).

Figure 37 Message - recording time reached
 After completion of data logging, store the data log as a new project.
 For this purpose, select the "Project/Save Project As" menu, determine the storage loca-
tion and the project name and confirm with "Save".
Figure 38 Saving the project.

If the data are not saved as a project, they are not readable later.

4.1.2 Output of data

 Start the SOPAS ET program, select "Open project" in the "Project" menu and open the
saved project.
Figure 39 Opening the saved project
 Select the "Tools / Data replay / Open replay file" menu.

 Read in the recorded file (select storage directory and file).
Figure 40 Opening the project
 If the devices were not connected to the PC select the "No" button.

Figure 41 Complete opened project
 After answering the question of figure 26 the project tree will be completed.
 To open the device pages of the saved project is optional, they also can be opened later
in the project tree.
Figure 42 "Tools/Data recorder" menu
 Data recorder will be opened


Figure 43 Data Recorder
Choose folder and file

of the recorded data
 Read the recorded file (select storage directory and file).
Figure 44 Data replay
Start data replay
 Navigation in the recording is possible in the "Data Recorder" window by actuating the
respective switch symbols (the effect of the symbol is displayed by selection with the
mouse cursor). Subject to change without notice

Figure 45 Data replay
 Choose the different pages by the "Project Tree" to see the requested information.

4. 2 Data backup
All parameters relevant for the collection, processing and input/output of measured values
as well as current measured values can be saved and printed. This allows the easy
reentering of set device parameters as needed as well as the registration of device data or
device states for diagnostic purposes.
Data can be saved in the following ways:
 Saving as a project
Saving the data as a project allows for saving of not only device parameters but also
data logs.
 Saving as a device file
All device data and parameters are recorded in a file. The parameters can be processed
without a connected device and transferred back to the device at a later time.
 Saving as a protocol
Device data and parameters are registered in the parameter protocol.
A Diagnosis protocol can be created for analysis of the device function and recognition
of possible malfunctions.
4.2.1 Saving as a project

If connections are frequently established, it is advisable to save a "Project". If connection to
the device is to be established again, only this "Project" must be opened. All previously
saved files are automatically transferred to SOPAS ET.
To save, select the respective device, select the "Project / Save Project" menu and specify
target directory and file name. The name of the file to be saved can be selected arbitrarily.
It is useful to specify a name with a reference to the measuring point involved (name of the
company, equipment designation).
Figure 46 "Project / Save Project" menu
 To establish the connection to the device, select the "Project / Open Project" menu and
start the desired project.

NOTICE:
The data of the FLSE100 and MCUP must be saved separately,
otherwise the MCUP settings will be lost after a possible system crash.
To establish the connection to the device, select the "Project / Open Project"
menu and start the desired project.
4.2.2 Saving as a device file

The following steps are requrired for saving:
 Select the respective device and move it into the "Project tree" window.
 Choose the "Communication / Upload all Parameters from Device" menu and load the
device data into the program to save current data.
Figure 47 Loading the device data into the program
 Switch the measuring system to "Maintenance" mode.

 Select the "Project / Export Device" menu and specify target directory and file name.
The name of the file to be saved can be selected arbitrarily. It is useful to specify a
name with a reference to the measuring point involved (name of the company, equip-
ment designation).

Figure 48 "Project / Export Device" menu
 To load saved data, select the "Project / Import Device" menu and open
the respective file.
 To load a saved device setting to the connected device, open the "Load
device data to device" submenu in the "Edit" menu. This transfers the data
from the SOPAS ET program to the sender/receiver unit.

4.2.3 Saving as a protocol

FLOWSIC100 Flare/Process protocols
 Select the sensor type (e.g. "FL100-EX") in the "Network Scan Assistant / Detected
devices tab in the "Available Devices" window and move to the "Project Tree" window.
 Select the "Diagnosis / Protocols" directory and click the button for the desired type of
protocol.
Figure 49 "Diagnosis / Protocols" directory
 The file name and storage location must be specified for export to a pdf file.
Figure 50 Specifying the file name and storage location


Figure 51 FLOWSIC100-EX parameter protocol (example)

Figure 52 FLOWSIC100-EX diagnosis protocol (example)


MCUP protocols
 Connect the measuring system with a PC/laptop, start the SOPAS ET program and connect with
the device.
 Select the "MCUP-P" device file in the "Network Scan Assistant / Detected devices" tab and
move to the "Project Tree" window.
 Select the "Diagnosis / Protocols" directory and click the button for the desired type of
registration.
Figure 53 "Diagnosis / Protocols" directory

Figure 54 MCUP parameter protocol


Figure 55 MCUP diagnosis protocol (section)

Firmware Update
5 Firmware Update

Firmware Update
General information
The procedure described in this Section allows the updating of the device software
(firmware) of the sender/receiver units and the MCUP control unit. The update must be
performed separately for the FLSE100 master, FLSE100 slave and MCUP.
NOTICE:
• Always update the firmware of the FLSE100 slave first.
• The procedure must then be repeated for the FLSE100 masters.
• Do not use any other programs in parallel during downloading.
Sender/receiver unit firmware update

The steps described in the following show the sequence for the update of the firmware of
the sender/receiver units.
 Connect the measuring system to the SOPAS ET program.
 Scan the network and move only the device file to be updated into the "Project tree"
window.
 Select password level "Service" and enter password "service".
 Save the device date as a project ( p. 62, §4.2.1) and protocols ( p. 65, §4.2.3).
 Set the measuring system to download mode and wait till the device is switched to the
"offline" state.
Figure 56 "Goto Download" submenu
 Enter password "service" in the "offline" state and select the "Communication / Firm-
ware download" subdirectory.
The firmware download must be started within 4 min after selection of the
download mode (otherwise automatic restart of the system).
MCUP firmware update

In order to update the MCUP firmware, follow the steps as described for the sender/
receiver unit firmware update, with the exception of the last point (second logon is not
required).

Firmware Update
Figure 57 "Communication / Start Flash Programm" subdirectory
The following window is displayed:
Figure 58 Selecting the current firmware file *.prg and setting the interface
 Click the "Open" button in the "Service File" entry field and select the storage location of
the current firmware file *.prg.

Firmware Update
 Select the interface, set the baud rate to 57600 and click the "Download" button. This
starts the device detection (normally completed already with a baud rate of 9600
baud).
Figure 59 Device detection
If the device detection is successful, the device is set to save mode and then to transfer
mode.
Downloading starts after erasing the flash memory.
Figure 60 Download
When the download is successful, the following screen is shown:
Figure 61 Downloading successfully completed
Correction of possible problems during downloading

1 Device detection was not successful
a) Repeat the procedure starting with network scanning.
b) Disconnect the MCUP for a short time from the supply voltage and then repeat the
complete procedure.
2 Downloading was interrupted after the flash memory was erased (time-out)
a) For the FLSE slave, same sequence as for 1.
b) The following steps must be performed for the FLSE master because of the firmware
that is missing in this case:
 Transfer the MCUP device into the project tree and set to download mode.
 Select the "Communication / Firmware Download" subdirectory and in the "Ser-
vice File" entry field, select the storage location of the current firmware file *-
master.prg, click the "Open" button and download the file.
 If required, perform the steps listed under 1.

Malfunction and Error Handling
6 Malfunction and Error Handling
Indication
Malfunctions
Correction of malfunctions
Optimization of device-internal parameters

6. 1 Indication
6.1.1 Signaling in the SOPAS ET program

The indicator assigned to the respective status lights in the "Overview" directory.
Sender/receiver unit
Figure 62 "FL100-EX / Overview" directory (example)

Overall measuring system
Figure 63 "MCUP-P / Overview - Measuring Point 1" directory


6.1.2 Display on LC-Display

The respective LED shines in case of malfunctions or maintenance request.
By pressing the "Diag" key, choice of the component ("MCUP-P" or "FLOWSIC100") and
"fault" or "warnings" (with arrow keys  or  and confirmation with "Enter"), possible causes
are shown as short information.
Figure 64 Status display on the LC display

Appears at maintenance request only.
Fl100 EX-PR80 Fl100 EX-PR80

Fl100 EX-PR80
(1) Q s.c. 747.7 m³/h AO Live Values
(1) MolMas 24.816 g/mol
Operating Mode
1 AO 1: 4,00 mA
(2) Q s.c. 0.0 m³/h 1 Set Maintenance
(2) MolMas 0.0 g/mol 2 AO 2: 4,00 mA
(3) Q s.c. 0.0 m³/h 3 AO 3: 0,00 mA
(4) MolMas 0.0 g/mol
/io/diag/ao/
/io/diag/ao/ Back
Diag Menu Back Start
MEAS
Adjustment AI Live Values
1 Start Check Cycle 1 AO 1: 4,00 mA
2 Maintenance 2 AO 2: 4,00 mA
/io/diag/ao/ /io/diag/ai/
Back Start Back
Fl100 EX-PR80 Fl100 EX-PR80 Fl100 EX-PR80 Status: Operation

Fl100 EX-PR80
Main Menu I/O (MCU-P) I/O Diagnosis I/O Information
1 I/O (MCU-P) 1 Operating Mode 1 Analog Outputs 1 Location: ...
2 FLOWSIC100 2 Adjustment 2 Analog Inputs 2 SICK
(Meas Point 1) 3 I/O Diagnosis 3 Device Info 3 SN: xxxxxxxx
4 I/O Parameter 4 Firmware:
5 xx.xx.xx
/ /io/ /io/diag/ao/
Back Enter Back Enter Back 6 Typ: MCU:Process
/io/diag/info/
Fl100 EX-PR80 Back
Operating Mode Fl100 EX-PR80
Fl100 EX-PR80
Diagnosis 1 Set Maintenance I/O Parameter
1 AO Parameter
1 MCU
2 AI Parameter
2 Meas Point 1
3 MCU Variant
/Io/
Back Start /io/para/ AO Parameter AO 1 Parameter
/diag/sensor/1
Back Enter 1 AO 1 Parameter 1 Limit Low
Back Enter
2 AO 2 Parameter 2 Limit High
3 AO 3 Parameter 3 Live Zero
Fl100 EX-PR80 Maintenance /io/para/ao/ /io/para/ao/1

Sensor 1 Operating Mode Back Enter Back Enter
1 Operating Mode 1 Maintenance
2 Parameter *
3 Diagnosis
4 Device Info Fl100 EX-PR80 Fl100 EX-PR80
/sensor/1 /sensor/1/ AI Parameter AI 1 Parameter
Back Enter Back Start 1 AI 1 Parameter 1 Limit Low
2 AI 2 Parameter 2 Limit High
Fl100 EX-PR80 Fl100 EX-PR80 (1) Operation

Fl100 EX-PR80
Diagnosis Error Parameter
/Io/para/ai/ /io/para/ai/1/
1 Errors 1 No Errors 1 Path Length
Back Enter Back Enter
2 Warnings 2 Installation Angle
3 Cross Section Area *
/diag/sensor/1 /diag/sensor/1/err/ /sensor/1/para/

Back Enter Back Back Enter
Password
XXXX
Fl100 EX-PR80 Fl100 EX-PR80 *: Number depends on
Warnings Diagnosis available AOs/Als
1 Noise too Large 1 AGC A: 10 dB
2 AGC B: 10 dB
3 Err A: 0%
4 Err B: 0%
/diag/sensor/1/warn/ /sensor/1/diag/
Back Back
Fl100 EX-PR80
I/O Information
1 Location: ...
Fl100 EX-PR80
2 FLOWSIC
Password Operating Mode
3 SN: xxxxxxxx
1 Set Maintenance
XXXX 4 Firmware:
5 xx.xx.xx
/sensor/1//info/
Back
/Sensor/1/parameter
Back Start

6.1.3 Signaling with relays in the MCUP

Warning or malfunction messages are output in the following manner:
 Relay 4 switches on in case of maintenance request (warning) (contacts 10 and 12 are
closed).
 Relay 1 switches off if malfunctions are present (contacts 1 and 2 are closed).
Figure 65 MCUP connections (non-ex, ATEX zone 2, CSA , cl I , div2 )
Figure 66 MCUP connections (ATEX zone 1)


Figure 67 MCU-P connections (non-ex 19 inch)

6.2 Malfunctions
6.2.1 Implausible measured values

In some cases, the FLOWSIC100 Flare/Process provides measured values that do not
seem plausible in comparison with projected or otherwise measured values or that have
excessively high short-time variations. A summary of possible cases, causes and actions is
listed in the following table.
Symptom Possible cause Action

The measured values Incorrect parameter setting of active measuring Check parameter settings
are stable, but the path and installation angle Check installation situation
calculated speed is Incorrect regression factors (see OI FLOWSIC100 Perform comparison measurement and enter new
(seemingly) incorrect Flare/Process, Section 4.3.4) regression factors, if required
Measuring axis not optimal for existing flow
conditions (see OI FLOWSIC100 Flare/Process,
Section 3.1.1)
Measured flow value is As for speed measurement As for speed measurement
(seemingly) incorrect Cross-section at the measuring location not Check equipment parameters
correctly determined Check scaling variables
Scaling variables are not correct (for flow s.c.)
Measured mass flow For calculation of mass flow and molecular Use another algorithm with dynamic determination of
and molecular weight weight the device is using a fixed value for coeffcient Kappa depending on actual gas
are (seemingly) adiabate coefficient Kappa (standard algorithm) composition:
incorrect which do not represent the real gas composition "Alcane algorithm V1.1"
suffciently "MR113 algorithm V1.1"
Inaccurate external pressure and temperature Check external pressure and temperature
measurement used for calculation of mass flow measurement:
and molecular weight Measurement position representative and free of
interfaces from otherinstallations and effects?
Measurement range suitable?
Measured Active measuring path not determined or entered Check the transducer - transducer distance
temperature value is exactly Calibrate the temperature measurement and enter the
(seemingly) incorrect As a result of the gas composition, different determined regression factors (see OI FLOWSIC100
standard velocity of sound of the actual gas Flare/Process, Section 4.3.4)
Enter the correct standard velocity of sound
("Configuration / Device Parameters" directory, "Gas
Parameters" field "Service" password level)
Measured values are Parameters for signal processing not optimal for Parameter optimization  p. 103, §6.5; possible
correct on average, the application concerned settings are, for example:
but too unsteady or Increase of damping time (in MCUP; see OI
with peaks FLOWSIC100 Flare/Process, Section 4.2.5)
Increase of the number for averaging
Number of avg. signals
Median buffer size
Vary "upper fraction" and "lower faction" percentage
values
Increase plausibility threshold
Increase limit SNR
Reduce burst duration for smaller ducts

6.2.2 General system malfunctions

Symptom Possible cause Action
No indication on LC • No supply voltage  Disconnect the measuring system from the supply voltage.
display of control unit • Defective fuse  Open the cover of the measuring/control unit.
• Defective power supply unit  Check the fuse.
• Connection cable not connected  Check the mains voltage after connection to terminals N and
correctly or defective L1 on the power supply unit in the control unit.
• Defective plug connector  Check the 24 V supply voltage on terminals 31 and 32 in the
• Defective processor PCB control unit (  figure 68).
• Defective LC display  Check plug connectors and cables.
WARNING:
For all work under voltage, always observe the
applicable safety precautions!
Analog output on live • The device has malfunction(s).  Check the device status
zero • Incorrect parameter settings  Check the device for malfunctions and correct, if possible.
 Check the parameter settings.
 Contact the manufacturer.
No analog signal or • Defective D/A converter Contact the manufacturer.
output of a fixed value • Device not in measuring mode
smaller than live zero
Communication • Wrong COM port on the PC  Check the interface settings (see OI FLOWSIC100 Flare/Pro-
between the • Incorrect parameter setting of inter- cess , Section 4.3.1)
measuring system face  Exit the SOPAS ET program, make a restart and establish con-
and the SOPAS ET • USB driver not installed correctly or nection again
program not possible not at all  Contact the manufacturer.
or interrupted
Figure 68 Connections in the MCUP (non-ex, zone 2, CSA cl I, div2)
Fuse holder

6.2.3 Malfunctions of sender/receiver unit

Detailed status information for the sender/receiver unit is provided by the "Diagnosis/Error
Messages/Warningss" directory (for a description of warning and malfunction messages,
see the following Sections).
Figure 69 "Diagnosis / Error Messages/Warnings" directory
Description Indicator
Clicking on the indication of some warning and error messages shows a short description
of possible causes and corrections under "Context Help". Placing the mouse pointer on the
name show tool tips.
Each measurement that is initiated by the master probe measures the transit time in and
opposite the flow direction. If no result can be obtained because of poor signal quality, this
is registered in an error memory.
If the number of invalid measurements exceeds the specified threshold ("Limit Warning"
parameter; default value 80%), "Maintenance request" is signaled.
If the error rate exceeds the value for "Limit malfunction" (default value 97%) "Malfunction"
is indicated.
If no valid values are measured within a definable period (default value 30 s), "Warning" is
output irrespective of the error rate. The period can be changed with the "Timer Warning"
parameter.

Warning and malfunction messages

Warning messages are output when no measurement is possible for some time or when
limits internally set in the FLOWSIC100 Flare/Process for individual device functions/
components are reached or exceeded which could result in incorrect measured values or
the approaching failure of the device.
Warning messages do not imply a malfunction of the measuring system. The

current measured value is still output at the analog output.
SOPAS ET Optional LC display Possible cause Action

Communication Communication • The MCUP - master and/or master -   p. 90, §6.3.2
A/B A/B slave connection cable was not correctly
connected (see OI FLOWSIC100 Flare/
Process, Section 3.2)
• Cable is interrupted, too long, resistance
is too high, not according to specifica-
tion
• Both sender/receiver units are set to
master or slave (type ex)
• One sender/receiver unit is defective
Parameter - • Device has not yet been parameterized  Enter the equipment data (again) (see
• The basic parameters entered were set OI FLOWSIC100 Flare/Process, Sec-
to 0 after the type change tion 4.2)
Measuring range Measuring range The parameterized measuring range is  Check the parameter settings.
exceeded.
NTC - The transducer temperature sensor does No activities required when there is no
not provide plausible measured values. other malfunction, otherwise replace
• Cable break transducer
• Short circuit of measuring line
Heavy noise Noise too large Signal is faulty  Check the transducers (  p. 39,
§3.2.2)
 Check measuring equipment for inter-
ference sources (  p. 93, §6.3.3)
No signal No signal found The device attempts currently to correct  No activity required
signal amplitude and time window.
Zero point offset Zero deviation The zero point offset found during the check  Initiate the check cycle (  p. 39,
cycle is too high §3.2.2).
Transducer Temperature The internally measured transducer  The limit for the transducer temperature
temperature temperature exceeds the set limit must be checked in relation to the gas
temperature in the duct and changed, if
required (Configuration / Device
Parameter" directory, "Limit Values"
group)
 On purged systems, check the purge air
Initialization Initialization When the device starts or after switching  No activities required
from maintenance to operating mode, a
resonance cycle and a signal search are
performed in the operating mode. Gain and

receiving window are set automatically.
Initialization is signaled until the value is
below the Limit warning error rate.
Transducer check - When the device starts, after switching  No activities required, when no other
from maintenance to operating mode, malfunctions occur.
when the transducer temperatures differ by
greater than 10 K or cyclically in case of a
malfunction, an internal transducer check
(resonance or check cycle) is performed.
The transducer frequencies are aligned.

