Page 1 Products Solutions Services 8029806/AE00/V2-4/2025-04 Operating Instructions FLOWSIC100 Flare-XT Ultrasonic Mass Flow Measuring Device...
Page 2 This work is protected by copyright. Any rights derived from the copyright shall be reserved for Endress+Hauser SICK GmbH+Co. KG. Reproduction of this document or parts of this document is only permissible within the limits of the legal determination of Copyright Law.
Page 3 FLOWSIC100 Flare-XT Warning symbols Information symbols IMMEDIATE HAZARD Important technical information for this product of severe injuries or death Hazard (general) Supplementary information Voltage hazard Link referring to information at another place Hazard in potentially explosive atmospheres Hazard through explosive substances/substance mix-...
Page 4 Clearance for fitting the Interface Unit ........33 Endress+Hauser...
Page 5 Fitting the weatherproof cover ......... . 86 Endress+Hauser...
Page 6 Fitting the stainless steel tag plate for Interface Unit Zone 1 ....120 Endress+Hauser O P E R A T I N G I N S T R U C T I O N S...
Page 7 Connecting shielding terminals ..........142 Commissioning FLOWSIC100 Flare-XT .
Page 8 System FLOWSIC100 Flare-XT ........
Page 9 Gasket installation ............225 Endress+Hauser...
Page 10 CONTENTS Endress+Hauser O P E R A T I N G I N S T R U C T I O N S 8029806/AE00/V2-4/2025-04...
Page 11 FLOWSIC100 Flare-XT About this document FLOWSIC100 Flare-XT About this document Function of this document Scope of application Target groups Further information Endress+Hauser O P E R A T I N G I N S T R U C T I O N S...
Page 12 About this document FLOWSIC100 Flare-XT Function of this document 1. 1 These Operating Instructions describe for the FLOWSIC100 Flare-XT measuring system with FLSE100-XT sender/receiver units and Interface Unit: ● Device components ● Installation ● Operation ● Maintenance work required for reliable operation For detailed information on functional checks/device settings, data backup, software update, malfunction and error handling and possible repairs, see the Service Manual.
Page 13 FLOWSIC100 Flare-XT For your safety FLOWSIC100 Flare-XT For your safety Basic safety information Intended use Information on cybersecurity threats Endress+Hauser O P E R A T I N G I N S T R U C T I O N S...
Page 14 Only use the FLOWSIC100 Flare-XT measuring system as described in these Operating Instructions. The manufacturer bears no responsibility for any other use. ▸ Do not attempt any work on or repairs to the FLOWSIC100 Flare-XT unless described in this Manual. ▸...
Page 15 FLOWSIC100 Flare-XT For your safety Information on cybersecurity threats 2 . 3 Protection against cybersecurity threats requires a comprehensive cybersecurity concept that must be continuously reviewed and maintained. A suitable concept consists of organizational, technical, procedural, electronic and physical levels of defense and takes into account appropriate measures for the different types of risk.
Page 16 For your safety FLOWSIC100 Flare-XT Endress+Hauser O P E R A T I N G I N S T R U C T I O N S 8029806/AE00/V2-4/2025-04...
Page 17 FLOWSIC100 Flare-XT System description FLOWSIC100 Flare-XT System description System components Functional principle System overview System configuration ASC technology (patented) – active sound correlation technology Logbook and archives Endress+Hauser O P E R A T I N G I N S T R U C T I O N S...
Page 18 System description FLOWSIC100 Flare-XT System components 3. 1 The FLOWSIC100 Flare-XT measuring system comprises the components: ● FLSE100-XT sender/receiver unit (details  p. 35, §5) For transmitting and receiving ultrasonic pulses, signal processing and controlling the system functions ● Control unit Interface Unit (details p. 93, §6)
Page 19 Functional principle 3 . 2 The FLOWSIC100 Flare-XT gas flow rate measuring devices operate according to the principle of ultrasonic transit time difference measurement. Sender/receiver units are mounted on both sides of a pipeline at a certain angle of inclination to the gas flow (Fig. 1).
Page 20 The sound velocity can be determined by resolving formulas 2.1 and 2.2 for c. · (2.4) · t System overview 3. 3 Fig. 2 System overview FLOWSIC100 Flare-XT Top view Front view Draufsicht Frontansicht To Interface unit Zur Interface unit...
Page 21 Configuration as Flare Instrument or Flare Meter 3.4.1 The FLOWSIC100 Flare-XT measuring system is available as a flare instrument, where the nozzles are welded to the existing pipeline. Optionally available as a variant with separately supplied spool piece for easier fitting of the sensors without welding. Here, the sensors are first integrated in the spool piece at the measuring point.
Page 22 FLOWSIC100 Flare-XT Configuration as 1-path or 2-path measuring system 3.4.2 FLOWSIC100 Flare-XT is available as 1- or 2-path measuring system. The following Figures show cross-duct installations (F1F-S, F1F-M, F1F-H). In principle, the configuration also applies to one-sided installation (F1F-P). Configuration Description Two sender/receiver units are mounted on the pipeline.
Page 23 FLOWSIC100 Flare-XT System description ASC technology (patented) – active sound correlation technology 3 . 5 If the ultrasonic signal is scattered due to extreme gas velocity, the ASC technology (active sound correlation technology) takes over. The ultrasonic transducer works like a microphone and correlates the strong noises at high flow rates to gas velocity.
Page 24 FLOWSIC100 Flare-XT Logbook and archives 3. 6 Logbook 3.6.1 The FLOWSIC100 Flare-XT stores certain relevant events in an event logbook with time stamp and counter reading. The following events are documented ● User logins ● Device status (information, maintenance, error) ●...