6.2.4 Control unit malfunctions

Malfunctions in the MCUP control unit are displayed in the "Diagnosis / Error messages /
Warnings" directory.
Figure 70 "Diagnosis / Error messages / Warnings" directory
Description Indicator
Clicking on the indicator displays a short description under "Help".
Malfunction message Significance Possible cause Action

AO configuration error The number of analog outputs • No parameters set for AO  Check the parameter settings (see OI
with parameter settings of • Connection error FLOWSIC100 Flare/Process, Section
optional modules does not • Module failure 4.2.2)
match the number of  Replace the defective module ( for instruc-
connected outputs. tions, refer to the relevant MCUP type in
Chapter 8).
AI configuration error The number of analog inputs No parameters set for AI  Check the parameter settings (see OI
•
with parameter settings of • Connection error FLOWSIC100 Flare/Process, Section
optional modules does not • Module failure 4.2.3)
match the number of  Replace the defective module ( for instruc-
connected outputs. tions, refer to the relevant MCUP type in
Chapter 8).


DO configuration error The number of digital outputs • No parameters set for DO  Check the parameter settings (see OI
with parameter settings of • Connection error FLOWSIC100 Flare/Process, Section 4.3)
optional modules does not • Module failure  Replace the defective module ( for instruc-
match the number of tions, refer to the relevant MCUP type in
connected outputs. Chapter 8).
DI configuration error The number of digital inputs • No parameters set for DI  Check the parameter settings (see OI
with parameter settings of • Connection error FLOWSIC100 Flare/Process, Section 4.3)
optional modules does not • Module failure  Replace the defective module ( for instruc-
match the number of tions, refer to the relevant MCUP type in
connected outputs. Chapter 8).
Sensor configuration The number of available • Sensor failure  Check addressing and availability of sen-
error sensors does not match the • Communication prob- sors (  p. 77, Fig. 63).
number of connected sensors. lems on RS485 line  Contact the manufacturer.
Module configuration No communication via • No parameters set for  Check the parameter settings (see OI
error interface module module FLOWSIC100 Flare/Process, Section
• Connection error 4.3.2)
• Module failure  Replace the defective module ( for instruc-
tions, refer to the relevant MCUP type in
Chapter 8).
EEPROM error It was not possible to write • EEPROM is damaged  Check the EEPROM / FRAM.Replace the
data to or read from the processor board (  p. 235, §b).
FLASH error internal parameter memory. • Other hardware error  Contact the manufacturer.
FRAM error • FRAM is damaged
I/O module error The optional input/output Hardware defect  Replace the defective module ( for instruc-
modules do not operate tions, refer to the relevant MCUP type in
correctly. Chapter 8).
Systemconfiguration At least one prejusted system • See configuration erros  See configuration errors.
invalid component is not available or  Contact manufacturer.
does not work properly
Supply voltage error Internal supply voltage (24 V • Overload  Contact the manufacturer.
DC) deviates by more than • Hardware defect
10% from setpoint value.
Undefined error Any internal error occured  Replace processor board.
Systemtest active • The Testmode is acti-  Disable Testmode and/or Maintenance
vated. mode to restore normal operation.
I/O modules warning Any I/O module detected an • Example: current to high  No action required
invalide state.
Default parameter The measuring system • No parameters set for  Contact the manufacturer.
active operates with the factory-set the measuring system
basic settings
Real time clock error The onboard real time clock is • The real time clock is  Replace processor board.
not readable, all clock defective.
depending function may not
operate correctly. (Check cycle
intervall)
No sensor active Communication to sensors • Damage on RS485 line  Check RS485 cable.
could not be established. • Sensors not connected  Connect the FLSE sensor.
• Faulty A/B wiring  Check A/B lines.
• Terminiation incorrect  Set the proper terminations.


AI error signal At least one AI detected an • An P/T transmitter is  Check all P/T transmitters.
error siganl according to defect.  Check the wiring.
NAMUR NE43. • Transmitter wiring is
faulty.
Path compensation Only possible wioth 2-path • Sensor damaged  Check sensor operation.
active setting: one path has failed • Sensor in error mode.
and is compensated with the
working path.
Counter (1/2/3) CRC The counter value is invalide. • Counter not initialized  Initialize counter.
error • FRAM defect  Replace processor board.
Data Archive (1/2/3) The data archive content is • Data archive not initial-  Initialize data archives.
CRC error invalide. ized  Replace processor board.
• FRAM defect
Data Archive (1/2/3) The maximum capacity of the • Capacity exceeded  Set the archive to lower interval/higher
full archive is reached. capacity.
 Set recording mode to "Rolling".
Impulse (1/2/3) range The maximum impulse • Flow value too high  Reduce the impulse factor.
error frequency is reached. • Pulse factor too high
Logbook full The maximum Logbook • Capacity exceeded  Reset the Logbook.
capacity is reached.  Set recording mode to "Rolling".
Logbook CRC error The Logbook content is invalid. • Logbook not initialized  Reset the Logbook.
• Hardware (FRAM) faulty  Replace processor board.
I/O range error The analog output/input • Measured value above  Check the settings.
current range is outside the set range  Check the scaling of the AO.
specified range • Parameter setting error  Contact the manufacturer.
• Load does not comply
with specification
• Scaling of the AO is
wrong

6. 3 Correction of malfunctions
For better understanding of warning and malfunction messages, internal functions of the
FLOWSIC100 Flare/Process are described here in more detail.
6.3.1 Internal functional sequence, signal processing
Figure 71 FLOWSIC100 Flare/Process Functional Diagram

Internal functional sequence
Function Description Remark

System Start after reset (switching on the operating
Startup voltage) or clicking the "Watchdog" button Initialization of measuring head controller
(initialization) ("Service" password level)
The device parameters are copied from the parameter memory to the data memory. The controller
Parameter Init calculates the check sum across the parameter memory and compares it with the saved check sum. If
(initialization) they are not identical, "Error Parameter" is signaled (also error message. If the system is not yet
configured: Active measuring path =0)
If the parameters are plausible, the master/slave transducer communication is established.
After successful establishment of the communication, the system attempts to find the ultrasonic
signals. Measurements are performed for this purpose where the time windows of the receivers are
selected adequately large so that all plausible application states can be reliably acquired. If a plausible
Signal Search
ultrasonic signal is found in each of these time windows, the size of the time window is reduced to the
(Initialization/ extent that only the ultrasonic signal is recorded. The normal measuring operation is then started.
measuring operation)
If the quality of the signals received (signal-noise-ratio, amplitude) does not meet the parameter
specifications, the error messages listed on p. 83, §6.2.3 and described in detail in the following are
generated.
The system adapts the position of the time window, the send performance and the gain separately for
each sender/receiver unit to the current receive conditions. If this tracking "looses" the signal, the
Operation Mode
system switches back to signal search (SIGNAL_SEARCH). Temporary interferences of the signals
(measuring operation)
received are signaled by warnings and result in the increase of the system reaction time. Section 6.4
contains a description of the control functions.
Check Cycle (function Signal check during the check cycle (evaluation of results  p. 39, §3.2.2)
check)
Parameters in MCUP and FLSE can be changed by switching to maintenance status. The system
continues to operate with the current measuring rate and performs all calculations analog to the
operation mode. With the exception of the measuring cycle parameter and the settings of the serial
Configuration Mode
interface, all parameter changes are immediately considered in the current calculations. After changing
the active measuring path, a reinitialization with signal search is started after exiting the configuration
mode (switching from maintenance to operation).

Signal processing (VCO adjustment)

The sender/receiver electronics are capable of controlling different types of transducers.
Each transducer type has a specific frequency (42...135 kHz), control voltage (40...800
Vpp) and control duration (25 µs...2 ms).
In the receiver section, the very weak signals of the ultrasonic transducers must be
strongly amplified and filtered. Signal filtering is required to suppress (electric and
acoustic) interference signals that are far away from the operating frequency. Filtering is
realized by a bandpass filter (clocked filter with constant quality). The center frequency and
thus the bandwidth of the filter can be varied with a clock signal. figure 72 shows the
operation of the band-pass filter. Only frequency components that are in the spectral band-
pass range of the filter can pass this filter. All other frequency components are suppressed
by the filter. A distinct amplitude reduction at the operating frequency is the result of
misadjustment (transducer frequency and center frequency of the filter do not match). The
receiver "listens" at the wrong frequency, i.e. it is insensitive to the actual signal. In
addition, signal distortions occur which result in distinct runtime offsets and thus falsify
the measured value.
Figure 72 Schematic diagram of band-pass receive signal processing
Amplitude
Frequency response of band-pass
Center frequency
of band-pass
Operating frequency of transducer
Suppressed interference components
Frequency
Operating frequency
of transducer
Band-pass range
Band-pass
6.3.2 Communication fault

The communication between the MCUP and the sender/receiver units is performed
according to the master (transducer A) - slave (transducer B) principle via an electrically
isolated, differential interface similar to the RS485 standard. Each sender/receiver unit is
uniquely identified via an address (FLSE master/FLSE slave). Only the MCUP sends
commands to the master sender/receiver unit which replies only when the address
specified in the command is its own address.
Problems in data communication are generally caused by wiring errors or damage
(lightning, overvoltage, e.g. by wiring errors) of components. Communication problems are

signaled on the optional LC display of the MCUP or in the SOPAS ET program.
Possible error causes:
The used sender/receiver units are both set to master or both to slave.
On a measuring path, one transducer must be set to master and the other one to slave
(assignment to flow direction according to OI FLOWSIC100 Flare/Process, Section 2.2.3).
In particular, for the replace of a FLSE, it must be guaranteed that a master and slave type
are always used together. The setting of a FLSE100 is shown on the device label on the
electronics housing.

The setting of the FLSE100 can be changed over miniature switches on the electronic
boards (see below).
Change of master/slave setting:
 Dismount the electronic unit according to the description in chapter 7 on page 113.
 Make necessary settings on miniature switches considering figure 73.
Figure 73 FLSE100 setting
Digital board Switch
4
3
2
1
Miniature switch Position
OFF
(white coloured) ON
Transducer Switch 4
Master ON
Slave OFF
The illustration shows the setting

for the FLSE100 to slave
NOTICE:
Master/slave setting using the miniature switches on electronic board is not
possible for S/R units ATEX zone 2 due to socketed electronics. Spare
electronic for S/R units ATEX zone 2 is available separately as master and
slave unit.
Termination error
 Check the termination according to p. 30, §3.1.1.
Cable material
NOTICE:
All notes exclusively only refer to the pure functionality of the device.
The plant operator is responsible to check and guarantee that the cables
used in hazardous areas fulfill the requirements at the respective plant.
If other cables than specified are used, the following errors could occur:
Cable material, see OI FLOWSIC100 Flare/Process , Section 2.3.4 and 3.3.4

a) The wire cross-section is too small. This means that the Ohmic resistance of the
cable and consequently the voltage drop over the cable length becomes greater. If
the voltage is measured on the FLSE100, it must be contacted. The typical current
of a transducer is approx. 60...70 mA, the voltage must be greater than 24 V ( 
p. 35, §3.2.1).
b) For cables with an operating capacity of greater than 110 pF per conductor, the
transmission bandwidth of the cable is restricted. The RS 485 signal forms of the
data communication are thus blurred. The result are communication errors or total
failure of data communication.
 Data transmission problems
If the previously listed error causes can be excluded, data communication signal level
and signal form must be checked ( figure 74).
Figure 74 Typical RS 485 data communication signal forms (measured on the terminals of the MCUP for a and b)
FLOWSIC100 Flare/Process data package, baud rate 57600 Bit
Command Response from transducer

to transducer
Amplitude
Time
If the signal forms and sizes do not match the representations in figure 74, components
can be damaged (e.g. by lightning, wiring errors, overvoltage) so that subassemblies
have to be replaced (possible repairs, see Chapter 7).

6.3.3 "Heavy noise" error

The signals received are always overlaid by interference signals. Ideally, the amplitude of
these interference signals is so low that they can be ignored. If the interference signals
reach clearly visible amplitude values, in particular in the range directly before the actual
useful signal (see OI FLOWSIC100 Flare/Process, Fig. 87 to 88), errors in the
determination of the runtime of ultrasonic signals result. This effect can be compensated
by the software to a limited extent. Depending on the interference level and the absolute
runtime of the ultrasonic signals, an offset in the measured value calculation occurs (the
shorter the runtimes, the more sensitive are the system reactions). During start-up or
maintenance, the noise level of the system must therefore be checked.
Possible noise sources
Structure-borne sound
The sender/receiver unit is not acoustically decoupled from the flange. This means that
sound energy from the equipment or from the ultrasonic transducers themselves can act
upon the transducers and generate interference signals. The system reacts especially
sensitive to such installation errors in the direct area of the transducers.
Possible causes:
 No seal between sender/receiver unit and nozzle
 Raised welding beads in the nozzle that touch the probe tube
 Nozzles that are warped or too narrow
 Use of incorrect fastening screws for the SIR units after an replacement.
CAUTION:
Use original screws only! Screws that are too long can destroy the
ultrasonic transducers, screw heads that are too large can come into
contact with the flange pipe and induce interference signals.
 External noise by pressure regulators or valves
– Contact the manufacturer
– Replace the sender/receiver unit with more efficient types if possible.
 Turbulences
Very high flow speeds can cause turbulences on the transducer that could cause noise.
This effect was clearly observed with probes that were very strongly directed into the
flow (installation angle to flow axis smaller than 45°).
 Wiring errors (only valid for non ex-protected device types)
When circuit boards of the transducer electronics, transducers or the transducer
cabling are replaced, it is possible that ground and signal line in the transducer circuitry
are interchanged. This causes a projection of the send current of the sending FLSE100
into the receive channel of the receiving FLSE100. The interference signal is very
similar to a structure-borne sound short circuit.
Test:
The two sender/receiver units must be arranged opposite to each other and electrically
insulated. An electric connection (e.g. cable) between the two FLSE100 must not result
in a malfunction of signal search.
Equipment noise
A source of interference noise can be velves or a measurement after turbines in a short
distance to the measuring location and without adequate acoustic decoupling.
Check the measuring system for noise
 Call up the "Diagnosis/Sensor Values" directory (password level "Sick Service", pass-
word "expert") and check signal sequences and basic noise in the "Signal Display"
group.

 Record the values displayed in the "Diagnosis Values" group in the "Gain" and "Pretime"
fields.
Figure 75 "Diagnosis/Sensor Values" directory ("Service" password level)
 Switch the sender/receiver units to the "Maintenance" mode.

 Change to the "Configuration/Device Parameter" subdirectory, enter the recorded gain

value in the "Gain" group in the "Gain level A" and "Gain level B" entry fields and the pre-
counter value in the "Receiving Window" group in the "Precounter" entry field.
Figure 76 "Configuration/Device Parameters" subdirectory
 In the "Gain" group, activate the "Gain control off" checkbox and in the "Receiving Win-
dow" group, activate the "automatic window control off" checkbox.
 In the "Transmit Parameters" group, activate the "listening (no transmitting)" checkbox.
 Change to the "Diagnosis/Sensor Values" directory and check the signal sequences.
 Repeat the procedure stepwise with gain values of up to 50 dB.
 The noise level should not be more than approx. 15% of the dynamic range.

 Terminate the check, set the precounter value to 0 and deselect the "listening (no trans-
mitting)", "Gain control off" and "automatic window control off" checkbox.
NOTICE:
The "listening (no transmitting)" checkbox must be deselected.
 Deactivate the "Maintenance" status.

Caution
By entering a value > 0 in the "Precounter" entry field ("Diagnosis/Sensor

Values" directory, "Diagnosis Values" group), it is possible to mask
interferences before the actual measurement signal. The precounter then
also starts even with automatic receiving window control only from this at
the earliest time (later start times are possible depending on the active
measuring path).
6.3.4 "No signal" error

The signal amplitudes received do not reach the value set in the "Plausib. threshold"
parameter.
Possible causes:
 The ultrasonic signals are excessively attenuated. This could be due to:
– Damping of the medium itself (e.g. high CO2 concentrations and/or hydrocarbon com-
pounds),
– Drift effect of very high flow speeds,
– Signal fluctuations from hot-cold boundry layers in the gas flow
 The receive filters are not aligned to the operating frequency of the transducers ( 
p. 88, §6.3.1 "Signal processing")
 The transducers are operated with wrong parameters (signal frequency, max. allowed
transmitting power). In most cases, the cause is that the device type selected in the
MCUP does not match the type of the connected FLSE100. Problems in the adjustment
of the receive filters can also cause a detuning of the send frequencies.
 Particles in the gas flow strike the diaphragm of the transducer against which the flow
is directed and thus generate signals with high amplitude that accidentally occur in the
recording window, but can interfere considerably with the signal amplitude control. The
strong interference signals reduce the receive sensitivity to such an extent that the
reception of the ultrasonic signals is no longer possible. A remedy can be the change of
the position of the measuring axis and the installation of rebound protectors (available
on requet only).
 The nozzles are not aligned correctly to each other (offset in flow direction, different
axes; compare OI FLOWSIC100 Flare/Process, Section 3.2.1).

6.3.5 "Measuring range" error

If plausible signals for both directions are determined in the signal search phase (signal-
noise ratio and received amplitude fulfill the parameterized minimum specifications), the
runtime of these signals is determined from which the flow speed is calculated. A limit of
60 m/s (180 fps) is set in the software for the value of the flow speed. A value in excess of
this limit is signaled as an error.
NOTICE:
The value can be changed in the "Configuration / Device Parameter"
subdirectory, "Limit Values" group, "Limit range" entry field ( p. 104,
Fig. 82).
Possible causes:
 Flow behavior at the measuring point, e.g. highly unsymmetric profile in connection with
an unfavorable orientation of the measuring axis (determined without previous profile
measurement).
 Equipment malfunctions resulting from gas speeds that are actually too high
 Signal forms that frequently precede the actual signal, exceed both trigger thresholds of
the signal evaluation and thus result in implausible runtime measurement. The check is
possible by the graphic representation of the signal search phase.
6.3.6 "Time plausibility" error

The phase position for determination of the transit time is not plausible.
Correctly adjusted zero phases of the individual paths is the basis for accurate transit time
measurement of the ultrasonic signals. The "Zero phase" parameters are correctly
adjusted if the red corr. cursor (corr. = corrected runtime;  p. 98, Fig. 77) is at least close
and the green cursor (transit time= runtime) is exactly on the second positive zero passage
of the received ultrasonic signal.
Conditions for the cursors "transit time" and "corr."
– The cursors should overlap at the point where the end of the second period of the
received signal intersects the zero line.
– Time difference between the two cursors is lower than half a period of the transit time
value.
– The transit time cursors should intersect the zero line at the end of the second signal
– period.
If this is not the case, the evaluation cursors must be displaced with the help of "Zero
phase up" (transducer B correction parameter) and "ZeroPhase down" (transducer A
correction parameter) until their zero passages are at the correct position. These
corrections should be made under operating conditions, i.e. under operating pressure and
with the real gas.
The parameter must be adjusted for one or both transducers, if necessary.
To check the "zero phase" parameter, switch to "Sick service" usel level, open the
"Diagnosis / Sensor values" directory and activate the "View envelope" checkbox.