Page 25 FLOWSIC100 Flare-XT System description Table 1 Archive overview Archive Recording interval unit Content ● Actual volume flow ● Standard volume flow Hour(s) ● Mass volume Day(s) ● CO2 emission Week(s) ● Temperature Data archive A ● Pressure Month(s) ● Actual volume counter without and with ASC...
Page 26 System description FLOWSIC100 Flare-XT Endress+Hauser O P E R A T I N G I N S T R U C T I O N S 8029806/AE00/V2-4/2025-04...
Page 27 FLOWSIC100 Flare-XT Project planning FLOWSIC100 Flare-XT Project planning Overview Recommendations for the installation location of the FLSE100-XT sensors Determining the installation location of the Interface Unit Endress+Hauser O P E R A T I N G I N S T R U C T I O N S...
Page 28 Project planning FLOWSIC100 Flare-XT Overview 4. 1 The following Table provides an overview of the project planning work necessary as prerequisite for trouble-free assembly and subsequent device functionality. Task Requirements Work step Follow specifications for new equipment; Flow distribution, Lowest possible influence on the...
Page 29 FLOWSIC100 Flare-XT Project planning Recommendations for the installation location of the FLSE100-XT 4 . 2 sensors To ensure the best performance of the FLSE100-XT sensors, it is crucial to analyze the flow profile and determine the optimal measurement location. Key points to consider: 1 Fully developed flow: The device's uncertainty is defined under conditions of a fully developed flow profile.
Page 30 Project planning FLOWSIC100 Flare-XT Criteria Requirements Almost free of vibrations, maximum allowable vibration velocity 7 mm/s (rms) Largest possible distance to control valves or other noisy fixtures With electrical connections and lighting Special care should be taken on the recommended orientation of the sensors. Ensure that the measurement path is aligned with one of the following setups: ●...
Page 31 Larger wall thicknesses require customer-specific solutions (available on request only). ● Minimum wall thickness depends on pressure, temperature, pipe size and static/dynamic load Wall and insulation at the measurement location (contact Endress+Hauser for support). thickness Nozzles may only be isolated when the gas temperature is < 100 °C.
Page 32 Project planning FLOWSIC100 Flare-XT Installation location for external pressure and temperature transmitters (option) 4.2.3 Pressure tappings and thermowells for external transmitters have to be installed in the following way: ● Pressure tapping connection: Directly at the measuring point, centrally above the measuring path, on the top of the pipeline ●...
Page 33 For easier access to the Interface Unit, we recommend installation in a control room (measuring station or similar). This considerably simplifies communication with the FLOWSIC100 Flare-XT for configuration or location of failure or error causes.
Page 34 Project planning FLOWSIC100 Flare-XT Endress+Hauser O P E R A T I N G I N S T R U C T I O N S 8029806/AE00/V2-4/2025-04...
Page 35 FLOWSIC100 Flare-XT Installation FLSE100-XT FLOWSIC100 Flare-XT Installation FLSE100-XT Intended use Product description Installation Electrical installation Endress+Hauser O P E R A T I N G I N S T R U C T I O N S 8029806/AE00/V2-4/2025-04...
Page 36 Installation FLSE100-XT FLOWSIC100 Flare-XT Intended use 5. 1 FLSE100-XT sender/receiver units may only be used to measure the gas velocity, gas volume, mass flow and molecular weight in pipelines. Do not exceed the maximum permissible pressure and temperature values shown on the type plates of the FLSE100-XT sender/receiver units in operation.
Page 37 FLOWSIC100 Flare-XT Installation FLSE100-XT Hazard through electrical equipment 5.2.2 WARNING: Danger through main voltage ▸ Disconnect power supply lines before working on power connections or parts carrying main voltage. ▸ Refit any contact protection removed before switching the main voltage back on again.
Page 38 – With additional extraction tool: 8 bar (g) For information on the extraction tool, refer to the corresponding Operating Instructions (Part No. 8030464). Endress+Hauser recommends participating in a training for handling the extraction tool. ● Temperature range: For health and safety reasons (high/low temperatures), Endress+Hauser recommends only operating the retraction mechanism in the temperature range 0 °C ...
Page 39 FLOWSIC100 Flare-XT Installation FLSE100-XT Operation in potentially explosive atmospheres 5.2.6 Depending on the respective device version, the FLSE100-XT sender/receiver units are designed for use in potentially explosive atmospheres: Table 2 Device versions Version Approval IECEx ATEX NEC/CEC (USA/CA) F1F-S Ex db [ia Ga] IIA T4 Ga/Gb II 1/2G Ex db [ia Ga] IIA T4 Ga/Gb Class I, Division 1, Group D, T4;...
Page 40 Installation FLSE100-XT FLOWSIC100 Flare-XT Specific conditions of use (denoted by X after the certificate number) 5.2.6.1 NOTICE: The specific conditions mention devices that belong to the predecessor product and are not described in this document. Specific conditions for FLSE100-XT-S, FLSE100-XT-R, FLSE100-XT-M and FLSE100-XT-P ●...
Page 41 FLOWSIC100 Flare-XT Installation FLSE100-XT Use of FLSE100-XT, depending on the temperature code and process temperature 5.2.6.2 Installation and use of sender/receiver units - electronics and transducers parts in the same area This area is a hazardous area, i.e. Zone 1 or Zone 2 in which an explosive atmosphere exists under normal atmospheric conditions of: –...
Page 42 Installation FLSE100-XT FLOWSIC100 Flare-XT NOTICE: Observe the ambient temperature Be aware that the ambient air around the pipeline might heat up. ● The ambient temperature around the electronic housing may not exceed +70 °C for the sender/receiver unit marked with T4.
Page 43 FLOWSIC100 Flare-XT Installation FLSE100-XT Restrictions on use 5.2.9 WARNING: Hazard through pressure/temperature ▸ Use the FLSE100-XT sender/receiver units only within the pressure and temperature limits as specified in these Operating Instructions and on the device type plate. ▸ The selected materials must be resistant to the process gases. It is the responsibility of the plant operator to ensure this.
Page 44 Installation FLSE100-XT FLOWSIC100 Flare-XT Application limitations for use in Ex zone 1 ▸ Ultrasonic probes made of titanium may be used in Zone 1 only when risks of ignition arising from impacts or friction on the sensor enclosure can be ruled out.
Page 45 FLOWSIC100 Flare-XT Installation FLSE100-XT Product description 5 . 3 Product identification 5.3.1 Product name: FLSE100-XT Endress+Hauser SICK GmbH+Co. KG Bergener Ring 27 Manufacturer 01458 Ottendorf-Okrilla Germany Type plate Fig. 7 Type plate example FLSE100-XT-S Fig. 8 Type plate example FLSE100-XT-M...
Page 46 Installation FLSE100-XT FLOWSIC100 Flare-XT Fig. 9 Type plate example FLSE100-XT-H Fig. 10 Type plate example FLSE100-XT-P Endress+Hauser O P E R A T I N G I N S T R U C T I O N S 8029806/AE00/V2-4/2025-04...
Page 47 FLOWSIC100 Flare-XT Installation FLSE100-XT Sender/receiver units 5.3.2 Cross-duct Fig. 11 F1F-S (Active and passive sensor shown as examples) Sensor length 1 Pressure compensation element Retraction nozzle 2 Electronics unit Duct probe 3 T-connector Sensor contour 4 TNC connector (connection for passive sensor)
Page 48 Installation FLSE100-XT FLOWSIC100 Flare-XT Fig. 12 F1F-M (only active sensor shown) Sensor length 1 Pressure compensation element 6 Retraction nozzle 2 Electronics unit 7 Duct probe 3 T-connector 8 Sensor contour 4 TNC connector (connection for passive sensor) 9 Transducer 5 Self-cutting ring Fig.
Page 49 FLOWSIC100 Flare-XT Installation FLSE100-XT Probe version Fig. 14 F1F-P 1 Pressure compensation element 6 Retraction nozzle 2 Electronics unit 7 Duct probe 3 T-connector 8 Transducer 4 Pressure compensation element 9 Sensor contour 5 Self-cutting ring Endress+Hauser O P E R A T I N G I N S T R U C T I O N S...
Page 50 Installation FLSE100-XT FLOWSIC100 Flare-XT Material for wetted parts (parts with process gas contact) 5.3.3 Fig. 15 Parts with process gas contact Cross-duct versions F1F-S / -M / -H Probe version F1F-P 1 Pipe screw fitting 10 Duct probe 2 Threaded ring...
Page 51 Spool piece option 5 . 4 The FLOWSIC100 Flare-XT can also be fitted with an optional spool piece to reduce geometric uncertainty of device installation and to simplify assembly. The exact design (nominal diameter, connection, material) always depends on the customer specifications.
Page 52 Installation FLSE100-XT FLOWSIC100 Flare-XT Transport and storage 5. 5 Comply with permissible storage conditions ( p. 181, §12). Transport protection 5.5.1 To prevent transport damage, the FLSE100-XT sender/receiver units must be secured according to Fig. 17 before each transport. ▸...
Page 53 FLOWSIC100 Flare-XT Installation FLSE100-XT Lifting requirements WARNING: Danger due to size and mass of the spool piece ▸ Only use lifting gear and load handling equipment (e.g. lifting straps) which are suitable for the weight to be lifted. Max. load information can be found on the type plate of the lifting gear.
Page 54 Installation FLSE100-XT FLOWSIC100 Flare-XT Installation 5. 6 Safety information 5.6.1 WARNING: Risks during installation ▸ Observe the relevant safety regulations as well as the safety notices on  p. 13, §2 during all installation work. ▸ Carry out assembly work on equipment with hazard potential (hot or aggressive gases, higher internal pipeline pressure) only when the equipment is at a standstill.
Page 55 FLOWSIC100 Flare-XT Installation FLSE100-XT Scope of delivery 5.6.2 ▸ Check that delivery includes all ordered parts. ▸ Check parts for possible transport damage. Pay particular attention to transducer surfaces, sealing surfaces on the flanges and, if delivered, the interior of the spool piece.
Page 56 The exact wall thickness must be determined for precise calculation of the pipeline inner diameter. “Schedule” information from the applicable standards is less accurate than an exact measurement. The wall thickness must be determined accurately to 0.1 mm. Endress+Hauser recommends using a suitable ultrasonic measuring instrument to determine the wall thickness.
Page 57 FLOWSIC100 Flare-XT Installation FLSE100-XT Installation accessories 5.6.6 Sender/receiver units are fitted to the pipeline using the following material: as example) Fig. 20 Installation accessories (using ANSI CL150 Connection ANSI CL150 2" 1 Blind flange 5 Marking 2 Ball valve (only when sender/receiver units are to be...
Page 58 Installation FLSE100-XT FLOWSIC100 Flare-XT Nozzles, blind flanges and seals 5.6.6.1 Nozzles are delivered with factory adaption to the nominal pipe diameter, welding bevel and marking for nozzle alignment according to the gas flow. Fig. 21 Nozzle 1 Welding bevel 2 Marking...