Figure 77 Correct setting of the zero phase

Figure 78 Incorrect setting of the zero phase


Activities to correct the "Zero phase" parameter

 Select the "Configuration / Device Parameters" directory.
Figure 79 "Configuration / Device Parameters" directory
 Change the values in the group "Receive parameters" window "Zero phase" under oper-
ating conditions (operating pressure, real gas).
The value of the "Zero phase" parameter can be determined empirically or by way of
calculation. Examples for the effect on the phase lag:
– "ZeroPhase" + 6.28 rad (= 2 p):
Displacement of the COR line by about one period to the right

– "ZeroPhase" - 3.14 rad (= p):
Displacement by about half a period to the left.
6.3.7 Checking the sender/receiver units

If sender/receiver units are dismantled from the measuring pipe for maintenance reasons
a reduced quick check in a control room can be performed. This can help if causes for
malfunctions cannot be readily detected.
CAUTION:
Observe all safety information according to p. 9, §1 and p. 25, §2.2
when the sender/receiver units are removed from the measuring pipe!
 Place the sender/receiver units on an elevated work surface, e.g. a table, and arrange
them opposite to each other (see Fig. 6.13), if possible, maintain the active measuring
path (if necessary, change temporarily in the "Configuration / Application Parameters"
directory; see OI FLOWIC100 Flare Section 4.2.1).
 Call up the "Diagnosis/Sensor Values" directory and check signal sequences and basic
noise in the "Signal Display" group.
Figure 80 External tests of sender/receiver units

Sender/receiver unit
Active measuring path
Minimum height
approx. 0.5 m
(to prevent noise
interferences)
Work surface
If measurement is not possible even in the dismantled condition, the error must be
isolated according to Section 3.2.2.
If the sender/receiver units operate normally in the dismantled condition, the application
must be checked for causes that can be attributed to the installation or equipment, such
as structure-borne noise, equipment noise or particles in the gas flow. For this purpose, the
sender/receiver units must be checked in the installed state according to the procedure
described in Section 6.3.3 under "Equipment noise".
If the receive signals of both sender/receiver units do not exceed the line for "Lower
fraction", there is no malfunction that can be attributed to the equipment. If the receive
signals of both FLSE100 are too high, this can be due to equipment noise.
When one of the sender/receiver units receives signals that are too high, this can be due to
structure-borne noise or striking particles.
6. 4 Special effects from the gas condition

The gas condition do not have any effect on the detection of transit time difference, but
can have effects on the single signal transmission from one to the other transducer. The
maximum measuring distance and the maximum possible gas velocity is depending on the
gas condition.
Figure 81 Influences on the signal transmission

Gas velocity Gas condition
Heavy gases Close to air Close to air
MW >30 g/mol MW approx. 20 g/mol MW <15 g/mol
Flow
direction
Sonic beam
Transducer
The signal amplitude is weakened The sonic beam is Normal sonic beam The sonic beam is broader
strongly by the drift effect at higher smaller than normal. No specific problems than normal.
velocities (> 70 m/s).  At low gas velocities  At low gas velocities
higher signal ampli- lower signal amplitudes
tudes by higher by lower energy density
energy density  At higher velocities the
 At higher velocities drift effect can be com-
the signal amplitude pensated in a better
decreases consider- way.
ably due to the drift  Possible reflections at
effect in correlation the pipe wall lying oppo-
with the smaller site can interfere the
beam received signal due to
the broader beam.
Certain gas components like CO2, methane or H2S in high concentration can lead to an
additional signal damping.
All effects influence each other. The positive effect by a broad beam can for example be
neutralized by a high CO concentration.

It is typical for flare gas applications that the gas composition can strongly change
depending on the operation so that problems appear only at certain operation conditions.
6.5 Optimization of device-internal parameters

Device-internal parameters whose modification can optimize system behavior and thus
allow adaptation to problematic applications or can be a remedy in the case of implausible
measured values are described in the following.
For the modification of device-internal parameters, the "FLOWSIC100 Flare/Process /
Configuration / Device Parameters" directory must be selected, the password "expert"
(level "Sick Service") entered and the measuring system set to the "Maintenance" mode.
NOTICE:
 If certain parameters are misadjusted in an impermissible manner,
malfunctions of the device or transducer failures caused by excessive
transmitting power could result. Repair in the factory is required in these
cases.
 Failures or malfunctions caused by incorrectly set parameters are not
accepted by SICK as guarantee claims.
 The programming for the ex-classification may not be changed in the
software. It must be in conformance with the device designation (see
device label).
6.5.1 Device parameters
Figure 82 "Configuration / Device Parameters" directory (the values are FLOWSIC100 Flare/Process H standard values)
Window Parameter Description

Transmit Transmit frequency It is imperative that it matches the transducer used, see Section <kursiv 9p>6.5.2)
Parameters On FLOWSIC100 PR, the frequency is automatically set to 135 kHz.
Total periods 1/2/3 The transducer is activated for sending with the activation periods and then actively
retarded. The number of total periods is the total of activation periods and retarding
periods.
Activation periods 1/2/3 Number of periods with which the transducer is activated.
Retarding attenuation The amplitude of the active attenuation of the transducer is exponentially reduced. The
1/2/3 speed of this reduction can be set with the retarding attenuation parameter.
Delay 1/2 Delay between 1st and 2nd transmit bursts.
Amplitude Amplitude of transmission voltage for the transducer. A value of 1 represents the
maximum allowed transmission voltage for the transducer.
Receive Zero phase A (Master) The "zero phase" parameters are correctly adjusted, if the red cursor (corr.- corrected
Parameters Zero phase B (Slave) transit time) is at least close to the green cursor (transit time) on an positive zero crossing
of the received signal. The cursors of the singal A and signal B have to be adjusted on the
same zero crossing.
System runtime A Total of the zero runtime of the transducer and the connected electronics. This value is
System runtime B deducted from the measured runtime to determine the actual runtime.
System runtime CCR A Difference of the system runtime of the correlation algorithm to the standard procedure.
System runtime CCR B
Signal Lower fraction Percentage of maximum amplitude of demodulated receive signal. Runtime
Processing determination is performed via a slope algorithm. All values of the demodulated receive
signal that are above this value are used for calculation of the leading edge.
Upper fraction Percentage of maximum amplitude of demodulated receive signal. Runtime
determination is performed via a slope algorithm. All values of the demodulated receive
signal that are below this value are used for calculation of the leading edge.
Number of averaged Number of the demodulated signal averaged in the time range.
signals Higher values, especially for signals with high interference; cannot be used with quick
variations of the gas speed (input of 1 required).
Setting values 1 to 50
Median buffer size Number of speed values to be saved for the median filter
Average median Portion of measured values used for averaging. A value of 0% corresponds to a typical
median filter, a value of 100 % to a floating average value filter.
CCR active The correlation algorithm is activated if the SNR drops below this value. This value acts as
"Limit SNR" if the CCR has not yet been activated.
Multiburst Number of repetitions of a transmit burst in one direction before measurement in the
opposite direction is performed
Measuring cycle Duration of a measuring cycle
Setting from 100 ms ... 1000 ms; minimum time is determined by the length of the
recording window and the sampling rate
Transmit delay B (Slave) Suppression of the decay time of probe A for short active measuring paths
Setting between 0 and half measuring cycle duration (typical value 20 ms)
Gain Gain level A (Master) Gain default; effective only when gain control is off ("Gain control off" checkbox is
Gain level B (Slave) activated)
Target amplitude Setpoint value of the amplitude of the gain control

Damping Regular damping of gain control
Gain control deactivated The automatic gain control is switched off by activating this checkbox. The measuring
system operates with the values set in the "Gain level A/Gain level B" entry fields.
Window Parameter Description

Receiving Window size Size of receiving window which is equivalent to the minimum number of acquired signals
Window that are used for runtime determination
Precounter Constant which, multiplied with 2 μs, results in the duration between the transmit signal
and the begin of the recording window.
The value must be calculated from active measuring path, sound velocity and gas
temperature. The signal must be near the average speed in the middle of the recording
window.
Value range 0 to 65000
With deselected automatic window control (checkbox is set), the entered value is directly
used as the precounter; with selected control, this value is the lower limit for the
precounter.
Control deactivated Switches off the automatic selection of the correct time window
Limits Limit warning If the error rate exceeds the value entered in this field, "Maintenance request" is output.
Limit malfunction If the error rate exceeds the value entered in this field, "Malfunction" is output.
Limit SNR The signal is rejected if the SNR of the signal is belower this limit. If error rate exceeds the
warning limit, status "Heavy Noise" is signalized. Attention! "CCR active" acts as "Limit
SNR" when correlation mode is not active!
Plausib. threshold Threshold of the receive amplitude (percentage of dynamic range) below which the
receive signal is considered to be invalid and is discarded. If the error rate reaches the
value set in the "Limit warning" window, the "No signal" warning messages is output. If
the value for "Limit malfunction" is reached, the "No signal" malfunction message is
output
Limit range If the error rate of transducer A reaches the value entered in this field, "Measuring range
warning" is output. If the value of the gas speed measured exceeds this value, the
measurement is discarded.
Limit max. transd. temp. Setting of the allowed limiting temperature for the ultrasonic transducers
Low flow cut-off For measured values below the value entered in this field, no flow is output.
LIMIT CCR max The signal is rejected if the maximum of the CCR is belower this limit. If error rate exceeds
the warning limit, status "Heavy Noise" is signalized.
Serial Baud rate Baud rate for communication via the interface
Interface: Bus address Software setting of the bus address when 0 is set by the hardware (  p. 32, §3.1.2)
Response delay Response delay of interface
Figure 83 Maximum amplitude, lower fraction and upper fraction parameters
128
Maximum amplitude
Demodulated signal
Upper fraction
Lower fraction
t0 t
6.5.2 Overview of standard parameters(default values)
Parameter Type FLOWSIC100

EX-S 80 EX-S 135 EX/EX-RE EX-PR 135
(standard) (high / low tem-
perature version)
Transmit Parameters
Transmit frequency 1 [kHz] 80 135 46 135
Total periods 1 4.0 5.0 4.0
Activation periods 1 2.0 4.0 2.0
Retarding attenuation 1 10.0 10.0 10.0
Delay 1 1.0 1.0 1.0
Delay 2 1.0 1.0 1.0
Amplitude [s] 0.9 0.8 0.9
Sensortype [kHz] 80 135 42 135
Receive Parameters
Zero phase A (Master) [rad] 8.0 8.0 8.0
Zero phase B (Slave) [rad] 8.0 8.0 8.0
System runtime A [μs] 30.0 30.0 30.0
System runtime B [μs] 30.0 30.0 30.0
System runtime CCR A [μs] 0.0 0.0 0.0
System runtime CCR B [μs] 0.0 0.0 0.0
Signal Processing
Lower fraction [%] 40 40 40
Upper fraction [%] 60 60 60
Number of averaged signals 10 10 10
Median buffer size 51 51 51
Average median [%] 70 70 70
CCR active {dB] 18 18 18
Multiburst 1 1 1
Measuring cycle [ms] 100 500 100

Transmit delay B [ms] 30 200 30
Gain
Gain level A [dB] 30 30 30
Gain level B [dB] 30 30 30
Target amplitude [%] 60 60 60
Damping [dB] 10 10 10
Gain control deactivated no no no
Parameter Type FLOWSIC100

EX-S 80 EX-S 135 EX/EX-RE EX-PR 135
(standard) (high /low tem-
perature version)
Receiving Window
Window size 2000 2000 2000
Precounter [ms] 0.00 0.00 0.00
Control deactivated no no no
Limits
Limit warning [%] 80 80 80
Limit malfunction [%] 97 97 97
Limit SNR [dB] 12 12 12
Plausib. threshold [%] 20 20 20
Limit range [m/s] 150.00 150.00 150.00
Limit max. transd. temp. [°C] 250.0 250.0 250.0
Low flow cut off [m/s] 0.0 0.0 0.0
Limit CCR max 500.0 500.0 500.0
Serial Interface:
Baud rate [Baud] 57600 57600 57600
Bus address 1 1 1
Response delay [ms] 4 4 4
6.5.3 "First max" parameter

If interference signals with a higher amplitude occur (e.g. by ceiling reflections) during
signal reception directly after the actual receive signal, incorrect measurements would
take place with the standard parameters for the lower and upper fractions.
Figure 84 Receive signal with interference

By activating the "First max" checkbox in the "Signal Processing" window, a further
maximum is searched for up to approx. 15 periods before the global maximum. This is then
used for further calculations ( p. 110, Fig. 85). The fraction thresholds then refer
proportionally to the value of the first maximum. The correct runtime is thus acquired.
Figure 85 Runtime calculation with the "First max" parameter set
6.5.4 "Total periods", "Activation periods", "Rel. transmit amplitude" parameters

In case of unfavorable application conditions, the number of usable measuring signals is
not sufficient, the following possibilities exist for improvement of the measuring behavior:
 In the "Transmit Parameters" window, "Rel. Transmit amplitude" entry field, increase the
value to max. 1.0 ( p. 104, Fig. 82).
 If this is not sufficient, the transmit signal duration can be increased in addition
(increase the default values from 4.0 to 8.0 in the "Transmit Parameters" window, "Total
periods" / "Activation periods" window).
Repair work for sender/receiver unit
7 Repair work for sender/receiver unit
General information
Electronics unit
Sensor assembly
Installation and mounting parts
7. 1 General information
1 Any repair work and the replacement of spare parts outside the factory SICK Dresden is
only permitted according to this Service Manual FL100 Flare/Process.
Dismounting and replacing parts and any other repair procedures not covered in the
Service Manual are not permitted and result in loss of any warranty claims!
2 Special care and attention have to be paid to all safety relevant notes on  p. 9, §1!
3 Validity of repair procedures for FL100 Process, released 2008:
FLOWSIC100 Flare FLOWSIC100 Process

FL100 EX, ATEX Zone 2 FL100 EX-Z2
FL100 EXRE, ATEX Zone 2 FL100 EX-Z2-RE
Further repair procedures of FL100 Flare device types EX, EXRE, EX-S and EXPR are
not applicable for FL100 Process.
4 SICK repair instructions have to be followed exactly. The described replacement proce-
dures include all necessary work steps with respect to mounting, dismounting, function
check, parameter settings, documentation, device designation (labeling) etc..
5 Any repair work and the replacement of spare parts on the labelingmeasuring system
have to be carried out by SICK trained persons and must be approved by responsible
skilled persons. The required SICK training has to be proved by a certificate. Detailed
requirements to service staff are defined on  p. 9, §1 of this manual.
6 Only use SICK original spare parts. The use of none-original parts is not permitted. All
original SICK spare parts are function checked by the manufacturer before delivery.
7 Choosing the correct spare part is a mandatory requirement for the replacement of
parts.
In case of replacing electronic unit and sensor assembly special attention has to be
paid to:
a) Ex-approval of the original sender/receiver unit
b) Device type of original sender/receiver unit
8 Any repair work on system components of the FL100 Flare/Process has to be docu-
mented and recorded in the service report completely.
9 Regarding the replacement of parts the following minimum information have to be doc-
umented in the service report:
Repaired system component:
– Device type
– Part number
– Serial number
– Defective part
– Failure description
– Successful function test after replacement of parts
Installed spare part:
– Part number
– Serial number (if relevant)
10 A copy of the service report has to be provided to the plant operator for gapless docu-
mentation of any repair work.
A further copy has to be provided to the manufacturer:
Address
SICK Engineering GmbH
Dpt. Application and Service
Bergener Ring 27
01458 Ottendorf-Okrilla
Germany
Mail: flow.help@sick.de
WARNING:
 Make sure the measuring system is disconnected from the power supply
and potential-free before you start any work on the FLOWSIC100 Flare/
Process.
 If the FLOWSIC100 Flare/Process is used in a hazardous area, power must
be disconnected in the safe zone.
 The pipeline section in which the meter is installed must be depressurised
and vented before the sender/receiver units can be replaced, unless
retractable sender/receiver units are used (for details on how to use it see
the OI FLOWSIC100 Flare).
7.2 Special notes for replacement of electronic unit at sender/receiver

units
1 For devices of FLOWSIC100 Process the spare part "Electronic unit FLSE100" of
FLOWSIC100 Flare can be used as following:
FLOWSIC100 Flare FLOWSIC100 Process
E-Unit FLSE100-EXZ2/EXZ2RE compatible with E-Unit FLSE100-EX/EXRE
ATEX Zone 2 ATEX Zone 2
2 Spare electronic units are labelled as following:
a) Ex label
– Model name: EX, EXS or EXPR depending on type
– Type key of FL100 Flare/Process with configuration details for electronics only; all
other properties are indicated with "N".
– Part number of spare part
– Serial number
– Ex-classification
– Standard ambient temperature specification -40 … +70 °C, no pressure and tem-
perature specification for measured medium
b) SICK label
– Type key of FL100 Flare/Process with configuration details for electronics only; all
other properties are indicated with "N".
– Model name: EX, EXS or EXPR depending on type
– Part number of spare part
– Serial number
– Indication Master / Slave
3 The manufacturer SICK recommends the labeling of the repaired FLSE100 with label
duplicates of the original S/R unit (Ex label, SICK label) with full device specification
after successful repair.
a) The label duplicate has a clear indication "Duplicate".
b) The label duplicate is available from the manufacturer on request.
c) For delivery of the label duplicate, the plant operator must provide the service report
of the device repair to the manufacturer containing all required information.
d) The labels have to be replaced carefully. The SICK service or a SICK trained service
technician of the plant operator takes full responsibility for the correct device desig-
nation of the S/R unit.
4 After finishing of replacement work the correct and tight closing of the electronics hous-
ing has to be checked and ensured.
7. 3 Special notes for replacement of transducer assembly

1 The spare sensor assembly is marked with a serial number at the transducer.
2 The part number of the spare part is shown on the SICK label at the packing of the
spare part.
3 When replacing the sensor assembly, a replacement of the sealings of the sender/
receiver unit is required:
– Internal and external sealing in retraction flange
– External O-ring sealings in probe flange
4 After every replacement of sensor assembly the process tightness of the sender/
receiver unit has to be checked and ensured with a suitable procedure.
The tightness check is in the responsibility of the plant operator.
NOTICE:
Spare part electronic unit ATEX Zone 2 of FLOWSIC100 Flare is compatible for
ex-protected types (ATEX Zone 2) of FLOWSIC100 Process and can be used for
replacement.
FL100 Flare FL100 Process

Device type FLSE1-EX, FLSE1-EXRE FLSE100-EXZ2, FLSE100 EXZ2RE
Ex approval ATEX Zone 2 ATEX Zone 2
Ex approval report ATEX09SICK32001X SICK08ATEX0001 X
Spare part 2060330, 2060407 2060330, 2060407 Subject to change without notice
7.4 Removing of sender/receiver units from installation for repair work
Please refer to  p. 25, §2.2.1 of this manual.