Page 59 The ball valve serves for safe separation of the sender/receiver units from the process and is required when the sender/receiver units are to be dismounted during the process. Endress+Hauser recommends using a ball valve. Ball valves for various flange connections (Cl150, CL300, PN25 DN50) and temperature ranges) are available.
Page 60 FLOWSIC100 Flare-XT Nozzle installation tool 5.6.6.3 The installation tool serves to align and weld the nozzle on the pipeline. Endress+Hauser offers various nozzle installation tools depending on the nominal pipe diameter and path configuration. The nozzle installation tool contains, per nozzle ●...
Page 61 FLOWSIC100 Flare-XT Installation FLSE100-XT Fitting the nozzles on the pipeline (measuring system without spool piece option) 5.6.7 General preparation work 5.6.7.1 The installation tool ( p. 60, §5.6.6.3) contains a foil strip (length approx. 4 times the pipe diameter, width approx. 0.75 of the pipe diameter) as a resource to determine the exact position of the nozzle on the pipeline.
Page 62 Calculate probe offset a with the geometry calculator in FLOWgate 1 Start FLOWgate operating software. 2 Create a FLOWSIC100 Flare-XT off-line device. 3 Open the “Geometry calculator” tile in the “Change parameters” menu. 4 Select the “Cross-duct” device type. 5 Select whether the installation is a 1- or 2-path installation.
Page 63 FLOWSIC100 Flare-XT Installation FLSE100-XT U / 2 Path 1 Path 2 Fig. 26 Marking the nozzle positions on the pipeline for cross-duct versions 1-path measurement 2-path measurement 6) Roll the strip back around the pipeline and mark the nozzle positions with crossing and marking points by using a metal center punch.
Page 64 Installation FLSE100-XT FLOWSIC100 Flare-XT Determining the nozzle position for the probe version 5.6.7.3 Fig. 27 Determining the nozzle positions on the strip 1-path measurement 2-path measurement 1) Start preparation work as shown in  p. 61, Fig. 23. 4a) Roll the strip out again and mark the kink line.
Page 65 FLOWSIC100 Flare-XT Installation FLSE100-XT Fig. 28 Marking the nozzle position(s) on the pipeline for the probe version 1-path measurement 2-path measurement 6) Roll the strip back around the pipeline and mark the nozzle positions with crossing and marking points by using a metal center punch.
Page 66 Installation FLSE100-XT FLOWSIC100 Flare-XT WARNING: Qualified personnel required ● Any welding and installation work on pipelines may only be carried out by authorized personnel with a specific qualification. ● Special qualified and approved procedures have to be followed. This procedure requires the written agreement by the plant operator.
Page 67 “Technical data”, a sinking of the nozzles into the pipe wall or a distortion of the nozzles must be avoided. ▸ For cross-duct versions of FLOWSIC100 Flare-XT (F1F-S, F1F-M, F1F-H): – Determine the distance D1 between outer pipe wall and centering after a sufficient time for cooling down.
Page 68 Installation FLSE100-XT FLOWSIC100 Flare-XT Fig. 31 Determining the effective nozzle length (Nozzle) Centering ▸ Ball valves have to be installed when using retractable sender/receiver units. The ball valves are installed after finishing nozzle welding. ▸ Check and ensure gas tightness of ball valve installation before you continue.
Page 69 FLOWSIC100 Flare-XT Installation FLSE100-XT Drilling holes into the pipeline if plant is in operation (“hot tapping”) WARNING: Hazards during “hot tapping” When sender/receiver units are installed on the pipeline when the system is in operation (“hot tapping”): ▸ Only have this work done by skilled persons qualified for “hot tapping”.
Page 70 Installation FLSE100-XT FLOWSIC100 Flare-XT Fitting the sender/receiver units 5.6.8 WARNING: General risks during installation ▸ Observe and follow the valid regulations and safety regulations as well as the safety notices in  p. 36, §5.2. ▸ Take special precautions for plants with increased hazard potential (toxic/ aggressive/explosive gases, higher pressure, higher temperature).
Page 71 FLOWSIC100 Flare-XT Installation FLSE100-XT Using the centering sleeves The mounting kit for the sender/receiver units includes centering sleeves. The centering sleeves serve to ensure the centering of the process flanges of the sender/ receiver units. Fig. 33 Using the centering sleeves...
Page 72 Installation FLSE100-XT FLOWSIC100 Flare-XT Check the following points before installation ● Sender/receiver units to be fitted for a particular measuring point must belong to the same system to ensure the maximum measurement accuracy possible. Exchanging structurally identical sender/receiver units from different measuring systems is not allowed.
Page 73 ● Gasket thickness ● Ball valve length ● Wall thickness NOTICE: The wall thickness must be determined accurately to 0.1 mm. Endress+Hauser recommends using a suitable ultrasonic measuring instrument to determine the wall thickness. Start operating software FLOWgate 2 Create a FLOWSIC100 Flare-XT off-line device.
Page 74 Installation FLSE100-XT FLOWSIC100 Flare-XT Fig. 36 Installation of F1F-S, F1F-M, F1F-H (cross-duct versions) Endress+Hauser O P E R A T I N G I N S T R U C T I O N S 8029806/AE00/V2-4/2025-04...
Page 75 FLOWSIC100 Flare-XT Installation FLSE100-XT Fig. 37 Installation of F1F-P (probe version) Endress+Hauser O P E R A T I N G I N S T R U C T I O N S 8029806/AE00/V2-4/2025-04...
Page 76 Tightening the self-cutting ring 5.6.8.2 Endress+Hauser recommends that the correct setting of the wetted part length and tightening the cutting ring be carried out in a workshop before installation in the pipeline. Tightening the self-cutting ring in the correct position ensures the correct wetted part length for installation in the pipeline.
Page 77 FLOWSIC100 Flare-XT Installation FLSE100-XT Proceed as follows to set the wetted part length and to tighten the self-cutting ring: 1 Loosen the pipe screw fitting. The pipe screw fitting is screwed hand-tight at the factory. Loosen the pipe screw fitting completely to set the wetted part length.
Page 78 Fitting the venting valve 5.6.8.3 A venting valve is available as an option from Endress+Hauser (Part No. 2108210). Use a suitable valve with 1/8" NPT thread when the valve available from Endress+Hauser is not used. WARNING: Hazard through gas in the pipeline ▸...
Page 79 5 Completely loosen the pipe screw fitting. 6 Open the ball valve. WARNING: Danger due to gas leaks When gas escapes, close the ball valve again and contact Endress+Hauser Service. 7 Push the sender/receiver unit into the pipeline. 8 Check the gasket of the pipe screw fitting for damage.
Page 80 Installation FLSE100-XT FLOWSIC100 Flare-XT Observe when aligning the probe version Before securing the self-cutting ring fitting again, align probe version F1F-P correctly: The measuring path must be aligned in flow direction, i.e. the arrow shown must point in flow direction.
Page 81 FLOWSIC100 Flare-XT Installation FLSE100-XT Alignment of the device to the flow direction using a laser WARNING: Risk of explosion The laser may only be used if no Ex atmosphere is present. Use of the laser is not permitted under Ex conditions.
Page 82  Pull the sender/receiver units back and disconnect them from the process by closing the ball valve,  p. 83, §5.6.9.  Contact Endress+Hauser Service. Endress+Hauser O P E R A T I N G I N S T R U C T I O N S...
Page 83 FLOWSIC100 Flare-XT Installation FLSE100-XT Pulling the sender/receiver units back 5.6.9 WARNING: Hazard through incorrect use of the retraction mechanism ▸ Observe the information on activating the retraction mechanism,  p. 38, §5.2.5. 1 Completely loosen the cap nut of the self-cutting ring fitting, → Fig. 43.
Page 84 5.6.10 The weatherproof cover (Part No. 2105581) serves to shield the electronics of the sender/ receiver unit from sunlight and weather influences. NOTICE: Apart from the Endress+Hauser weatherproof cover, no other loads may be mounted on the devices. Overview 5.6.10.1 Fig.
Page 85 FLOWSIC100 Flare-XT Installation FLSE100-XT Fig. 45 Dimensions [mm] Endress+Hauser O P E R A T I N G I N S T R U C T I O N S 8029806/AE00/V2-4/2025-04...
Page 86 Installation FLSE100-XT FLOWSIC100 Flare-XT Fitting the weatherproof cover 5.6.10.2 1 Fasten the holder on the sender/receiver unit:  Fasten the holder with the pipe clip to the probe neck of the sender/ receiver unit using hexagon head screws with nuts and washers.
Page 87 5.7.1 All assembly work previously described must be completed (as far as applicable) before starting installation work. Unless otherwise agreed with Endress+Hauser or an authorized representative, all of the installation work must be carried out by the plant operator. This includes laying and connecting the power supply and signal cables and installing switches and power fuses.
Page 88 Installation FLSE100-XT FLOWSIC100 Flare-XT With a supply voltage of 24 V (as e.g. also from a mains-supplied Interface Unit) and a current consumption of 40 mA for a sender/receiver unit, the following maximum line resistance results:   24V 20V –...
Page 89 “Exi” or a blue cable cov- ering or with blue shrink sleeves on the cable ends or with the Endress+Hauser item num- ber, at least on the associated packaging. The technical safety data are shown in the Type Examination Certificate.
Page 90 Installation FLSE100-XT FLOWSIC100 Flare-XT Connection overview 5.7.5 Pin assignment in the terminal compartment of the sender/receiver units Fig. 46 Terminal compartment FLSE100-XT sender/receiver with electronics (active sensor) 1 Terminal compartment open 2 Grounding terminals Table 9 Connection of the sender/receiver units...
Page 91 FLOWSIC100 Flare-XT Installation FLSE100-XT Connection diagrams 5.7.6 Fig. 47 Cabling of the sender/receiver units Display connection Service RS485** gnd B A Higher level MCUP processor board control system (Interface Unit) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15...
Page 92 Installation FLSE100-XT FLOWSIC100 Flare-XT Endress+Hauser O P E R A T I N G I N S T R U C T I O N S 8029806/AE00/V2-4/2025-04...
Page 93 FLOWSIC100 Flare-XT Installation Interface Unit FLOWSIC100 Flare-XT Installation Interface Unit Intended use Safety information Product description Installation Electrical installation Endress+Hauser O P E R A T I N G I N S T R U C T I O N S...
Page 94 Installation Interface Unit FLOWSIC100 Flare-XT Intended use 6. 1 The Interface Unit is a device for recording, processing and transferring of measured values. For example, the Interface Unit can be used for controlling the sender/receiver units FLSE100-XT as well as for the calculation, evaluation, output and display of measured value data.
Page 95 FLOWSIC100 Flare-XT Installation Interface Unit Hazards through electrostatic discharges 6.2.4 The electronic housing is painted in the factory with a layer thickness of max. 0.2 mm. Special paintwork can have a higher layer thickness. WARNING: Ignition hazard through electrostatic discharge The plastic display surface dimensions of the display flap and of the display exceed the allowable value for ignition group IIC.