 Socket wrenches SW 7, SW 8, SW 9, SW 10
 Jaw wrenches SW 7, SW 8, SW 9, SW 10, SW 17
 Medium-sized phillips screwdriver
 Small and medium-sized slot screwdriver
 Pointed pliers
Special tools available from the manufacturer:
Figure 86 "Tool for cover of Exd housing", Part No. 2060292
Figure 87 "Tool for fastening ring electronic housing", Part No. 4067517
Figure 88 "Tool for screen connection", Part No. 2060293

Overview of replaceable parts — sender/receiver units
Figure 89 Replaceable parts of sender/receiver units

Non-retractable types
3
4
5
3
1 2
3
5
Retractable types
3
4
5
3
1 2
3
5
1 Electronics unit with junction box 4 Housing cover with safety catches
2 Sensor assembly with ultrasonic transducer 5 Cable glands/blind plugs
6 3 Pressure compensation element 6 Electronics unit without junction box
7.5 Electronics unit of device type FLOWSIC100 EX-S and EX-PR
7.5.1 Replacement of electronics unit housing parts

Device type ATEX Zone 1 / IECEx and CSA
NOTICE:
 Both sensors of a measuring system must have the same firmware version.
If necessary, the electronics of the S/R unit not included in repair work,
should be updated.
 After finishing of repair work, the correct and tight closing of electronics
housing, cable glands and blind plugs has to be checked and ensured.
Figure 90 Replacement of electronics housing parts
Electronics housing assembled
Accessory set for electronics housing Exd

1 1
3
1 Socket screw MUX and spring washer

5 2 Cover with locking bracket
3 O-ring
4 Earth terminal parts
5 Blind plugs
Part No. Spare Part

2052499 Cover set for electronic housing Ex-d Al
2065857 Accessory set for electronic housing Ex-d Al metric
2052492 Accessory set for electronic housing Ex-d Al NPT
7.5.2 Replacement of complete electronics unit

7.5.2.1 Device type ATEX Zone 2
 Remove screws on probe connection with 7mm wrench.
Figure 91 Removal of probe connection
 Pull probe connection away from electronics unit, and unscrew PG cable glands using
11 mm wrench.
Figure 92 Unscrewing cables

 Carefully disconnect the MCX plugs.
Figure 93 Removal of cables
 Replace electronics unit, and repeat steps in reverse order to reassemble.
Part No. Spare Part

FLSE100-EXS, Standard temperature version:
2060324 FLSE100-EXS NNNNNNNNNN NN 82CSAMY NN
FLSE100-EXS, High/Low temperature version:
2060327 FLSE100-EXS NNNNNNNNNN NN 12CSAMY NN
FLSE100-EXPR, all temperature versions:
2060352 FLSE100-EXPR NNNNNNNNNN NN 12CSAMY NN
7.5.2.2 Device type ATEX Zone 1 with Exe junction box

 See description for type ATEX Zone 1 without junction box and type CSA ( p. 123,
§7.5.2.3)
Part No. Spare Part

FLSE100-EXS, Standard temperature version:
2060325 FLSE100-EXS NNNNNNNNNN NN 81CDAMY NN
2062085 FLSE100-EXS NNNNNNNNNN NN 81CDSMY NN
FLSE100-EXS, High/Low temperature version:
2060328 FLSE100-EXS NNNNNNNNNN NN 11CDAMY NN
2062091 FLSE100-EXS NNNNNNNNNN NN 11CDSMY NN
FLSE100-EXPR, all temperature versions:
2060353 FLSE100-EXPR NNNNNNNNNN NN 11CDAMY NN
2062125 FLSE100-EXPR NNNNNNNNNN NN 11CDSMY NN
7.5.2.3 Device type ATEX Zone 1/IECEx without junction box and CSA
 Loosen 4 hexagon socket screws on probe connection.
 Remove probe connection from electronics unit.
Figure 94 Removing probe connection from electronics housing

 Disconnect MCX plugs.

 Connect new electronics unit to sensor cables:
– Cable 1 = Sensor A
– Cable 2 = Empty / Temp. Sensor (for EX-PR)
– Cable 3 = Sensor B
Figure 95 Connecting cables of electronics unit and probe
 Mount probe connection to new electronics unit.
Part No. Spare Part

FLSE100-EXS, ATEX Zone 1/IECEx, Standard temperature version
2060326 FLSE100-EXS NNNNNNNNNN NN 81CDAMN NN
2062086 FLSE100-EXS NNNNNNNNNN NN 81CDSMN NN
2062087 FLSE100-EXS NNNNNNNNNN NN 81CDATN NN
2062088 FLSE100-EXS NNNNNNNNNN NN 81CDSTN NN
FLSE100-EXS, ATEX Zone 1/IECEx, High/Low temperature version
2060329 FLSE100-EXS NNNNNNNNNN NN 11CDAMN NN
2062092 FLSE100-EXS NNNNNNNNNN NN 11CDSMN NN
FLSE100-EXS, CSA CI I, Div1, Standard temperature version
FLSE100-EXS, CSA CI I, Div1, High/Low temperature version
FLSE100-EXPR, ATEX Zone 1/IECEx, all temperature versions
2060354 FLSE100-EXPR NNNNNNNNNN NN 11CDAMN NN
2062126 FLSE100-EXPR NNNNNNNNNN NN 11CDSMN NN
2062127 FLSE100-EXPR NNNNNNNNNN NN 11CDATN NN
2062128 FLSE100-EXPR NNNNNNNNNN NN 11CDSTN NN
FLSE100-EXPR, CSA CI I, Div1, all temperature versions
2062129 FLSE100-EXPR NNNNNNNNNN NN 13CDATN NN
2062130 FLSE100-EXPR NNNNNNNNNN NN 13CDSTN NN
7.5.3 Replacement of terminal block

Device type ATEX Zone 2 and Zone 1 with junction box
 Undo 4 screws to open junction box
Figure 96 Junction box
Figure 97 Terminal connections Zone 1
Figure 98 Terminal connections Zone 2
 Remove screws to the left and right of the terminal block (unless otherwise stated, the
following figures depict ATEX Zone 2 version).
Figure 99 Remove screws holding terminal block

 Use special tool to undo screws holding terminal block.
NOTICE:
Special tool must be used for loosening the screws holding the terminal block.
Using screwdrivers will destroy them.
 Loosen left and lower right screws.
Figure 100 Removing screws using special tool ( Part No. 2060293)
 Disconnect wires from terminals.
NOTICE:
Note down the terminal connections before disconnecting the wires!
Figure 101 Disconnect wires
When screwing in the new terminal block, ensure the following order of serrated washers
and distance rings: (from left to right):
1 Serrated washer
2 Small distance ring (ATEX zone 2 only)
3 Distance ring
4 Wire holder (Use special tool)
5 Clamping nut (ATEX zone 2 only)
Figure 102 Assembly parts for device type ATEX Zone 1 with junction box
1 3 1 4
Figure 103 Assembly parts for device type ATEX Zone 2
 Mount the terminal block, repeating steps in reverse order. Ensure correct wiring.
Figure 104 Housing with dismounted terminal block
Part No. Spare Part

2060307 Terminal block Exe ATEX Zone 2
7.5.4 Replacement of cable glands

7.5.4.1 Device type ATEX Zone 2 and ATEX Zone 1 with junction box
NOTICE:
Only cable glands with corresponding EX-certification may be used.
 Use 22mm wrench to remove cable gland and replace it with a new one.
Figure 105 Replacement of cable glands at junction box
Part No. Spare Part

5321743 Cable gland M20x1.5 D6-12 EX
7.5.4.2 Device type ATEX Zone 1/IECEx without junction box and CSA
NOTICE:
Figure 106 Replacement of cable glands at eletronics housing Ex-d
Cable glands see SICK price list!
7.5.5 Replacement of blind plugs

 Use 24mm wrench to remove sealing plug and replace it with a new one.
Figure 107 Replacement of blind plug at junction box

Part No. Spare Part

5319622 Sealing plug M20x1.5 EX IP66 PA-SW
7.5.5.2 Device type ATEX Zone 1 without junction box and CSA
Figure 108 Replacement of blind plug at electronics housing Ex-d
Part No. Spare Part

4055551 Sealing plug Exd M20x1.5 1.4571
5320603 Sealing plug Exd 1/2" NPT 1.4571
7.5.6 Rotation of electronics unit

NOTICE:
The maximum rotation of the electronics unit must not exceed 180°. Twisting
of the transducer cable is to be avoided (danger of cable damage).
1 Undo screws holding probe connection to electronics unit (pictured for ATEX Zone2).
Figure 109 Undo probe connection screws
2 Rotate head by a maximum rotation angle of ±180°.

3 Re-mount electronics unit with the 4 hexagon socket screws.
7.5.7 Replacement of pressure compensation element

Removing the pressure compensation elements may impair pressure tightness
of the flame-proof enclosure and annull the declared protection rating.
Do not remove the screw inside the port of the pressure compensation
element.
Using the sender/receiver unit without the pressure compensation element is
not permitted.
A pressure compensation element is installed on each probe connection.
1 Use a 17mm ring wrench to loosen pressure compensation element.
2 Replace pressure element with a new one.
Figure 110 Pressure compensation element on FLSE EXS probe connection, analog unit
Figure 111 Pressure compensation element on FLSE EXS probe connection digital unit,
Figure 112 Pressure compensation element on electronics housing
Part No. Spare Part

5314131 Pressure compensation element M12x1,5-SS
7. 6 Electronics unit of device type FLOWSIC100 EX/EX-RE

NOTICE:
 Both sensors of a measuring system must have the same firmware
version.If necessary, the electronics of the S/R unit not included in repair
work, should be updated.
 After finishing of repair work the correct and tight closing of electronics
housing, cable glands and blind plugs has to be checked and ensured
7.6.1 Replacement of electronics unit housing parts

Device type ATEX Zone 1 and CSA
Figure 113 Replacement of electronics housing parts
Electronics housing assembled
Accessory set for electronics housing Exd

1 1
1 Socket screw MUX and spring washer

2 Cover with locking bracket
5 3 O-ring
4 Earth terminal parts
5 Blind plugs
Part No. Spare Part

2052499 Cover set for electronic housing Ex-d Al
2065857 Accessory set for electronic housing Ex-d Al metric
2052492 Accessory set for electronic housing Ex-d Al NPT
7.6.2 Replacement of complete electronics unit

NOTICE:
 Before exchanging the electronic unit the system has to be read out by the
SOPAS ET program or save a parameter protocol (see chapter 4.2.3).
Learn Procedure Signal Pattern

 Connect the measuring system to the SOPAS ET program.
 Scan the network and move device and MCU file into project window.
 Select password level "Service" and enter password "service".
 Open dialog "Function check manual".
Figure 114 Learn signal pattern by using function check menu
 Change to "maintenance mode".

 Press button "Learn signal pattern" and wait for approx. 30sec until the green LED
"Valid pattern signal" is on.
 After this the signal is learned and stored in MCUP.
 Change back to measurement mode.

 Complete.
7.6.2.1 Device type ATEX Zone 2

 Undo screws connecting electronics unit using a 7mm wrench.
Figure 115 Undo electronics unit screws
 Pull electronics unit carefully apart from the probe connection, and loosen PG cable
glands with 11mm wrench.
Figure 116 Undo PG cable glands

 Carefully loosen seal (1) in the PG cable gland using tweezers or screwdriver, and dis-
connect the MCX plug.
Figure 117 Removing seal in PG cable glands
Figure 118 Sender/receiver unit with electronics unit removed
 Mount new electronics unit, repeating steps in reverse order.
Part No. Spare Part

2060330 FLSE100-EX NNNNNNNNNN NN 42CSAMY NN Master
2060407 FLSE100-EX NNNNNNNNNN NN 42CSAMY NN Slave
7.6.2.2 Device type ATEX Zone 1 with junction box, ATEX Zone 1/IECEx and CSA
 Open cover of electronics housing using SICK special tool "Tool for cover of Exd hous-
ing", Part No. 2060292
Figure 119 SICK special tool - Opening of electronics housing
 Release the wires connected to the PCB.
Figure 120 Removed wires

 Use SICK special tool "Tool for fastening ring electronic housing", Part No. 4067517, to
carefully release the mounting ring inside the electronics housing.
Figure 121 SICK special tool - release of mounting ring in electronics
 Extract the PCB (2) carefully from the electronics housing, Take especial care when pull-
ing the cables back through the openings in the terminal board (1).
Figure 122 Extraction of electronics block
2
 Remove the PCB entirely from the electronics housing.
Figure 123 PCB removed
 Release one pair of fastening screws (1) from the terminal board in order to release the
analog or digital PCB.
Figure 124 Terminal board

 Gently pull analog PCB and digital PCB board apart.
Figure 125 Remove sensor wires, separate analog and digital PCB
 Make a note of the order of connections of sensor connections . The two white connec-
tions are NTC wires (1), and can be connected to either terminal.
 Remove the sensor wires from the analog PCB.
Figure 126 Sensor connections on analog PCB
 Remove internal locking screw-nut with 10mm wrench.
Figure 127 Removing locking screw-nut

If the locking screw-nut is not correctly in place, the pressure tightness of the
flame-proof enclosure may be impaired. Using the sender/receiver unit without
the locking screw-nut is not permitted
 Remove 4 fastening screws on probe connection.
Figure 128 Remove probe connection

 Remove the electronics housing carefully from the probe connection.
Figure 129 Separated electronics housing
 To mount the new electronics unit, repeat each step in reverse order.
Part No. Spare Part

FLSE100-EX/EXRE, ATEX Zone 1 with Exe junction box GRP
2060331 FLSE100-EX NNNNNNNNNN NN 41CDAMY NN
2062107 FLSE100-EX NNNNNNNNNN NN 41CDSMY NN
FLSE100-EX/EXRE, ATEX Zone 1/IECEx without junction box
2060332 FLSE100-EX NNNNNNNNNN NN 41CDAMN NN
2062108 FLSE100-EX NNNNNNNNNN NN 41CDSMN NN
2062109 FLSE100-EX NNNNNNNNNN NN 41CDATN NN
2062110 FLSE100-EX NNNNNNNNNN NN 41CDSTN NN
FLSE100-EX/EXRE, CSA CI I, Div1
2062111 FLSE100-EX NNNNNNNNNN NN 43CDATN NN
2062112 FLSE100-EX NNNNNNNNNN NN 43CDSTN NN
7.6.3 Replacement of terminal block

Device type ATEX Zone 2 and ATEX Zone 1 with junction box only
Please refer to  p. 126, §7.5.3 of this manual!
Part No. Spare Part


NOTICE:
Please refer to  p. 132, §7.5.4.1 of this manual!
Part No. Spare Part

5321743 Cable gland M20x1.5 D6-12 EX
7.6.4.2 Device type ATEX Zone 1 without junction box and type CSA

Part No. Spare Part

5319622 Sealing plug M20x1.5 EX IP66 PA-SW
7.6.5.2 Device type ATEX Zone 1 without junction box and CSA
Part No. Spare Part

4055551 Sealing plug Exd M20x1.5 1.4571
5320603 Sealing plug Exd 1/2" NPT 1.4571
7.6.6 Rotation of electronics unit
7.6.7 Replacement of pressure compensation element
Part No. Spare Part

5314131 Pressure compensation element M12x1,5-SS
7.7 Sensor assembly of device type FLOWSIC100 EX-S
7.7.1 Replacement of sensor assembly FLOWSIC100 EX-S - non-retractable types

Device type ATEX Zone 1, Zone 2 and CSA
NOTICE:
Replacement of non-retractable sensor assembly requires:
 New adjustment of signal system running time:  p. 47, §3.5
 After finishing of repair work, the tightness of the sender/receiver unit
assembly have to be checked and ensured.
 Undo 4 screws holding probe connection to sensor.
Figure 130 Unscrew probe connection
 Remove PG cable gland using 11mm wrench.
Figure 131 PG cable gland

 Replace sensor assembly.
Figure 132 Spare part sensor assembly
 Repeat steps in reverse order to reassemble sender/receiver unit.
Part No. Spare Part

FLSE100-EXS, Standard temperature version
2062099 FLSE100-EXS 148SA218VS NN NNNNNNN NN
2062100 FLSE100-EXS 148TA218VS NN NNNNNNN NN
2060334 FLSE100-EXS 176SD518VS NN NNNNNNN NN
2060347 FLSE100-EXS 176TD518VS NN NNNNNNN NN
FLSE100-EXS, High/Low temperature version
2062101 FLSE100-EXS 148TA211VN NN NNNNNNN NN
2063817 FLSE100-EXS 176TD511VN NN NNNNNNN NN
Part No. Spare Part

Gaskets for process connection
5319678 Gasket ANSICL150 2Z
7040843 Gasket DN50PN16
Bolts mounting set
2034315 Bolts mounting set ANSICL150 2Z
2059321 Bolts mounting set DN50PN16 M16
7.7.2 Replacement of sensor assembly FLOWSIC100 EX-S - retractable types

NOTICE:
 After finishing of repair work, the tightness of sender/receiver unit
assembly has to be checked and ensured. Special attention has to be
paid to tightness of sealings in probe retraction mechanism.
 Replacement of retractable sensor assembly requires:
– Replacement of sealings at retraction mechanism  p. 162, §7.7.3
– New adjustment of signal system running time  p. 47, §3.5
7.7.2.1 Standard / high temperature version

 Remove probe connection by loosening 4 screws with Allen key
Figure 133 Removing probe connection
 Release the coupling nut holding the cable.
Figure 134 Unscrewing coupling nut

 Loosen sealing ring on cable, and pull out cable.
Figure 135 Removing seal and cable
 Release alignment piece with Allen key.
Figure 136 Releasing alignment piece
 Loosen brass screw by half a turn - do not unscrew completely!
Figure 137 Loosening brass screw
 Remove alignment piece.
Figure 138 Removing alignment piece

 Remove sealing nut on PG cable gland by holding locking nut with wrench.
Figure 139 Removing sealing nut
 Pull sensor assembly out through both flanges.
Figure 140 Removing transducer rod
 Replace the sealings in the retraction mechanism according to  p. 163, §7.7.3.1.
 To complete the replacement, the sensor assembly should be aligned as shown below,
with transducer contour (2) pointing away from vent (1) on top of retraction flange.
Figure 141 Reassemble sender/receiver unit
2
7.7.2.2 Low temperature version

 Remove probe connection by loosening 4 screws with Allen key.
To remove the sensor assembly, the clamping jig has to be loosened in the following way:
 Loosen the nuts at the clamping jig in the same order as shown in figure 143 and figure
144.
Figure 143 Loosening the nuts at clamping jig
Figure 144 Loosening the bottom nuts at clamping jig
NOTICE:
The clamping jig of the compression gland is only used at low temperature
version.
 Move the probe flange near to the retraction flange to dismount the clamp at sensor
assembly (see figure 145).
Figure 145 Dismounting clamp at sensor assembly
 Remove the sensor assembly towards the retraction flange.
Figure 146 Removing sensor assembly
 Replace the sensor assembly in reverse order.