Page 96 ▸ Observe all safety information. ▸ If anything is not clear: Please contact Endress+Hauser Customer Service. Designated users All operators of the Interface Unit should be specifically trained on this device, knowledgeable of relevant regulations, and able to assess potential hazards related to its operation.
Page 97 FLOWSIC100 Flare-XT Installation Interface Unit Specific requirements for use of devices in hazardous areas ▸ Cabling/installation, device setup, maintenance and testing may only be carried out by experienced persons familiar with the rules and regulations for hazardous areas, in particular: –...
Page 98 FLOWSIC100 Flare-XT Product description 6. 3 Product identification 6.3.1 Product name: Interface Unit Endress+Hauser SICK GmbH+Co. KG Bergener Ring 27 Manufacturer 01458 Ottendorf-Okrilla Germany Type plate The type plate is located on the right side of the device. Fig. 48...
Page 99 FLOWSIC100 Flare-XT Installation Interface Unit Fig. 50 Type plate CSA Div 2 (example) Fig. 51 Type plate CSA Div 1 (example) Endress+Hauser O P E R A T I N G I N S T R U C T I O N S...
Page 100 Installation Interface Unit FLOWSIC100 Flare-XT Device versions 6.3.2 Fig. 52 Zone 2/Div. 2 resp. Non-Ex Fig. 53 Zone 1/Div. 1 Ex d Fig. 54 Zone 1/Div. 1 Ex d e Endress+Hauser O P E R A T I N G I N S T R U C T I O N S...
Page 101 FLOWSIC100 Flare-XT Installation Interface Unit Device components 6.3.3 Device components, Interface Unit, Zone 2/Div. 2 resp. Non-Ex 6.3.3.1 Fig. 55 Overview 1 Type plate Enclosure base 2 Display Pressure compensation element 3 Infrared interface Exterior ground terminal 4 Display flap...
Page 102 Installation Interface Unit FLOWSIC100 Flare-XT Fig. 56 Metric cable glands (optionally available with 9 cable glands) 1 Metric cable gland M20 2 Metric cable gland M25 3 Exterior ground terminal Fig. 57 Sealing plugs NPT (optionally available with 9 cable inlets) 1 Sealing plugs NPT 1/2"...
Page 103 FLOWSIC100 Flare-XT Installation Interface Unit Device components, Interface Unit, Zone 1/Div. 1 6.3.3.2 Fig. 58 Overview, Ex d and Ex d e 1 Type plate 4 Display flap 2 Display 5 Screw-on tabs 3 Infrared interface 6 Exterior ground terminal...
Page 104 Installation Interface Unit FLOWSIC100 Flare-XT Fig. 59 Overview, Ex d and Ex de - enclosure open Electronics cover 10 Cable inlets Enclosure base 11 Enclosure door /display flap) Cylinder screw Endress+Hauser O P E R A T I N G I N S T R U C T I O N S...
Page 105 FLOWSIC100 Flare-XT Installation Interface Unit Fig. 60 Ex d enclosure, sealing plugs, metric (optionally available with 9 sealing plugs) 1 Sealing plugs, metric, M20 2 Sealing plugs, metric, M25 3 Exterior ground terminal 4 Identification plates for thread size Fig. 61 Ex d enclosure, sealing plugs NPT, metric (optionally available with 9 sealing plugs) 1 Sealing plugs NPT 1/2"...
Page 106 Installation Interface Unit FLOWSIC100 Flare-XT Fig. 62 Ex d e enclosure, cable glands, metric (optionally available with 9 cable glands) 1 Metric cable gland M20 2 Metric cable gland M25 3 Exterior ground terminal 4 Identification plates for thread size...
Page 107 FLOWSIC100 Flare-XT Installation Interface Unit Device description 6.3.4 The Interface Unit is used for the acquisition, processing and output of measured values and serial data. A multitude of different digital, analog and serial sensors can be connected to the Interface Unit.
Page 108 Installation Interface Unit FLOWSIC100 Flare-XT The following interfaces are provided: ● 1 Ethernet interface (Modbus TCP) for the Standard variant 2 Ethernet interfaces (Modbus TCP) for the Extended variant ● 3 RS485 interfaces (Modbus RTU / ASCII) ● 1 RS232 interface, for firmware updates I/O module definition 6.3.5.2...
Page 109 FLOWSIC100 Flare-XT Installation Interface Unit Installation 6 . 4 Safety information 6.4.1 WARNING: Risks during installation ▸ Observe the safety information in  p. 94, §6.2. ▸ Observe and comply with regulations of the plant operator. Otherwise hazards are possible and safe operation is not ensured.
Page 110 Installation Interface Unit FLOWSIC100 Flare-XT Fitting the Interface Unit 6.4.4 Fit the Interface Unit in an easily accessible and protected position. Carry out all assembly work on-site. The following must be taken into account: ▸ Maintain the ambient temperature range in accordance with the Technical Data under consideration of possible radiant heat (shield when necessary).
Page 111 FLOWSIC100 Flare-XT Installation Interface Unit Wall fitting 6.4.4.1 NOTICE: ▸ Use suitable fixing material for mounting. ▸ Observe the total weight of the Interface Unit as well as local and legal regulations for the design of the wall construction and fastening material.
Page 112 Installation Interface Unit FLOWSIC100 Flare-XT Option “Mounting kit, 2-inch pipe mounting” 6.4.4.2 Part numbers for the “Mounting kit, 2-inch pipe mounting”, see  p. 206, §14.2. ▸ Use two round steel bows (1), associated nuts (2) and washers (3) to fasten installation plate (4) on the 2-inch pipe, →...
Page 113 FLOWSIC100 Flare-XT Installation Interface Unit Fig. 66 Fitting the Interface Unit on the installation plate Interface Unit Zone 2 Interface Unit Zone 1 Detail 2 Detail 2 Detail 2 Detail 2 Nut M10 DIN934 Washer B10.5 DIN125 Screw M10 DIN912...
Page 114 Installation Interface Unit FLOWSIC100 Flare-XT Fitting the weatherproof cover 6.4.5 Weatherproof cover for Interface Unit for wall fitting 6.4.5.1 NOTICE: The weatherproof cover for wall fitting (Part No. 2108970) is delivered without fastening material. ▸ Use suitable fastening material to fit the weatherproof cover on the wall.
Page 115 FLOWSIC100 Flare-XT Installation Interface Unit Fitting the Interface Unit on the weatherproof cover Fig. 69 Holes for fitting the Interface Unit Zone 1 Holes for fitting the Interface Unit Zone 2 Weatherproof cover for Interface Unit for fitting on a 2-inch pipe 6.4.5.2...
Page 116 Installation Interface Unit FLOWSIC100 Flare-XT Fitting the weatherproof cover on the installation plate Fig. 70 Interface Unit Zone 2 Interface Unit Zone 1 Detail Detail Detail Installation plate Nut M8 DIN934 Weatherproof cover Holes for fitting on the installation plate for Zone 2...
Page 117 FLOWSIC100 Flare-XT Installation Interface Unit Fig. 71 Fitting the Interface Unit on the weatherproof cover Holes for fitting the Interface Unit Zone 2 Holes for fitting the Interface Unit Zone 1 Fig. 72 Interface Unit, Zone 2, with weatherproof cover fitted...
Page 118 Installation Interface Unit FLOWSIC100 Flare-XT Fig. 73 Interface Unit, Zone 1, with weatherproof cover fitted Detail Screw M10 DIN912 Washer B10.5 DIN125 Nut M10 DIN934 Endress+Hauser O P E R A T I N G I N S T R U C T I O N S...
Page 119 FLOWSIC100 Flare-XT Installation Interface Unit Fitting the tag plate (available as option) 6.4.6 Two versions of the tag plate are available: ● As label The label with the tag number is already glued on at the factory when this variant is selected.
Page 120 Installation Interface Unit FLOWSIC100 Flare-XT – Use both longer screws for the Interface Unit with NPT cable entries (with flange plate): For fitting the tag plate, first unscrew two screws from the flange plate and replace these with the longer screws. Fit the contact disc with one of the two screws between the screw head and tag plate;...
Page 121 ▸ The user must ensure that the enclosure is suitably protected against danger from impacts or friction. This is particularly important when the FLOWSIC100 Flare-XT is installed in Zone 0 (see § 8.3 EN 60079-0). Endress+Hauser O P E R A T I N G I N S T R U C T I O N S...
Page 122 Installation Interface Unit FLOWSIC100 Flare-XT Cable specification 6.5.2 WARNING: Electrical hazard ▸ The cables and wires must be permanently installed. The plant operator must provide adequate strain relief. ▸ Cables must have a permitted operating temperature of min. 70 °C.
Page 123 FLOWSIC100 Flare-XT Installation Interface Unit Analog output Max. 30 VDC, max. 24 mA, recommended cable cross-section: min. 0.5 mm , twisted pair, shielded Analog input Max. 30 VDC, max. 24 mA, recommended cable cross-section: min. 0.5 mm , twisted pair,...
Page 124 Installation Interface Unit FLOWSIC100 Flare-XT Cable glands 6.5.3 NOTICE: Requirements for cable glands ▸ Pay attention to the requirements in EN 60079-14 when selecting the cable glands and during installation. ▸ For devices with Ex-approval, the cable entries must have the following Ex-approval: –...
Page 125 FLOWSIC100 Flare-XT Installation Interface Unit Requirements for installation in the Ex zone 6.5.4 WARNING: Dangerous voltage ▸ It must be ensured that the rated voltage U 60 V is not exceeded when connected to devices not belonging to the system, in particular external power supply devices, power supply units, etc.;...
Page 126 Installation Interface Unit FLOWSIC100 Flare-XT Electrical connections of the Interface Unit 6.5.5 Overview, electrical connections, Zone 2/Div 2 and Non-Ex 6.5.5.1 Fig. 77 Connection area and inner electronics of the Interface Unit Connection area Terminal blocks  p. 129, §80...
Page 127 FLOWSIC100 Flare-XT Installation Interface Unit Overview, electrical connections, Interface Unit Zone 1 6.5.5.2 Fig. 78 Connection area and internal electronics of the Interface Unit Zone 1 Ex d Connection area Terminal block  p. 129, §80 1 Mainboard, 6 Exterior ground terminal (connected with GND)
Page 128 Installation Interface Unit FLOWSIC100 Flare-XT Fig. 79 Terminal area and internal electronics, Interface Unit Zone 1 Ex d e Connection area Terminal blocks 1 Terminal blocks 2 Shielding terminals 3 Terminal assignment label, Ex d e terminal compartment 4 Exterior ground terminal (connected with GND)
Page 129 FLOWSIC100 Flare-XT Installation Interface Unit Fig. 80 Mainboard 1 Slots for I/O modules 1-6 7 Fuse F2 2 Field connections for I/O modules P4 - P9 – direct connec- 8 Field connection J2 – power supply connection of the inter-...