NOTICE:
Take care of the correct dimensioning of the clamping jig during assembling
(see figure 147).
Figure 147 Dimensioning of clamping jig
Part No. Spare Part

2060335 FLSE100-EXS 330SNN18VS RN NNNNNNN NN
2060336 FLSE100-EXS 330TNN18VS RN NNNNNNN NN
FLSE100-EXS, High temperature version
2062102 FLSE100-EXS 330TNN11VH RN NNNNNNN NN
2062103 FLSE100-EXS 330TNN11VL RN NNNNNNN NN
Part No. Spare Part

Bolts mounting set
7.7.3 Replacement of sealing set at probe retraction mechanism

NOTICE:
 Replacement of sealings requires dismounting of sensor assembly
according to  p. 153, §7.7.2.
 All sealings for retraction mechanism are available as complete set for
different temperature versions of the S/R unit.
 Pay attention to correct assignment of the sealings according to figure 148
respectively figure 155!
 After finishing the repair work, the tightness of the sealings has to be
checked and ensured with special attention.
7.7.3.1 Sender/receiver unit FLSE100-EXS standard/high temperature version
Figure 148 Sealings at retraction mechanism: FLSE100-EXS standard/high temperature version
7
6
2
4
3 1
A Internal sealings retraction flange

1 Quad ring sealing, part no. 5313807
2 PTFE sealing element, part no. 5323652
B Internal sealings probe flange
3 Quad ring sealing, part no. 5313807 (standard temp. version)
O-ring sealing, part no. 5321271 (high temp. version)
4 O-ring sealing, part no. 5321087
C External sealings probe flange
Sealing Cover
7 Cover plate
A Replacement of internal sealings of retraction flange (1,2)

 Remove internal sealing (1) from the retraction flange using a pair of tweezers.
Figure 149 Removing sealing ring
 Insert a new sealing ring in retraction flange.
Figure 150 Inserting new sealing ring
 Dismount the cover plate (7) at retraction flange by using Phillips screwdriver.
Figure 151 Removing cover plate
 Remove the internal sealing (2) in retraction flange by carefully pressing in the direction
of the cover plate.
Figure 152 Removing PTFE sealing

 Insert the PTFE sealing and mount the cover plate.
B Replacement of internal sealings (3,4) of probe flange

 Replace the internal sealings (3, 4) in the probe flange using a pair of tweezers.
Figure 153 Replacing O-rings in retraction flange
C Replacement of external sealings of probe flange

 Replace the external sealings (5, 6) in probe flange using a pair of tweezers.
Figure 154 Replace O-rings
NOTICE:
When replacing the seals, the guiding rods should be newly greased.
7.7.3.2 FLSE100-EXS low temperature version
Figure 155 Sealings at retraction mechanism: Low temperature version
1
2
7
6
5
9
10
4
3

4 Compression gland, part no. 4064647

7 Seal element, part no. 5324383
Sealing Covers
8 Cover plate
9 Clamping ring
Clamping jig for compression gland
10 Clamping jig for compression gland
A Replacement of internal sealings (1,2) of retraction flange

 Remove internal sealing (1) from the retraction flange using a pair of tweezers.
Figure 156 Removing sealing ring
 Insert new sealing ring in retraction flange.
Figure 157 Inserting new sealing ring
 Remove the internal sealing (2) in retraction flange by carefully pressing in the direction
of the cover plate.
Figure 159 Removing PTFE sealing

B Replacement of internal sealings (3, 4) of probe flange

 Before removing the internal sealings (3, 4) in probe flange, dismount the clamping jig.
For this loosen the threaded rods.
Figure 160 Loosening the threaded rods
 The compression gland (4) can be extracted easily.
Figure 161 Removing clamping ring and compression gland
 Remove the internal sealing (3) using a pair of tweezers or a screwdriver.
Figure 162 Removing O-ring sealing (picture shows external sealings already removed)
C Replacement of external sealings of probe flange (5, 6, 7)

 Dismount the probe flange and remove the external sealings (5, 6, 7) from the probe
flange.
Figure 163 Removing external sealings
 Insert all sealings and mount clamping jig and probe flange.
NOTICE:
Part No. Spare Part

2062104 Sealing set retraction mechanism EX-S standard temp
FLSE100-EXS, High temperature version
2062105 Sealing set retraction mechanism EX-S high temp
FLSE100-EXS, Low temperature version
2062106 Sealing set retraction mechanism EX-S low temp
7.7.4 Replacement of sensor contour FLSE100-EXS
Figure 164 Replacing high speed contour (shown for retractable high speed versions)
1 2
 To replace the contour (2), use 3 mm Allen key to remove all 3 hexagon socket screws
(1) on contour.
Figure 165 Removing contour

NOTICE:
Ensure that the contour fits to the alignment of the transducer considering the
flow direction.
Figure 166 Contour aligned to transducer
Part No. Spare Part

2050478 High speed contour EX-S
7.8 Sensor assembly of device type FLOWSIC100 EX/EX-RE
7.8.1 Replacement of sensor assembly FLOWSIC100 EX non-retractable types

NOTICE:
Replacement of a non-retractable sensor assembly requires:
 New adjustment of signal system running time  p. 47, §3.5.
assembly has to be checked and ensured.
7.8.1.1 Device Type ATEX Zone 2

 Use a 7mm wrench to undo 4 hexagon nuts holding probe connection to remove elec-
tronics unit.
 Release cable with 11 mm wrench and unplug it from electronics unit.
Figure 167 Removing electronics unit
 Pull electronics unit carefully apart from probe connection, and loosen PG cable glands
with 11mm wrench.
Figure 168 Undo PG cable glands

 Carefully remove seal (1) in PG gland with tweezers and disconnect MCX plug.
Figure 169 Removing seal in PG cable glands
Figure 170 Sender/receiver unit with electronics unit removed
 Remove 4 screws on probe connection using a 4 mm Allen key.
Figure 171 Remove probe connection
 Replace transducer and reassemble device, repeating steps in reverse order.
Figure 172 Spare part Transducer with cable

7.8.1.2 Device type ATEX Zone 1 and CSA

 Remove screws from safety catches and open housing.
Figure 173 Releasing safety catches
 Use special tool to loosen holding ring inside the electronics housing.
The special tool is available from the manufacturer (part no. 4067517).
Figure 174 Loosening holding ring
 Open spring-type terminal to loosen all cables.
Figure 175 PCB Connection
 Move electronics block slowly approx. 3cm (1.25 inch) out of housing.
 While moving the electronics block, carefully pull cables back through opening in PCB
Connection.
 Unscrew 2 screws from connection PCB.
Figure 176 Loosening screws on PCB Connection

 Remove plug from PCB Connection.
Figure 177 Removing plug from PCB Connection
 Remove electronics block.
Figure 178 Electronics block removed
 Use screwdriver to loosen the screw terminals for the sensor cables (see figure 126 and
instructions on page 148).
 Use 10mm wrench to loosen locking screw-nut.
Figure 179 Loosening the locking screw-nut

If the locking screw-nut is not correctly in place, the pressure tightness of the
flame-proof enclosure may be impaired. Using the sender/receiver unit without
the locking screw-nut is not permitted
 Pull each sensor cable through socket union separately.

 Loosen 4 hexagon socket screw to dismount probe connection from flange.
Figure 180 Dismounting probe connection from flange

 Replace the sensor assembly with a new one and re-mount by following steps in reverse
order.
 Connect the sensor wires to the terminals on the PCB.
Figure 181 Re-connect electronics
Figure 182 Sensor connections

Transducer (+)
Temp 1 and Transducer (-)
Temp2
 Interlock analog and digital PCB.
Figure 183 Interlock analog and digital PCB
 Slide the electronics block half-way into the electronics housing. Loop the sensor cable,
and place it between the two electronic boards.
Figure 184 Looping sensor cable
 Lay the connection cable sideways between the PCB‘s. Then insert the electronics into
the electronics housing.
Figure 185 Inserting electronics into housing

 Thread the connection cables through the circular openings in the board just before
fully inserting the electronics.
Figure 186 Feeding connection cables through electronics board
 Connect the wires on the board according to Figure 47, section 3.5.2.2 of Operating
Instructions FL100 Flare.
Figure 187 Terminal PCB connections
Part No. Spare Part

FLSE100-EX, ATEX Zone 2, Standard temperature version
2062115 FLSE100-EX 198SA214VS NN N2NNNNN NN
2062116 FLSE100-EX 198TA214VS NN NN2NNNNN NN
2060346 FLSE100-EX 226SD514VS NN N2NNNNN NN
2060345 FLSE100-EX 226TD514VS NN N2NNNNN NN
FLSE100-EX, ATEX Zone 1/IECEx, CSA CI I, Div1, Standard temperature version
2062117 FLSE100-EX 198SA214VS NN NNNNNNN NN
2062118 FLSE100-EX 198TA214VS NN NNNNNNN NN
2060343 FLSE100-EX 226SD514VS NN NNNNNNN NN
2060344 FLSE100-EX 226TD514VS NN NNNNNNN NN
FLSE100-EX, ATEX Zone 2, High/Low temperature version
2062152 FLSE100-EX 198TA214VN NN N2NNNNN NN
2062153 FLSE100-EX 226TD514VN NN N2NNNNN NN
FLSE100-EX, ATEX Zone 1/IECEx, CSA CI I, Div1, High temperature version
2062154 FLSE100-EX 198TA214VH NN NNNNNNN NN
2062155 FLSE100-EX 226TD514VH NN NNNNNNN NN
Part No. Spare Part

Bolts mounting set
7.8.2 Replacement of sensor assembly FLOWSIC100 EX-RE retractable types

NOTICE:
Replacement of retractable sensor assembly requires:
 Replacement of sealings at retraction mechanism  p. 196, §7.8.3.
 New adjustment of signal system running time  p. 47, §3.5.
assembly has to be checked and ensured. Special attention has to be paid
to tightness of sealings in probe retraction mechanism.
7.8.2.1 Device type ATEX Zone 2 standard / high temperature version

 Remove electronics unit as described for non-retractable type ATEX Zone 2  p. 175,
§7.8.1.1.
 Replace sensor assembly as described below  p. 186, §7.8.2.2.
 Re-mount electronics unit again as in  p. 175, §7.8.1.1.
7.8.2.2 Device type ATEX Zone 1 and CSA standard /high temperature version
 Remove electronics block as described for type ATEX Zone 1  p. 143, §7.6.2.2, and then
continue as follows:
 Push the probe tube carefully back through the probe connection.
Figure 188 Feed probe tube through probe connection
 Pull sensor assembly through sender/receiver unit.
Figure 189 Extraction of sensor assembly Subject to change without notice
Figure 190 Spare part "Sensor assembly FL100 EX-RE"
 Replace the sealings in the retraction mechanism according to  p. 196, §7.8.3.1.

Mounting of new sensor assembly

 Use small flexible tubing to thread the transducer cable more easily through the flange.
Slide the tubing over the wires before threading it through the flange.
Figure 191 Threading sensor
 Insert new sensor assembly into retraction flange, and slide it through.
Figure 192 Sliding sensor tube through flange
 Slide electronics with gasket (large flat gasket) onto the probe tube.
Figure 193 Re-mounting electronics unit with gasket
 Re-fasten the screws holding the electronics unit to the probe connection.
Figure 194 Screw electronics to probe connection

 Connect the sensor wires to the terminals on the PCB.
Figure 195 Re-connect electronics
Figure 196 Sensor connections

Transducer (+)
Temp 1 and Transducer (-)
Temp2
 Interlock analog and digital PCB.
Figure 197 Interlock analog and digital PCB
 Slide the electronics block half-way into the electronics housing. Loop the sensor cable,
and place it between the two electronic boards.
Figure 198 Looping sensor cable
 Lay the connection cable sideways between the PCB‘s. Then insert the electronics into
the electronics housing.
Figure 199 Inserting electronics into housing

 Thread the connection cables through the circular openings in the board just before
fully inserting the electronics.
Figure 200 Feeding connection cables through electronics board
 Connect the wires on the board according to Figure 47, section 3.5.2.2 of Operating
Instructions FL100 Flare.
Figure 201 Terminal PCB connections
7.8.2.3 Device type ATEX Zone 2 low temperature version

 Remove and mount electronics unit as described for non-retractable type ATEX Zone 2.
 Remove probe connection by loosening 4 screws with Allen key.

 To dismount the sensor assembly loosen the clamping jig by loosening the nuts with
10mm wrench (only unfasten, not dismount).
Figure 203 Loosening clamping jig
10 mm nuts
NOTICE:
The clamping jig of the compression gland is only used at the low temperature
version.
 Push the sensor assembly through the retraction flange carefully.
Figure 204 Removing sensor assembly
 Install sensor assembly and mount clamping jig.
NOTICE:
Part No. Spare Part

FLSE100-EXRE, ATEX Zone 2, Standard temperature version
2060337 FLSE100-EX 380SNN14VS RN N2NNNNN NN
2060338 FLSE100-EX 380TNN14VS RN N2NNNNN NN
FLSE100-EXRE, ATEX Zone 1/IECEx, CSA CI I, Div1, Standard temperature version
2060339 FLSE100-EX 380SNN14VS RN NNNNNNN NN
2060340 FLSE100-EX 380TNN14VS RN NNNNNNN NN
FLSE100-EXRE, ATEX Zone 2, High temperature version
2062119 FLSE100-EX 380TNN14VZ RN N2NNNNN NN
FLSE100-EXRE, ATEX Zone 1/IECEx, CSA CI I, Div1, High temperature version
2062120 FLSE100-EX 380TNN14VH RN NNNNNNN NN
FLSE100-EXRE, ATEX Zone 2, Low temperature version
2062121 FLSE100-EX 380TNN14VL RN N2NNNNN NN
Part No. Spare Part

Bolts mounting set

NOTICE:
according to  p. 186, §7.8.2.
 Pay attention to correct assignment of the sealings according to figure 205
respectively figure 212!
 After finishing of repair work, the tightness of sealings at retraction
mechanism has to be checked and ensured with special attention.
7.8.3.1 Sender/receiver unit standard /high temperature version
Figure 205 Standard/high temperature sealings
6
5
4
3


3 Quad ring sealing, part no. 5313807 (standard temp. version
O-ring sealing, part no. 5321271 (high temp. version)
Sealing cover
7 Cover plate
A Replacement of internal sealings (1,2) of retraction flange

 To access retraction flange seals, follow the steps described on  p. 143, §7.6.2.2 and 
p. 186, §7.8.2.2.
 Replace flange seals as shown below:
 Remove the internal sealing (1) from the retraction flange using a pair of tweezers.
Figure 206 Removing internal sealing (1); Quad-ring, part no. 5313807
 Insert the new sealing (1) in the retraction flange.
Figure 207 Inserting internal sealing (1): Quad-ring, part no. 5313807
 Turn the retraction flange 180° and remove the internal sealing (2) in retraction flange
by carefully pressing into direction of cover plate.
Figure 209 Removing PTFE sealing element, part no. 5323652

 Replace the internal sealings (3, 4) in probe flange using a pair of tweezers.
Figure 210 Replacing O-rings in retraction flange
C Replacement of external sealings (5, 6) of probe flange

 Replace the external sealings (5, 6) in probe flange using a pair of tweezers.
Figure 211 Replacing O-rings

7.8.3.2 FLSE100-EXRE sender/receiver unit low temperature version
Figure 212 Low temperature version
1
7
2
6
5
9
10
4
3

4 Compression gland, part no. 4064647

7 Seal element, part no. 5324383
Sealing covers
8 Cover plate
9 Clamping ring
Clamping jig for compression gland
10 Clamping jig for compression gland
A Replacement of internal sealings (1, 2) of retraction flange

 Remove the internal sealing (1) from the retraction flange using a pair of tweezers.
Figure 213 Removing internal sealing (1); Quad-ring, part no. 5313807
 Insert the new sealing (1) in the retraction flange.
Figure 214 Inserting internal sealing (1): Quad-ring, part no. 5313807
 Turn the retraction flange 180° and remove the internal sealing (2) in retraction flange
by carefully pressing into direction of cover plate.
Figure 216 Removing PTFE sealing element

 Remove the internal sealing (3) from the probe flange.
Figure 217 Removing O-ring sealing (picture shows external sealings already removed)
 Before removing the internal sealing (4) in probe flange, dismount the clamping jig by
loosening the nuts with 10 mm wrench.
Figure 218 Loosening clamping jig
10 mm nuts
Figure 219 Removing clamping ring and compression gland
C Replacement of external sealings (5, 6, 7) of probe flange

 Dismount the probe flange and remove the external sealings (5, 6, 7) from the probe
flange.
Figure 220 Removing external sealings
 Insert all sealings and mount the probe flange.
Part No. Spare Part

FLSE100-EXRE, Standard temperature version
2062122 Sealing set retraction mechanism EX-RE standard temp
FLSE100-EXRE, High temperature version
2062123 Sealing set retraction mechanism EX-RE high temp
FLSE100-EXRE, Low temperature version
2062124 Sealing set retraction mechanism EX-RE low temp
7.8.4 Replacement of sensor contour FLSE100-EX/EXRE

 To replace the contour, use 2mm Allen key to remove all 3 hexagon socket screws on
sensor contour.
Figure 221 Loosening contour
 Ensure that the contour is properly aligned with the transducer.
Part No. Spare Part

2052494 High speed contour EX/EX-RE
7.9 Sensor assembly of device type FLOWSIC100 EX-PR
7.9.1 Replacement of sensor assembly FLOWSIC100 EX-PR - non-retractable types

Device type ATEX Zone 1, Zone 2 and CSA
NOTICE:
Replacement of non-retractable sensor assembly requires:
 New adjustment of signal system running time:  p. 47, §3.5
assembly have to be checked and ensured.
 Detach the probe connection from the sensor assembly by unscrewing the 4 fastening
screws with a 4 mm Allen key.
Figure 222 Detaching probe connection

 Carefully pull probe connection from flange, and undo PG cable glands.
 Carefully loosen seal in PG cable glands with tweezers or screwdriver, and unplug sen-
sor cables (1).
Figure 224 Unplugging cables
1
 Unscrew PG cable gland nut and sealing nut from temperature sensor (2), and pull out
temperature sensor.
Figure 225 Removing temperature sensor
 Re-mount sensor, repeating steps in reverse order.

NOTICE:
 Ensure that cables are correctly re-connected. All cables are clearly
marked.
 Other replacement possible for EX-PR sensor:
– sensor contour
 Any further dismantling of the sensor assembly is not permitted.
Figure 226 Spare part sensor assembly (non-retractable)

Part No. Spare Part

FLSE100-EXPR, all temperature versions, pipe size 12 … 48"
2052588 FLSE100-EXPR 220TA311VS NN NNNNNNN NN
2060341 FLSE100-EXPR 220TD811VS NN NNNNNNN NN
FLSE100-EXPR, all temperature versions, pipe size 50 … 72"
2052591 FLSE100-EXPR 350TA311VS NN NNNNNNN NN
2062131 FLSE100-EXPR 350TD811VS NN NNNNNNN NN
Part No. Spare Part

2
Bolts mounting set
7.9.2 Replacement of sensor assembly FLOWSIC100 EX-PR retractable types

NOTICE:
Replacement of retractable sensor assembly requires:
 Replacement of sealings at retraction mechanism according to p. 212,
§7.9.3.
 New adjustment of signal system running time according to p. 47,
§3.5.
assembly has to be checked and ensured. Special attention has to be
paid to tightness of sealings in probe retraction mechanism.
Device Type ATEX Zone 1, Zone 2 and CSA

 Follow the steps described for non-retractable type described on  p. 207, §7.9.1 to
remove electronics unit.
 Continue with  p. 212, §7.9.3 to remove sensor from retraction flange and to replace
seals.
 Replace new sensor assembly, and repeat steps in reverse order to re-mount.
Figure 227 Spare part sensor assembly
Part No. Spare Part

FLSE100-EXPR, Standard/High temperature versions, pipe size 12 … 48"
2060342 FLSE100-EXPR 400TNN11VS RN NNNNNNN NN
FLSE100-EXPR, Standard/High temperature versions, pipe size 50 … 72"
2052589 FLSE100-EXPR 530TNN11VS RN NNNNNNN NN
FLSE100-EXPR, Low temperature versions, pipe size 12 … 48"
2062145 FLSE100-EXPR 400TNN11VL RN NNNNNNN NN
FLSE100-EXPR, Low temperature versions, pipe size 50 … 72"
2062146 FLSE100-EXPR 530TNN11VL RN NNNNNNN NN
Part No. Spare Part


Bolts mounting set

NOTICE:
according to p. 211, §7.9.2.
 Pay attention to correct assignment of the sealings according to figure
235!
 Release fixing ring using 2 mm Allen key, and slide away from contour.
Figure 228 Unscrewing fixing ring
 Heat all screws on contour using a hot air gun (30 ...60 s at 2000 Watt per screw) in
order to loosen loctite glue.
NOTICE:
Take care not to aim the hot air gun at the transducer.
Figure 229 Heating screws with hot air gun
 Undo the screws and remove the contour from the probe.
Figure 230 Head of sender/receiver unit with high speed contour removed
NOTICE:
Sensor contour consists of 2 pieces, mounted with 4 screws. All screws on the
sensor contour are fixed with Loctite glue. In order to loosen the screws, the
connections must be heated beforehand. All screws must be fixed with Loctite
glue after replacing the contour.
 Slide the fixing rings off the end of the probe.
Figure 231 Sliding off fixing rings
 Remove the 4 cotter pins securing the guiding rods, and pull the probe through the
retraction flange.
Figure 232 Sliding probe through retraction flange
Figure 233 Probe removed
NOTICE:
 For the replacement of sealings it is necessary to remove the sensor from
the retraction flange. For this follow the steps described on  p. 211, §7.9.2!
Figure 234 FLSE100-EXPR standard / low / high temperature version
1
3

B External sealings probe flange
HT-PTFE sealing element, part no. 5324916 (standard/high temp.
3
version)
LT-PTFE sealing element, part no. 5325207 (low temp. version)
A Replacement of internal sealing (1) of retraction flange

 Remove Quad-ring sealing (1) with a pair of tweezers, and replace it with a new one.
Figure 235 Replacing Quad ring sealing
B Replacement of external sealings (2, 3) of probe flange

 Replace the external sealings of the probe flange (2, 3) according to  figure 211.
 To reassemble, repeat all steps in reverse.
 Take care when replacing the probe, orientate the probe with the protection tubing (
figure 236, 2) pointing to the vent ( figure 236, 1) on the retraction flange as shown
below.
Figure 236 Sender/receiver unit remounted in retraction flange without sensor contour
2
NOTICE:
Part No. Spare Part

FLSE100-EXPR, Standard/High temperature version
2062147 Sealing set retraction mechanism EX-PR standard/high
temp
FLSE100-EXPR, Low temperature version
2062149 Sealing set retraction mechanism EX-PR low temp
7.9.4 Replacement of sensor contour

NOTICE:
Sensor contour consists of 2 pieces, mounted with 4 screws. All screws on the
sensor contour are fixed with Loctite glue. In order to loosen the screws, the
connections must be heated beforehand. All screws must be fixed with Loctite
glue after replacing the contour.
Figure 237 EX-PR sensor contour
 Remove both parts of the contour and replace them with new ones.
Figure 238 Dismantled sensor contour

Part No. Spare Part

2060323 High speed contour EXPR
7. 1 0 Replacement of installation and mounting parts of device type FL100

EX-S
NOTICE:
 Pipeline section in which the meter is installed has to be depressurized
and vented.
 After replacement of installation and mounting parts, the tightness of
the installation has to be checked and ensured.
 For mounting and dismounting the S/R unit, please follow instructions
in Operating Manual FL100 Flare, chapter 3.5.1 and 3.5.2.
7.10.1 Replacement of relief valve (option for retractable S/R units only)
 Use 16mm wrench to remove and replace relief valve (  figure 239, 1).
 Afterwards, use 11mm wrench to tighten lock screw.
Figure 239 Relief ball valve
Spare Part Part No.

Relief ball valve 5324407
7.10.2 Replacement of analog connection cable

 Loosen the securing ring at the cable connectors (1).
 Replace the cable with a new one.
 Connect and secure the new cable.
Figure 240 Replacing analog connection cable
1 1
Spare Part Part No.

Connection cable analog, Exi, TNC/TNC, 3 meter 2050614
7.10.3 Replacement of mounting accessory parts - non-retractable types

Replacing flange gasket, bolts and nuts
 Carefully pull out the sender/receiver unit, replace the required parts according to
p. 224, Fig. 241 and install the sender/receiver unit again at the pipeline.
Spare parts:
– Grooved seal B9A 2" 150 1,4571 Part No. 5319678
– Grooved seal DN50PN16 1.4571 Part No. 7040843
Mounting sets with screws:

– Mounting set ANSI CL150 2” Part No. 2034315
– Mounting kit K125/M16 PN16 Part No. 7042202
Mounting sets with studbolts:

– Mounting kit PN16DN50 bolts SS Part No. 2059321
7.10.4 Replacement of mounting accessory parts - retractable types
WARNING:
 Observe the allowable maximum pressure for operating the changing
– Device types FLSE100-EXS and EXRE: 16 bar at 50°C (see OI
FLOWSIC100 Flare/Process figure 14).
– Device type FLSE100-EXPR: 0.5 bar at Tmax. -20 ... +200 °C
flange.
and/or hot gasses (risk of serious injuries)!
Replacing nozzle gasket, blind flange, ball valve

Take cotter pins (1) out of guide rods (2) and loosen fastening nuts (3) according to p. 224,
Fig. 241.
 Hold the sender/receiver unit (4) tight and pull it back slowly to stop.
 Close the 2" ball valve (5).
A small amount of gas remains in the retraction flange and can escape uncontrolled
into the environment during dismounting of the sender/receiver unit from the ball valve.
with the relief ball valve option. To do so, connect the ball valve with a
suitable hose that ends away from the measuring point.
WARNING:
 Take special precautions at toxic, aggressive, explosive, health
endangering and/or hot gasses (risk or serious injuries) when using
retractable sender/receiver units without the vent device option.
valve 2".
 Fit blind flange (8) and seal on the ball valve 2" with fastening screws (3).
Figure 241 Mounting accessory parts - retractable types
Sender/receiver unit installed
1 2
4 7 5
Sender/receiver unit removed
1 2 3 6
4 5
 After replacing the parts, install the sender/receiver unit again at the pipeline in the
reverse sequence.
NOTICE:
For mounting and dismounting the sender/receiver unit please follow
instructions in Operating Manual FL100 Flare, chapter 3.5.2.
Seals:


Blind flange:
– Blind flange ANSI CL150 2” CS Part No. 2051991
Ball valve:
– Ball valve ANSI CL150 2” SS Part No. 2051963

EX/EX-RE
NOTICE:
and vented.
7.11.1 Replacement of relief valve (option for retractable S/R units only)
1 Use 16mm wrench to remove and replace venting valve.
2 Afterwards, use 11mm wrench to tighten lock screw.
Spare Part Part No.



Carefully pull out the sender/receiver unit, replace the required parts ( p. 224, Fig. 241)
and install the sender/receiver unit again at the pipeline.
Spare Part Part No.

Grooved seal B9A 2" 150 1,4571 5315113
Mounting set ANSI 150 2z 2034315
WARNING:
 Observe the allowable maximum pressure for operating the changing
– Device types FLSE100-EXS and EXRE: 16 bar at 50°C (see OI
FLOWSIC100 Flare/Process figure 14).
– Device type FLSE100-EXPR: 0.5 bar at Tmax. -20 ... +200 °C
flange.
and/or hot gasses (risk of serious injuries)!
Replacing nozzle gasket, blind flange, ball valve

 Take cotter pins (1) out of guide rods (2) and loosen fastening nuts (3) ( p. 224,
Fig. 241).
 Hold the sender/receiver unit (4) tight and pull it back slowly to stop.
 Close the 2" ball valve (5).
A small amount of gas remains in the retractable nozzle and can escape uncontrolled
into the environment during dismounting of the sender/receiver unit from the ball valve.
with therelief ball valve option. To do so, connect the ball valve with a
suitable hose that ends away from the measuring point.
WARNING:
 Take special precautions at toxic, aggressive, explosive, health
endangering and/or hot gasses (risk or serious injuries) when using
retractable sender/receiver units without the vent device option.
valve 2" (or 3").
 Fit blind flange (8) and seal on the ball valve 2" (or 3") with fastening screws (3).
Figure 243 Mounting accessory parts - retractable type (exemplary picture of device type FL100 EX-S)
Sender/receiver unit installed
1 2
4 7 5
Sender/receiver unit removed
1 2 3 6
4 5
 After replacing the parts, install the sender/receiver unit again at the pipeline in the
reverse sequence.
NOTICE:

Spare parts:


Blind flange:
Ball valve:

EX-PR
NOTICE:
and vented.
7.12.1 Replacement of relief ball valve (option for retractable S/R units only)
1 Use a 16mm wrench to remove and replace venting valve.
2 Following replace, use an 11mm wrench to tighten lock screw.
Spare Part Part No.


Replace the parts according to  p. 227, §7.11.3.
NOTICE:
Spare parts:

– Mounting kit DN80PN16 M16 Part No. 2058053

Replace the parts according to  p. 227, §7.11.3.
NOTICE:
Spare parts:

– Mounting kit DN80PN16 M16 Part No. 2058053
Blind flange:
Ball valve:
MCUP control unit
8 MCUP control unit

MCUP control unit
8. 1 General information
 All general notes listed on  p. 114, §7.1 have to be considered for repair work at MCUP.
NOTICE:
After finishing of repair work the correct and tightness closing of MCUP
housing have to be checked and ensured.
NOTICE: Update of Firmware

FLOWSIC100 Process MCUP‘s were formerly equipped with firmware
FLOWSIC100 EMI, which has different firmware to FLOWSIC100 Flare, and no
FRAM memory chip for the data archive. Such MCU‘s should be updated with
FLOWSIC100 Process software, and the FRAM memory deactivated in the
SOPAS ET software.
WARNING:
Make sure the measuring system is disconnected from the power supply and
potential-free before you start any work on the FLOWSIC100 Flare/Process.
If the FLOWSIC100 Flare/Process is used in a hazardous area, power must be
disconnected in the safe zone.
MCUP control unit
8.2 MCUP control unit - compact housing (non ex-protected)

8.2.1 Replacement of processor board
 Open the door of the MCUP control unit.
 Disconnect the cable from terminals (1), unscrew fastening nuts (2).
 Unplug Display unit connection (3) (squeeze the plug connector together to release
cables).
 Remove shield connector (4), unscrew bolts (5) and carefully take out the processor
board.
Figure 245 Removing the processor board

2 1 3 2
6 1 5 4
 Insert, attach and connect the new processor board.

 Close the door, connect the power supply and resume measuring operation.
NOTICE:
There is a screwed fastening of display unit at a later release of MCUP compact
housing. In this case please follow the replacement instructions according to
p. 245, §8.4.3.
Part No. Spare Part

2056004 Processorboard MCUP non-Ex compact/medium size
MCUP control unit
8.2.2 Replacement of optional modules

 Remove the defective module:
– Remove the analog module from the module carrier (press the latches together).
– Pull the defective interface module from the hat rail (pull forward with the latches)
and pull off the connection cable.
Figure 246 Removing expansion modules

Analog module Interface module
2 3 1 3 5 4
Terminals for connection cable
 On the analog module, remove the coding jumper form the module carrier with pointed
pliers.
New I/O modules have a jumper on the connector side (same color as the
type-dependent color identification on the module top which remains on
the module carrier after it was initially inserted).
Figure 247 Coding of I/O modules
Coding jumper
Connector side
New
I/O module Same color
Top
Module carrier
Coding jumper after initial plugging
 Insert the new analog module into the module carrier, press the new interface module
onto the hat rail and connect the connection cable.
 Close the door, connect the power supply and resume measuring operation.
Care should be taken when exchanging the module carrier or refitting of an I/O
module, that identically constructed module carriers are used (design with
screws or with stick connection).
Optional modules see SICK price list!
MCUP control unit
8.2.3 Replacement of LC-display

To replace the front panel of the display unit, the door must be replaced as the front panel
is glued.
 Loosen terminal (1), pull off plug connector (2) and loosen cable lug (3).
 Remove cap (4) and pull out pin (5).
 Remove the door and install new door in the reverse order.
Figure 248 Door removal
4
 Reconnect the power supply and screen.
Part No. Spare Part

2046586 Door MCU-NWOD/N2OD with LC-Display
MCUP control unit
8.2.4 Replacement of power supply unit

 Remove the MCUP control unit from the installation location and take it to an area with
good lighting and sufficient work surfaces.
 Open the door of the control unit.
 Remove the processor board ( p. 235, §b).
 Pull off fuse holder (1), unscrew fastening nuts (2) for the installation plate, take out the
installation plate together with the power supply unit and unscrew the fastening screws
for power supply unit (3).
Figure 249 Removing the power supply unit
 Disconnect the connection cable from the power supply unit, connect and mount the
new power supply unit.
Figure 250 Power supply unit connections

Green/
Brown
yellow
White
Black
Black
 Reassemble the MCUP control unit in the reverse order, take it to the installation loca-
tion and reconnect the power supply.
Part No. Spare Part

2050635 Power supply unit 24V DC 75W
MCUP control unit
8.2.5 Replacement of fuse

 Pull out fuse holder.
Figure 251 Fuse holder
 Open cap on side of fuse holder.
Figure 252 Opened fuse holder

 Remove fuse and replace it with a new one.
Part No. Spare Part

2054541 Set fuses T2A0
MCUP control unit
8. 3 MCUP control unit - 19" version (not ex-protected)

 Loosen the fastening screws (1) and remove front plate (2) with LC display; remove the
plug connector from the display.
 Pull out the processor module (3).
Figure 253 Front view (version with LC display)

1 2 1 3
 Loosen the fastening nuts (4).

 Loosen the cable mount (5) and remove the connection cable to the LC display (6).
Figure 254 Processor module

4 5 7 6
 Assemble the processor module with new board (7) and slide it into the plug-in unit (7).
 Reconnect the power supply and resume measuring operation.
Part No. Spare Part

2063330 Processor board MCUP 19"
MCUP control unit

Analog/digital module
 Loosen the fastening screws (1) and remove the cover plate (2).
 Press together the brackets (3) at the module to be replaced and pull out the module
(4).
Figure 255 Exchanging optional analog/digital modules
1 2 1 3 4
 Plug a new module and attach the cover plate.

Interface modules
 Loosen the fastening screws (1) and remove the cover plate (2).
Figure 256 Front view

1 2 1
 Pull out the interface module, plug a new module and attach the cover plate.
MCUP control unit
8.3.3 Replacement of display unit

 Loosen the fastening screws (1) and remove the LC display.
 Disconnect the plug connector from the display.
Figure 257 Front view (version with LC display)

1 2 1
 Connect and attach the new LC display.

Part No. Spare Part

2065868 Frontpanel with LC display MCUP 19"

 Remove the plug connector (1), disconnect the earth wire (2), loosen the fastening
screws (3) and pull out the module (4) from the 19" rack (5).
 Loosen the fastening screws (6) for the cover (7) and remove the cover.
 Loosen the fastening screws (8) for the power supply unit (9) and remove the power
supply unit from the mounting plate (10).
Figure 258 Dismounting the power supply unit

3 1 3 5 8 9
4 3 2 10
MCUP control unit
 Disconnect the connection cables at the power supply unit, connect the new power sup-
ply unit and fasten it.
Figure 259 Connections at the power supply unit
Green/yellow
Brown
White
Black
Black
 Attach the cover, put the complete module again into the 19" rack and fasten it.
 Connect the plug connector and switch on the supply voltage.
Part No. Spare Part

2050591 Power supply unit MCUP 19"
MCUP control unit
8.3.5 Replacement of fuses

 Pull out fuse holder using a screwdriver.
Figure 260 Dismounting fuse holder
 Remove fuse from fuse holder and replace it with a new one.
Figure 261 Removed fuse
Part No. Spare Part

MCUP control unit
8.4 MCUP control unit - medium size housing (non-ex, ATEX Zone 2, CSA
Cl I, Div2)

8.4.1.1 MCUP non-Ex protected
See description "Replacement of processor PCB" of MCUP compact ( p. 235, §b).
Part No. Spare Part

2056004 Processorboard MCUP non-Ex compact/medium size
8.4.1.2 MCUP ATEX Zone 2 and CSA CI I, Div2

 Unscrew two screws of plastic protection shield.
 Remove plastic protection shield.
See description "Replacement of processor PCB" of MCUP compact ( p. 235, §b).
Part No. Spare Part

2062078 Processorboard MCUP ATEX/CSA

See description "Replacement of optional modules" from MCUP compact ( p. 236, §8.2.2).

 Use 7mm wrench to loosen all 8 nuts from front panel holder.
 Disconnect display connector from display PCB.
Figure 262 Touch panel holder and backside display

MCUP control unit
 Remove front panel holder first.
Figure 263 Panel holder removed
 Remove complete assembly (front panel incl. display and display PCB) and replace it
with a new one.
Figure 264 Complete assembly
Part No. Spare Part

2055943 LC display MCUP compact/medium size screwed
MCUP control unit

See description "Access to I/O modules, interface module and power supply" from MCUP
medium ( p. 245, §8.4.2) to get access to the power supply.
See description "Replacement of power supply" from MCUP compact ( p. 238, §8.2.4).
Part No. Spare Part

2062150 Power supply unit MCUP ATEX Zone 2/CSA CI I, Div2
Figure 265 Fuse holder
 Pull fuse holder back.
Figure 266 Fuse holder in back position

MCUP control unit
 Open cap of fuse holder from the side.

 Remove fuse and replace it with a new one.
 Close cap and push fuse holder back in original position.
Figure 267 Opened cap
Part No. Spare Part

Please refer to  p. 259, §8.5.6!
MCUP control unit
8.5 MCUP control unit - Exd housing (ATEX Zone 1)

NOTICE:
 After replacement of parts, the tightness of MCUP housing Exd/Exe
have to be checked and ensured with special attention.

 Loosen grub screw (1) with Allen key 2.5.
 Place handles in lid (2), and turn to remove lid (beware of grease on thread inside lid).
 Lift lid from casing and place face down on a flat surface.
 Loosen (don‘t remove) screws holding display panel (3).
 Slide back display panel (4).
 Lift display panel (5), and slide down into casing (6) to prevent damage.
Figure 268 Removing the lid and displacing the display panel
Grub screw
3 Screw fastening display
4
5 6
MCUP control unit
 Remove hexagon bolts holding the processor board using a size 7open-end wrench (7).
 Remove hexagon nut securing display unit cable using a size 7 socket key, and remove
the plastic fastening and the bolt below fixing the processor board (8).
 Remove hexagon nuts securing processor board using a size 7 socket key (9).
Figure 269 Removing fixings
Spacing screws
7
Hexagon Bolts
Hexagon nuts
9 9
Hexagon Nut
NOTICE:
 Make sure that no parts fall into the housing of the MCUP.
 The height of the spacing screws (for resting the display unit on) should not
be altered.
MCUP control unit
 Remove connections from processor board as follows:

– Display cable is held with a catch - squeeze catch gently to
release (10)
– Analog module cable (if present) can be levered out carefully
with a slot screwdriver (11)
– Pull out interface module cable (12)
24V power supply cabling should be removed by loosening the fixings with a small slot
screwdriver (13). Note order of cables for reassembly (listed in table, below).
Power supply
connections
Wire Terminal
Brown grnd 49
White + 48
Black 46
Figure 270 Removing the connections
Display unit cable
10
13
11
12
24V supply cabling
Interface module cable
Analog module cable

MCUP control unit
 Carefully lift out the faulty processor board and place on a soft surface/material to pro-
tect bottom. Rest on edge of casing (with terminal wiring still attached) (14).
 Take replacement processor board, and one by one, disconnect each wire from the ter-
minal on the faulty processor board and attach to new processor board terminal exactly
as configured on the faulty board (15),
or alternatively:
 On each cable, a number is printed. Make a list which cable is connect to which termi-
nal on the processor PCB. According to the list, you can remove all cables and connect it
to the new PCB afterwards.
NOTICE:
 Take care that the underside of the processor board is not damaged.
 Reassemble cabling and fixings of new processor board exactly as for original processor
board.
 Note the serial number of both processor boards and list in protocol.
Figure 271 Removing the processor board and exchanging the terminal connections
15
14 Terminal connections
MCUP control unit
 To finalise the replace, enter the MCUP serial number in SOPAS, under the menu
‘Device InformationRegistering the serial number in SOPAS.
MCUP Serial Number
‘
Part No. Spare Part

2062078 Processorboard MCUP ATEX/CSA
MCUP control unit

Use 7mm hexagon screw driver to remove 3 nuts of the processor PCB and display holder.
See MCUP compact  p. 236, §8.2.2.
NOTICE:
The ex-certification is valid for the original configuration the the MCUP as
delivered only. Any subsequent extension to the I/O configuration must be
agreed with the manufacturer.

 Use 2.5mm Allen key to loosen the hexagon socket screw on the top of the cap.
 Use specail tools to unscrew the cap.
 Slide the display updwards and lift it up.
See description "Replacement of display" of MCUP compact ( p. 237, §8.2.3).
Part No. Spare Part

2052585 LC display MCUP ATEX Zone 1

8.5.4.1 Housing type STAHL
 Disconnect all plugs on processor PCB.
 Before you disconnect the wires, check the number on each wire separately.
 Make a list which cable is connect to which terminal on the processor PCB. This is nec-
essary for re-connecting the wires.
 Use 7mm wrench to loosen the 3 fastening nuts of the holder.
Figure 272 Display and processor PCB holder
MCUP control unit
 Remove holder incl. processor PCB and display completely.

 Use 25 Torx screwdriver to loosen the 4 screws of the power supply holder.
 Use 7mm wrench to loosen the 2 fastening nuts from the hat rail.
Figure 273 Removed processor PCB with holder
Fuses
 With a detached hat rail, the power supply holder can be taken out of the housing with-
out removing the modules from the hat rail.
NOTICE:
Take care when removing power supply holder including power supply.
These parts have sharp edges and can cut the isolation of cables.
MCUP control unit
 Use cross screwdriver to disconnect all connected wires from the power supply.
 Use cross screwdriver to loosen the only screw on the power supply side.
Figure 274 Power supply connections
 Use cross screwdriver to loosen the 2 screws on the power supply holder.
Figure 275 Holding screws of power supply unit
 Take off the power supply from the holder and replace it with a new one.
 To assemble, repeat all steps in the reverse order.
Part No. Spare Part

MCUP control unit
8.5.4.2 Housing type CORTEM

 Disconnect mains voltage.
 Disconnect mains voltage inside housing.
Figure 276 Mains voltage cables
 Use cross screwdriver to loosen 4 fixing screws of the ground plate.
Figure 277 Overview: Electronics in housing

MCUP control unit
 Remove ground plate including eclectronics.

 Use cross screwdriver to loosen all cables from power supply unit.
 Use cross screwdriver to loosen screw from power supply unit.
Figure 278 Power supply unit: front side
 Remove power supply unit and replace it with a new one.
Figure 279 Power supply unit: back side
 Perform all steps in reverse order to fix and connect the power supply unit again.
Part No. Spare Part

2062084 Power supply unit MCUP ATEX Zone 1 Cortem housing
MCUP control unit

See description from MCUP Ex-Zone 1  p. 254, §8.5.4 to get access to the fuse holder.
 Pull out fuse holder.
 Open cap on side of the fuse holder.
 Remove fuse and replace fuse with a new one.
Part No. Spare Part

NOTICE:
All cable glands have to be dismounted and mounted using a wrench.
Figure 280 Brass cable gland
Figure 281 Plastic cable gland

MCUP control unit
Figure 282 Blind plug at MCUP Ex-Zone 1
8.5.8 Replacement of sealing at Ex-d housing cover
NOTICE:
The housing cover sealing has to be free of grease.
 Avoid the contact between sealing and grease at the cover while
assembling the sealing.
Figure 283 Sealing at cover of MCUP Zone1
Sealing
Part No. Spare Part

2064006 O-RING GEHAEUSE MCUP EXZ1 ET
Annex
9 Annex
Zero Point Box

Periodic Field Test
Basic Function Test
Annex
9. 1 Zero Point Box
Annex
No part of this publication may be reproduced, used or circulated without express Vervielfältigung dieser Unterlage sowie Verwertung und Mitteilung ihres Inhaltes SICK AG
9.2
prior permission. Breach of this clause is a punishable offence and offenders will ist unzulässig, soweit nicht ausdrücklich zugestanden. Zuwiderhandlungen sind
be held liable for indemnity (German Law ref.: LitUrhG, UWG, BGB). All rights strafbar und verpflichten zu Schadenersatz (LitUrhG, UWG, BGB). Alle Rechte All rights reserved
reserved for patent or CTM registration. für den Fall der Patenterteilung oder GM-Eintragung vorbehalten.
V1.7
ECN
Date
2010/12/14
bellaal
Name
Date
2010-06-16
Periodic Field Test
holzbsv
Created
Date
D-01458 Ottendorf-Okrilla
Released
Repl. for:
Type: FL100
FLOWSIC100 FLARE
Periodic field verification
FLOWSIC100 Flare/Process · Service Manual · 8013520/V 2-1/2016-06 · © SICK Engineering GmbH

Repl. by:
PERIODIOC FIELD TEST ENGL
PERIODISCHER FELDTEST ENGL
Ident No: E_56314

Sh. 1 / 32
263
Annex
Contents
1.0 Objective.................................................................................................................. 3
2.0 General information ................................................................................................. 3
3.0 Test while operation interrupted ............................................................................... 4
3.1 Analysis and documentation of current device status............................................... 4
3.2 Parameter testing .................................................................................................... 5
3.3 Probe removal and inspection.................................................................................. 6
All rights reserved
3.4 Zero-point test.......................................................................................................... 7

3.5 MCUP I/O test........................................................................................................ 11
SICK AG
3.6 Reinstallation ......................................................................................................... 12

3.7 Documentation of repairs and replacements .......................................................... 13
4.0 Test during operation ............................................................................................. 14
4.1 Analysis and documentation of current device status............................................. 14
ist unzulässig, soweit nicht ausdrücklich zugestanden. Zuwiderhandlungen sind
strafbar und verpflichten zu Schadenersatz (LitUrhG, UWG, BGB). Alle Rechte
Vervielfältigung dieser Unterlage sowie Verwertung und Mitteilung ihres Inhaltes
4.2 Parameter Testing ................................................................................................. 15

4.3 Carrying out a check cycle ..................................................................................... 16
4.4 Documentation of repairs and replacements .......................................................... 16
für den Fall der Patenterteilung oder GM-Eintragung vorbehalten.
5.0 Annexe – Test protocols ........................................................................................ 16

No part of this publication may be reproduced, used or circulated without express
prior permission. Breach of this clause is a punishable offence and offenders will
be held liable for indemnity (German Law ref.: LitUrhG, UWG, BGB). All rights

reserved for patent or CTM registration.
Date Created Date Released

2010-06-16 holzbsv

V1.7 2010/12/14 bellaal Type: FL100 Ident No: E_56314
ECN Date Name D-01458 Ottendorf-Okrilla Repl. for: Repl. by: Sh. 2 / 32
Annex
1.0 Objective
This document describes the procedure for a field verification for FLOWSIC100 FLARE EX,
EX-S and EX-PR. The procedure is described in the initial sections. The protocols required are
listed in the appendices.
Accompanying documents:
- FLOWSIC100 FLARE operating and installation instructions

- FL100 Flare/Process service manual
- Software manual
All rights reserved
SICK AG
2.0 General information
After startup of the FLOWSIC100 FLARE, sensors and electronics are subjected to extreme
process conditions. The devices must demonstrate a high level of both availability and
precision.
In order to ensure that the device is functioning correctly, two types of tests can be carried out.
The tests differ according to the availability of the installation in operation during the test:
1. Test during operation

2. Test while operation interrupted
“Test during operation” is carried out when the sensors cannot be removed because
production cannot be interrupted, and the pipeline not opened.
Test type 2 is for situations in which the sensor can be removed for the duration of the test. In
this case, the testing of the sensor can function additionally as a zero-point.
This service may be carried out by the owner's trained personnel or by SICK’s Service
Department. Those carrying out the service should be able to demonstrate the following
capabilities:
- familiarity with electrical appliances, especially explosion-proof ones,

- service, installation and configuration of the FLOWSIC100 FLARE,
- conduct in the explosion zone,
- conduct when dealing with gases which constitute a potential risk (hot, poisonous
and explosive gas under pressure)
All activities performed as part of this service by the owner's personnel or by the SICK Service
Department must be logged.
The service tests the device under the following criteria:
- occurrence of wear
- measurement drift
- damage
- dirt

2010-06-16 holzbsv

Annex
- correct configuration
- electrical safety
- mechanical safety (pressure-loaded parts)
The manufacturer recommends carrying out the “Test while operation interrupted” one year
after commissioning. As long as the devices show no abnormalities, the “Test during
operation” may be carried out annually.
All rights reserved
3.0 Test while operation interrupted

SICK AG
3.1 Analysis and documentation of current device status
1. Before the FLOWSIC100 measuring system is subjected to a more precise

inspection, a position must be agreed with the owner regarding the current device
functioning. Here it should be clarified whether the device has displayed any
unusual behavior during the past period of time and whether it has functioned
according to specifications. This information must be logged.
2. Carry out an external inspection at the test point. The device must be inspected
with regard to external damage to housing, sensors and converters as well as
wiring, dirt, intactness of labels and tightness of seals. It is intended that the
sender/receiver units and the MCUP be inspected.
3. Establish a communication connection must be produced via the service interface.

SOPAS ET must be connected to the device. Create a new project or open the
appropriate project. In this process, both the FLOWSIC100 sender/receiver units
(FLSE) and the Multi Control Unit Process (MCUP) must be implemented in the
project.
4. Open the “Errors and warnings" tab in the FLSE page, and log the unlogged
events.
5. Open the “logbook” tab in the MCUP page. Read from the logbook and check for
conspicuous events.
6. Open the "Diagnosis/sensor values” tab in the FLSE page and configure a data
recording. Select the parameter group “group/diagnosis log”. Abnormalities must be
documented. The recording should last between three and five minutes. For
instructions see the Service Manual.
7. Read the meter statuses for mass and standard volume and for those of the fault
volume meter and note them in the log.
8. The most important measured and diagnostic values must be tested for plausibility.
For this purpose, the following measurements on the “Diagnosis/sensor values”
page should be analyzed:
a) Gas velocity plausibility test compared with current

process status

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Annex
b) Sound velocity plausibility test compared with current

process status, possibly SOS based on
calculating gas composition,
deviation < 1%
c) SNR > 20 dB
d) AGC < 80 dB
e) Pressure comparison with process status
f) Temperature comparison with process status
g) Molecular mass comparison with process status

h) Tightness of seals (operation) comparison with process status
All rights reserved
The sound velocity can be tested against a theoretical sound velocity, which
SICK AG
can be calculated on the basis of the current gas composition. For this purpose,
the GERG 2004 Berechnungsverfahren (GERG 2004 Calculation procedure)
can be used, which is integrated in the MEPAFLOW 600 CBM.
For a comparison of the sound velocity, an average should be taken over 3

minutes. The gas concentration and composition must not change more than
1% during the comparison. The temperature must not change more than 0.5°C
during the measurement.
These values can also be exceeded in special applications. In these cases, the
plausibility limits for the special application must be used.
This concludes the documentation of the device's current status.
3.2 Parameter testing
1. The most important parameters should be tested for correctness. This includes
testing and documenting the following:
Figure 1
a) Installation angle - SOPAS ET Sensor parameter

b) Path length - SOPAS ET Sensor parameter
c) Cross sectional area - SOPAS ET Sensor parameter

2010-06-16 holzbsv

Annex
Figure 2
All rights reserved
d) Pipe diameter - SOPAS ET MCUP/Measuring point parameter

SICK AG
e) Nominal diameter - SOPAS ET MCUP/Measuring point parameter

f) Sensor type - SOPAS ET MCUP/Measuring point parameter
g) Adjust factor - SOPAS ET MCUP/Measuring point parameter
3.3 Probe removal and inspection
After analysis of the actual device status, the sensors (FLSE) must be removed from the
system. For this purpose, the specifications given in the FLOWSIC100 FLARE and
FLOWSIC100 Process operating instructions must be followed.
Note:
During the removal of the devices from the pipeline, combustible, toxic or pressurised
gas can escape. For this reason, all applicable regulations as well as instructions in the
Service Manual and Operating Manual must be strictly observed. No action may be
taken without prior permission of the plant operator.
1. The parts of the probe in contact with gas must be visually inspected. The following
main points merit particular attention:
- dirt
- mechanical damage (deformation, breaks, cracks and slack or loose parts),

- gasket inspection,
2. The sensors must then be cleaned. Cleaning must not be by mechanical means.
Aggressive or corrosive solvents must not be used. Subject to change without notice

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Annex
3.4 Zero-point test
For the annual equipment test, the manufacturer recommends that a zero-point test be carried
out. The test must be run under specified conditions for gas composition, temperature,
pressure and humidity. For this purpose, the test should be performed in a cabinet specially
designed by the manufacturer. This equipment ensures that the gas velocity is almost 0 m/s
and that external influences are eliminated as much as possible, during the test.
1. The sensors must be assembled inside the zero-point box. Care must be taken to
ensure that the sensors are pushed forward properly as far as they will go.
All rights reserved
The sensors should be assembled with their flanges in the mechanical mounting in
the zero-point box.
SICK AG
Figure 3
- the inner dividing wall can be set in three different positions

- the position of the dividing wall should be set to give a path length of about 200mm
Figure 4
- The positioning cones screwed into the dividing wall can be set to a right or left
position, depending on the device model and whether or not the sensors should be
mounted at an angle.

2010-06-16 holzbsv

Annex
2. The distance between the diaphragm surfaces must be measured and noted.
- Use the distance measurement tool provided for this procedure
All rights reserved
SICK AG
Figure 5: Measuring the distance; the instruments are stored on the

inside of the lid
3. Connect the SOPAS ET program and the sensors. The path length written in
SOPAS ET for normal operation should be logged in the protocol, and the new path
length for testing entered in it’s place (the path length value for normal operation
must be re-entered once the test is complete).
Figure 6: SOPAS ET configuration of path length
4. Finally, change the measurement mode in order to enable the new parameter.
5. The zero-point box must be closed and protected from direct sunlight (avoid
thermal convection), and the temperature and humidity in the box measured and
logged.
6. The sender/receiver units should be connected to a 24 V dc power supply.
7. After closing the box, wait 20 minutes until any possible flows and temperature
compensations have become adjusted inside. Only then can the real test begin (the
sensors must be connected to the power supply during this time).
8. Terminate the SOPAS ET program and start the DynamicX test program. Open the
EXCEL template "DynamicX_ZeroFlowBox_V01.xls" using the “Open file”
button.

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Annex
9. Start a communication connection by clicking the ”Start connection” button and

configure it according to the menu shown. The data recording should either contain
at least 300 entries or take at least five minutes.
All rights reserved
SICK AG
Figure 7
10. The communication is started by clicking the "Connect" button. The measurements
and the diagnosis values are then received via the interface and are recorded
directly in the EXCEL template.
11. While the recordings are in progress, the measurements for temperature and
humidity can be configured on the ”View” page of the EXCEL Template. For the
pressure measurement, it is sufficient to enter the mean barometric air pressure. If
a barometer is available, the measured value should be accepted.
Figure 8: Pressure, temperature and humidity measurement

2010-06-16 holzbsv

Annex
Figure 9
12. On conclusion of the data recording, test the mean values for gas and sound
velocity for plausibility, including their trends. The following limit values must be
observed:
All rights reserved
80/135 kHz:
Mean values:
SICK AG
Avg. VOG < +/- 20mm/s

Avg. VOS < +/- 1%
Trend:
VOG < +/- 20mm/s
VOS < +/- 1%
42 kHz:
Mean values:
Avg. VOG < +/- 30mm/s
Avg. VOS < +/- 1%
Trend:
VOG < +/- 30mm/s
VOS < +/- 1%
If the limit values are not held, it may be assumed that the sender/receiver units
are not performing adequately. A detailed inspection of the sensors is
recommended. The factory must be consulted in order to solve the problem.
13. The plausibility of the AGC and SNR diagnosis quantities must be then tested. For
this procedure, the sender/receiver units remain in the zero-point box and the
following criteria observed:
AGC < 40 dB
SNR > 30 dB


2010-06-16 holzbsv

Annex
All rights reserved

SICK AG
Figure 10
3.5 MCUP I/O test

Finally, the MCUP I/O channels must be tested for proper functioning and precision. An
agreement must be reached with the operator that the MCUP is partly taken out of operation
for that purpose. It should also be noted that the measurements made during the can deviate
from measurements taken during normal operation. First, the analog outputs are tested and
then the analog input test is performed.
1. Disconnect and insulate the wires of the particular. A calibrated ammeter must be
connected to the output. The current values 4, 12 and 20 mA must be stipulated
one after the other on the "System Test" page, via SOPAS ET, and the
measurements read from the ammeter and logged.

The acceptable error for an analog output is 0.04 mA. If the error is greater than
this, the output should be recalibrated.
2010-06-16 holzbsv

Annex
2. Disconnect and insulate the wires of the particular analog. A calibrated current
source must be connected to the input. The completed power measurements can
be displayed on the "I/O Diagnosis" page, via SOPAS ET. The current values 4, 12
and 20 mA must be stipulated one after the other, via the calibrated current source.
Read the measurements from the ammeter and log them in the protocol.
The acceptable error for an analog input is 0.04 mA. If the error is greater than this,
the input should be recalibrated.
3. The MCUP relay outputs should be tested. For this purpose, the switch output
statuses may be stipulated on the “System test" page in the SOPAS ET. During the
test, the wires must be disconnected and a continuity tester connected. All the
All rights reserved
switch outputs must be tested for proper functioning.

SICK AG
4. The digital inputs are enabled by short-circuiting or opening the appropriate clamps.
In order to do this, the wires must be disconnected and insulated. The particular
digital input is then energized by a jumper. The switching status of the appropriate
digital input may be tested on the “System test" page in the SOPAS ET. The results
must be documented.
3.6 Reinstallation
The appliance must be reinstalled after completion of the test. This includes re-assembly of
the sensors in the pipeline, guaranteeing the tightness of the seals, and rewiring the MCUP.
Following that, the following important diagnostic or functional checks must be carried out:
1. Detecting and logging the meter statuses for the particular measurement point
2. Testing the following diagnostic values and measurements against the display
values on the control system:

process status
calculating gas composition
c) SNR > 20 dB
d) AGC < 80 dB

i) Pulse output
3. Finally, save the project file in the SOPAS ET (Project Æ “Save”) and export the
MCUP and sender/receiver unit device files. These files contain the last parameter
configuration and may be used for restoring the last configuration status, should
problems arise. (Highlight MCUP or sensor, project Æ " Export device")

2010-06-16 holzbsv

Annex
V1.7
ECN
Date
2010/12/14
bellaal
Name
Date
2010-06-16
holzbsv
Created
Date
3.7 Documentation of repairs and replacements
Released
the item numbers and writing them in the protocol.
Repl. for:
Type: FL100

Repl. by:
All use of replacement parts and repairs made should be documented. This includes noting
Ident No: E_56314

Sh. 13 / 32
275
Annex
4.0 Test during operation
4.1 Analysis and documentation of current device status
1. Before the FLOWSIC100 measuring system is subjected to a more precise

inspection, a position must be agreed with the owner regarding the current device
functioning. Here it should be clarified whether the device has displayed any
unusual behavior during the past period and whether it has functioned according to
specifications. This information must be logged.
2. Carry out an external inspection at the test point. The device must be inspected
All rights reserved
with regard to external damage to housing, sensors and converters as well as

wiring, dirt, intactness of labels and tightness of seals. It is intended that the
SICK AG
sender/receiver units and the MCUP be inspected.
3. Establish a communication connection must be produced via the service interface.

SOPAS ET must be connected to the device. Create a new project or open the
appropriate project. In this process, both the FLOWSIC100 sender/receiver units
(FLSE) and the Multi Control Unit Process (MCUP) must be implemented in the
project
4. Open the “Errors and warnings" page in the FLSE page, and log the unlogged
events.
5. Open the “logbook” tab in the MCUP page. Read from the logbook and check for
conspicuous events.
6. Open the "Diagnosis/sensor values” tab in the FLSE page and configure a data
recording. Select the parameter group “group/diagnosis log”. Abnormalities must be
documented. The recording should last between three and five minutes. For
instructions see the Service Manual.
7. The meter statuses for mass and standard volume and for those of the fault volume
meter must be read off and noted in the log.
8. The most important measured and diagnostic values must be tested for plausibility.
For this purpose, the following measurements on the “Diagnosis/sensor values”
page should be analyzed:

process status

calculating gas composition,
deviation < 1%
c) SNR > 20 dB
d) AGC < 80 dB


2010-06-16 holzbsv

Annex
The sound velocity can be tested against a theoretical sound velocity, which
can be calculated on the basis of the current gas composition. For this purpose,
the GERG 2004 Berechnungsverfahren (GERG 2004 Calculation procedure)
can be used, which is integrated into the MEPAFLOW 600 CBM.
For a comparison of the sound velocity, an average should be taken over 3

minutes. The gas concentration and composition must not change more than
1% during the comparison. The temperature must not change more than 0.5°C
during the measurement.
These values can also be exceeded in special applications. In these cases, the
plausibility limits for the special application must be used.
All rights reserved
SICK AG
This concludes the documentation of the device's current status.
4.2 Parameter Testing

1. The most important parameters should be tested for correctness. This includes
testing and documenting the following:

Figure 11
a) Installation angle - SOPAS ET Sensor parameter

b) Path length - SOPAS ET Sensor parameter
c) Cross sectional area - SOPAS ET Sensor parameter
Figure 12
d) Pipe diameter - SOPAS ET MCUP/Measuring point parameter

e) Nominal diameter - SOPAS ET MCUP/Measuring point parameter

f) Sensor type - SOPAS ET MCUP/Measuring point parameter
g) Adjust factor - SOPAS ET MCUP/Measuring point parameter
2010-06-16 holzbsv

Annex
4.3 Carrying out a check cycle
1. In order to check the devices, a check cycle should be carried out. For this the
menu ‘Function Check’ can be started by clicking on the button “Start function
check manually”.
All rights reserved
SICK AG
Figure 13
The test current can be measured during the check cycle via the analog output.
Following the test, the Menu “Error Messages/Warnings” should be checked as to
whether the error “Zero-point offset” is written.
See Service Manual FLOWSIC100.
4.4 Documentation of repairs and replacements

All use of replacement parts and repairs made should be documented. This includes noting
the item numbers and writing them in the protocol.
5.0 Annex – Test protocols

The following sections include the protocols for the procedures “Test during operation” and
“Test while operation interrupted”. Fill out the appropriate protocol for each test.


2010-06-16 holzbsv

Annex

FLOWSIC100 FLARE
All rights reserved
Test while operation interrupted

SICK AG
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2010-06-16 holzbsv

Annex
1 Analysis and documentation of current device status
1 Agreement with owner on the current device performance, abnormalities, special features,
failures etc.
Details:
___________________________________________________________________________
_________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
All rights reserved
__________________________________________________________________________
SICK AG
2 Inspection of the measurement point, external damage, dirt and wear to FLSE and MCUP
Details:
___________________________________________________________________________
_________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
3 Creating a SOPAS ET communication connection and testing current device status

FAULT MAINTENANCE REQUIREMENTS (indicate if applicable)
SOPAS ET test, “Errors and Warnings” page - log unlogged events

4
__________________________________________
__________________________________________
__________________________________________
__________________________________________
Read logbook and test

5
Execute data recording and test and log abnormalities

6
Details:
___________________________________________________________________________
_________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
Detecting the meter statuses

7
Standard volume: ____________________________
Mass: ____________________________
Fault volume meter: ____________________________
Plausibility test of measurement and diagnostic values

2010-06-16 holzbsv

Annex
8
VOG OK
SOS OK
SNR OK
AGC OK
Pressure OK
Temperature OK
Molecular mass OK
Tightness of seals, in operation OK
2 Parameter testing
All rights reserved
1 Test of the most important installation parameters using SOPAS ET Software

SICK AG
Sensor:
Installation angle _______________________________
Path length _______________________________
Cross sectional area _______________________________
MCUP
Pipe diameter _______________________________

Nominal diameter _______________________________
Sensor type _______________________________
Adjust factor _______________________________
3 Probe removal and inspection
1 Removal and inspection, testing and logging of external damage to the parts coming into
contact with gas and of the pressure-bearing parts.
Details:
___________________________________________________________________________
_________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
2 Cleaning the sensors

4 Zero-point test
1 Assembling the sensors in the zero-point box
2 Calculating and logging the diaphragm distance: ______________________
3 Logging the path length to date: ______________________

4 Parameterization of the diaphragm distance in the zero-point box with the SOPAS ET “Path
length” parameter
5 Switch measurement mode on

2010-06-16 holzbsv

Annex
6 Box closed, record temperature and humidity
Temperature: ____________________________
Humidity: ____________________________
Barometric pressure: ____________________________
7 Wait 15 minutes for equalizing operations
8 Start Dynamic and open "ExcelInterop_ZeroFlowCheck_COLA.xls"
9 Configure new DynamicX communication connection

All rights reserved
10 Start communication
SICK AG
11 Enter temperature, pressure and humidity in the zero-point EXCEL template
12 VOG and VOS plausibility test
Mean values:
80/135 kHz 42kHz
Avg. VOG < +/- 20mm/s Avg. VOG < +/- 30mm/s
Avg. VOS < +/- 1%
Trend:
80/135 kHz 42kHz
Avg. VOG < +/- 20mm/s Avg. VOG < +/- 30mm/s
VOS < +/- 1%
13
SNR and AGC plausibility test
AGC < 40 dB
14 SNR > 30 dB
Visual check of Standard/KKR signal form
5 MCUP I/O test
1 Analog output test:

Disconnect the analog wires, connect calibrated ammeter, specify current values ("SOPAS
ET/System test") and log the measurements
Acceptable analog output error 0.4 mA
AO identifier
Power test
4 mA
12 mA

2010-06-16 holzbsv

Annex
V1.7
ECN
Date
2010/12/14
bellaal
Name
4 mA
4 mA
20 mA
12 mA
20 mA
12 mA
20 mA
Yes/no
Yes/no
Yes/no
Yes/no
Yes/no
Yes/no
OK (valid)
OK (valid)
Power test
Power test
Date
AO identifier
AO identifier
Measurement
Measurement
Measurement
2010-06-16
holzbsv
Created
Date
Released
Repl. for:
Type: FL100

Repl. by:
Ident No: E_56314

Sh. 21 / 32
283
284
V1.7
ECN
Date
2010/12/14
bellaal
Name
4 mA
4 mA
20 mA
12 mA
20 mA
12 mA
Yes/no
Yes/no
Yes/no
Yes/no
Yes/no
Yes/no
OK (valid)
OK (valid)
OK (valid)
Power test
Power test
Date
AO identifier
AO identifier
Measurement
Measurement
2010-06-16
holzbsv
Created
Date
Released
Repl. for:
Type: FL100
Repl. by:
Ident No: E_56314

Sh. 22 / 32

Annex

Annex
Yes/no
Yes/no
Yes/no
AO identifier
Power test
All rights reserved
4 mA
12 mA
SICK AG
20 mA
Measurement
OK (valid)
Yes/no
Yes/no
Yes/no
If an analog output does not reach the required level of accuracy, the output may be
recalibrated.
2 Analog input test

Disconnect the analog wires, connect calibrated ammeter, specify current values with the
power source, read off the measurements ("I/O Diagnosis") and log them
Acceptable analog output error 0.04 mA

AI identifier
Power test
4 mA
12 mA
20 mA
Measurement

2010-06-16 holzbsv

286
V1.7
ECN
Date
2010/12/14
bellaal
Name
4 mA
4 mA
20 mA
12 mA
20 mA
12 mA
Yes/no
Yes/no
Yes/no
Yes/no
Yes/no
Yes/no
OK (valid)
OK (valid)
OK (valid)
Power test
Power test
Date
AI identifier
AI identifier
Measurement
Measurement
2010-06-16
holzbsv
Created
Date
Released
Repl. for:
Type: FL100
Repl. by:
Ident No: E_56314

Sh. 24 / 32

Annex

Annex
V1.7
ECN
Date
2010/12/14
bellaal
Name
4 mA
4 mA
20 mA
12 mA
20 mA
12 mA
Yes/no
Yes/no
Yes/no
Yes/no
Yes/no
Yes/no
Yes/no
Yes/no
Yes/no
OK (valid)
OK (valid)
Power test
Power test
Date
AI identifier
AI identifier
Measurement
Measurement
2010-06-16
holzbsv
Created
Date
Released
Repl. for:
Type: FL100

Repl. by:
Ident No: E_56314

Sh. 25 / 32
287
Annex
AI identifier
Power test
4 mA
12 mA
20 mA
All rights reserved
Measurement
SICK AG
OK (valid)
Yes/no
Yes/no
Yes/no
If an analog input does not reach the required level of accuracy, the input may be recalibrated.
3 Test switch output:

Disconnect the wires, connect a continuity tester, calibrated ammeter, specify switching status
("SOPAS ET/System test") and log the results
Relay 1
Relay 2
Relay 3
Relay 4
Relay 5
Relay 6
OK/failure
OK/failure
OK/failure
OK/failure
OK/failure
OK/failure

2010-06-16 holzbsv

Annex
4 Test switch input:

Disconnect the wires, short-circuit and open the digital inputs, test the switching status
("SOPAS ET/System test") and log the results
Digital In 1
Digital In 2
Digital In 3
Digital In 4
All rights reserved
OK/failure
OK/failure
SICK AG
OK/failure
OK/failure
6 Reinstallation
1 Detecting the meter statuses

Standard volume: ____________________________

Mass: ____________________________
2 Plausibility test of measurement and diagnostic values and comparison with the display values
in the control system.
VOG OK ____________________________
SOS OK ____________________________
SNR OK ____________________________
AGC OK ____________________________
Pressure OK ____________________________
Temperature OK ____________________________
Molecular mass OK ____________________________
Tightness of seals, in operation OK ____________________________
Pulse output OK ____________________________
3 Saving project and device file
Save project
MCUP - export device
Sensor - export device

2010-06-16 holzbsv

Annex
7 Repairs and recording spare parts
EĂŵĞ /ƚĞŵŶŽ͘ ZĞĂƐŽŶĨŽƌƌĞƉůĂĐĞŵĞŶƚ ^ĞƌŝĂůŶŽ͘ ^ĞƌŝĂůŶŽ͘

ŶĞǁ ŽůĚ

All rights reserved
SICK AG

The test has been completed in full. The device is functioning within the specified parameters.
The test has not been completed in full. The following deviations are recorded:
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
_________________________ ______________________ ________________

Name of engineer Signature Date and time

2010-06-16 holzbsv

Annex

FLOWSIC100 FLARE
All rights reserved
Test during operation

SICK AG
ůŝĞŶƚŝŶĨŽƌŵĂƚŝŽŶ
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^ĞƌǀŝĐĞŝŶĨŽƌŵĂƚŝŽŶ
ĂƚĞŽĨƚŚŝƐƐĞƌǀŝĐĞ͗
dŝŵĞŽĨƚŚŝƐƐĞƌǀŝĐĞ͗
dĞĐŚŶŝĐŝĂŶŶĂŵĞ͗
dĞĐŚŶŝĐŝĂŶƉŚŽŶĞ͗
dĞĐŚŶŝĐŝĂŶĞŵĂŝů͗
ĂƚĞŽĨůĂƐƚƐĞƌǀŝĐĞ͗

2010-06-16 holzbsv

Annex
1 Analysis and documentation of current device status
1 Agreement with owner on the current device performance, abnormalities, special features,
failures etc.
Details:
___________________________________________________________________________
_________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
All rights reserved
__________________________________________________________________________
SICK AG
2 Inspection of the measurement point, external damage, dirt and wear to FLSE and MCUP
Details:
___________________________________________________________________________
_________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
3 Creating a SOPAS ET communication connection and testing current device status

FAULT MAINTENANCE REQUIREMENTS (indicate if applicable)
SOPAS ET test, “Errors and Warnings” page - log unlogged events

4
__________________________________________
__________________________________________
__________________________________________
__________________________________________
Read logbook and test

5
Execute data recording and test and log abnormalities

6
Details:
___________________________________________________________________________
_________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
Detecting the meter statuses

7
Standard volume: ____________________________
Mass: ____________________________
Plausibility test of measurement and diagnostic values

2010-06-16 holzbsv

Annex
8
VOG OK
SOS OK
SNR OK
AGC OK
Pressure OK
Temperature OK
Molecular mass OK
Tightness of seals, in operation OK
2 Parameter testing
All rights reserved
1 Test of the most important installation parameters using SOPAS ET Software

SICK AG
Sensor:
Installation angle _______________________________
Path length _______________________________
Cross sectional area _______________________________
MCUP
Pipe diameter _______________________________

Nominal diameter _______________________________
Sensor type _______________________________
Adjust factor _______________________________
3 Zero-point and current test
1 Start a check cycle manually (Menu: “MCUP/Adjust/Function check”)
Analog current zero-point _________________________ mA

Analogs current span test _________________________ mA
Following the test, check whether the Menu “Sensor Error messages/Warnings writes
“Zeroflow offset”?

2010-06-16 holzbsv

Annex
4 Repairs and recording spare parts
EĂŵĞ /ƚĞŵŶŽ͘ ZĞĂƐŽŶĨŽƌƌĞƉůĂĐĞŵĞŶƚ ^ĞƌŝĂůŶŽ͘ ^ĞƌŝĂůŶŽ͘

ŶĞǁ ŽůĚ

All rights reserved
SICK AG

The test has been completed in full. The device is functioning within the specified parameters.
The test has not been completed in full. The following deviations are recorded:
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
_________________________ ______________________ ________________

Name of engineer Signature Date and time

2010-06-16 holzbsv

Annex
9.3 Basic Function test
9.3.1 Test set-up
Following repair work, and before being mounted in the pipeline, a basic function test
should be carried out. For this purpose, the sensor units should be set up at a defined
distance. If a Zero point box is available, the sensor units can be assembled in the box. The
distance between the sensor units should be at least 0.5 m (except for probe version).
Figure 284 Simple test assembly
 Connect to power supply

 Establish communication RS485 with laptop or PC
 Start SOPAS ET and connect to device
 Go to page "Device Parameters"
 Check that correct device type to be tested is selected
Figure 285 Sopas Parameters

 Go to page "Application Parameters" and measure and configure the measuring dis-
tance (+/- 1mm)
Annex
9.3.2 Test
When the device is in operation, the following measurement and diagnosis values should
be checked:
– Deviation of the amplifier gain control A and B not greater than ± 6 dB
– For all S and PR devices, the deviation must not be greater than ± 2 dB
– SNR greater than 25 dB and deviation A to B not more than ±5 dB
– The acoustic temperature for precisely positioned measuring distance should be ±3 K
– The gas velocity (Zero point) should be below 0.2 m/s (absolute), and not vary more
than ±0.1 m/s.
– The signal displayed should have approximately the following form ("View envelope"off):
Figure 286
NOTICE:
The parameters for the "Zero Phase" should not be altered for measurements
in air. This parameter should be checked following installation in the pipeline.
For this parameter, both cursors should be superimposed, as shown in the
figure below.
Figure 287
Annex
9.3.3 Finalizing the test
Following successful completion of the test, the original measuring distance for the
installation should be re-configured. The device can be reinstalled in the pipeline.
8013520/V2-1/2016-06
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Belgium/Luxembourg 3KRQH 3KRQH
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Chile 3KRQH 3KRQH
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SICK AG | Waldkirch | Germany | www.sick.com

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This manual is intended exclusively for trained

© SICK Engineering GmbH. All rights reserved.

2 FLOWSIC100 Flare/Process · Service Manual · 8013520/V 2-1/2016-06 · © SICK Engineering GmbH

Information about use in potentially explosive atmo-

Hazard by voltage Important technical information for this product

Hazards by explosive or combustible gases Supplementary information

Hazard by noxious substances Link to information in another place

Warning Levels / Signal Words

FLOWSIC100 Flare/Process · Service Manual · 8013520/V 2-1/2016-06 · © SICK Engineering GmbH 3

4 Data Back-up with the SOPAS ET Program . . . . . . . . . . . . . . . . . . . . 53

4 FLOWSIC100 Flare/Process · Service Manual · 8013520/V 2-1/2016-06 · © SICK Engineering GmbH

4.2 Data backup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

7 Repair work for sender/receiver unit . . . . . . . . . . . . . . . . . . . . . . . . . . 113

FLOWSIC100 Flare/Process · Service Manual · 8013520/V 2-1/2016-06· © SICK Engineering GmbH 5

6 FLOWSIC100 Flare/Process · Service Manual · 8013520/V 2-1/2016-06 · © SICK Engineering GmbH

7.9 Sensor assembly of device type FLOWSIC100 EX-PR . . . . . . . . . . . . . . . . . . . . . . . . . . . 207

8 MCUP control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233

FLOWSIC100 Flare/Process · Service Manual · 8013520/V 2-1/2016-06· © SICK Engineering GmbH 7

8 FLOWSIC100 Flare/Process · Service Manual · 8013520/V 2-1/2016-06 · © SICK Engineering GmbH

About this document

FLOWSIC100 Flare/Process · Service Manual · 8013520/V 2-1/2016-06 · © SICK Engineering GmbH 9

1. 1 About this document

Abbreviations used in this manual

10 FLOWSIC100 Flare/Process · Service Manual · 8013520/V 2-1/2016-06 · © SICK Engineering GmbH

1.2 Main hazards

WARNING: Gas hazard

1.2.2 Hazards with electrical equipment

WARNING: Mains voltage Danger

1.2.3 Hazards due to explosive or combustible gases

WARNING: Hazards due to explosive or combustible gases

FLOWSIC100 Flare/Process · Service Manual · 8013520/V 2-1/2016-06 · © SICK Engineering GmbH 11

1.3.1 Purpose of the device

1.3.2 Correct use

• Sender/receiver units marked ATEX II 2 G IECEx and CSA Class I Division 1

1.3.2.3 Use depending on temperature class / process temperature

12 FLOWSIC100 Flare/Process · Service Manual · 8013520/V 2-1/2016-06 · © SICK Engineering GmbH

1.3.2.4 Permitted gas temperature depending on temperature code of FLSE100

Zone 1 or 2 Non-ex Zone 1 or 2 Zone 1 or 2 Zone 1 or 2 Zone 0

FLOWSIC100 Flare/Process · Service Manual · 8013520/V 2-1/2016-06 · © SICK Engineering GmbH 13

Subject to change without notice

14 FLOWSIC100 Flare/Process · Service Manual · 8013520/V 2-1/2016-06 · © SICK Engineering GmbH

1.3.2.5 Sender/receiver unit with probe retraction mechanism

WARNING: Specified temperature and pressure ranges

WARNING: Hazardous gas (possibly explosive or toxic)

1.3.2.6 MCUP control unit

• Control units with marking ATEX II 2 G Ex de II C T6 are approved for use in

WARNING: Explosion hazard

FLOWSIC100 Flare/Process · Service Manual · 8013520/V 2-1/2016-06 · © SICK Engineering GmbH 15

1.3.3 Restrictions of use

WARNING: Pressure/temperature hazard

WARNING: Dangerous voltage

The ultrasonic transducers/probes are preferably intended for installation in gas-carrying

WARNING: Leakage hazard

16 FLOWSIC100 Flare/Process · Service Manual · 8013520/V 2-1/2016-06 · © SICK Engineering GmbH

1.4 Responsibility of user

1.4.1 General information

FLOWSIC100 Flare/Process · Service Manual · 8013520/V 2-1/2016-06 · © SICK Engineering GmbH 17

Specific requirements for use of devices in hazardous areas

 Cabling /installation, device set-up, maintenance and check may be only

Special local conditions

Subject to change without notice

18 FLOWSIC100 Flare/Process · Service Manual · 8013520/V 2-1/2016-06 · © SICK Engineering GmbH