Page 130 Installation Interface Unit FLOWSIC100 Flare-XT Exterior ground terminal 6.5.5.3 Interface Unit Zone 2/Div. 2 Fig. 81 Protective ground connection 1 Contact disc (ensure correct alignment) 2 Line 3 Washer 4 Nut (torque: 6.0 Nm for M6) Interface Unit Zone 1/Div. 1 Fig.
Page 131 FLOWSIC100 Flare-XT Installation Interface Unit Terminal assignment 6.5.6 The pin assignment is shown on the sticker on the inside of the door: ● Device module configuration ● Connection area for field-side wiring ● Termination resistors of serial RS485 lines ● Identification of fuses and fuse characteristics Fig.
Page 132 Installation Interface Unit FLOWSIC100 Flare-XT Connection area for field-side wiring 6.5.7 For the exemplary wiring of a complete measuring point, e.g. connection of 1-path and 2- path sender/receiver units, see  p. 211, §15.2. Terminal block, Interface Unit for Zone 2 /Div. 2 resp. Non-Ex version 6.5.7.1...
Page 133 FLOWSIC100 Flare-XT Installation Interface Unit Terminal block, Interface Unit for Zone 1 Ex d 6.5.7.2 Fig. 86 Terminal block, Zone 1 Ex d Table 13 Terminal assignment of the terminal blocks Zone 1 Ex d Terminal Short name Function Comment...
Page 134 Installation Interface Unit FLOWSIC100 Flare-XT Overview of field connections mainboard and 115 ... 230 VAC power supply 6.5.7.3 Fig. 87 Field connections Plug/terminal Pin identification Function Comment Conductor size name Minus pole – DC, GND Power supply of electronic 0.5 … 1.5 mm...
Page 135 FLOWSIC100 Flare-XT Installation Interface Unit Plug/terminal Pin identification Function Comment Conductor size name P4 to P9 Directly connected to I/ 0.5 … 1.5 mm O module slots 1 to 6, example: P4 connected to slot 1 etc. Exact pin assignment depending on the mod- ule, see →...
Page 136 Installation Interface Unit FLOWSIC100 Flare-XT Fig. 88 AC configuration example (variant A) Fig. 89 DC configuration example (variant L) Endress+Hauser O P E R A T I N G I N S T R U C T I O N S...
Page 137 FLOWSIC100 Flare-XT Installation Interface Unit Connection assignment of I/O modules 6.5.8 Table 14 Signal definition of individual modules I/O module ident. Analog module type 1 Analog module type 2 Digital module type 1 Interface module (2AI/2AO) (2AO) (2DI/6DO) FOUNDATION Fieldbus...
Page 138 Installation Interface Unit FLOWSIC100 Flare-XT Electronics cover 6.5.9 Fig. 90 Electronics cover The electronics cover serves to protect the internal electronics from contamination. The labeling on the electronics cover refers to the module slots. Fig. 91 Electronics cover labeling Labeling...
Page 139 FLOWSIC100 Flare-XT Installation Interface Unit Switching (Open Collector - Namur) on digital modules 6.5.10 NOTICE: Electrical parameters, see Technical Data,  p. 187, §12.3 “Digital outputs”. Figure 92 DO circuitry (Open Collector - Namur) „OPEN COLLECTOR“ „NAMUR“ 10 k Termination resistors of serial RS485 lines 6.5.11...
Page 140 ● Fuse F1 - protection of the DC supply for the complete electronic unit Fuse characteristics: Manufacturer: Eska Fuses Part No.: 520.521 Endress+Hauser Part No.: 2104408 D5 * 20; 2.5 A; quick-blow; with extinguishing agent ● Fuse F2 - depending on variant for securing the AC supply line Fuse characteristics: Manufacturer: Eska Fuses Part No.: 522.722...
Page 141 FLOWSIC100 Flare-XT Installation Interface Unit Torque values for screw connections 6.5.13 All screw connections have to be tightened with a specific torque value: Table 15 Torque values Electrical connection Definition of torque value Terminal block 0.5 - 0.6 Nm Terminal P1 0.5 - 0.6 Nm...
Page 142 Installation Interface Unit FLOWSIC100 Flare-XT Connecting shielding terminals 6. 6 1 Strip the cable > 22 mm. > 22 mm 2 Leave a piece of the sheath in place to hold the wires together. As an alternative,  use a cable strap.
Page 143 FLOWSIC100 Flare-XT Installation Interface Unit 5 Ensure the insulation of the cable is not clamped under the shielding terminal.   6 Check that the cable is correctly seated.  Endress+Hauser O P E R A T I N G I N S T R U C T I O N S...
Page 144 Installation Interface Unit FLOWSIC100 Flare-XT Endress+Hauser O P E R A T I N G I N S T R U C T I O N S 8029806/AE00/V2-4/2025-04...
Page 145 FLOWSIC100 Flare-XT Commissioning FLOWSIC100 Flare-XT FLOWSIC100 Flare-XT Commissioning FLOWSIC100 Flare-XT General information Opening the display protective flap Setting the display language Commissioning with the FLOWgate operating software Field setup wizard Function checks after commissioning Endress+Hauser O P E R A T I N G I N S T R U C T I O N S...
Page 146 Commissioning FLOWSIC100 Flare-XT FLOWSIC100 Flare-XT General information 7. 1 ● Before commissioning, the sender/receiver units and the Interface Unit must be installed and electrically connected. ● The display language can be set directly on the device via the display,  p. 147, §7.3.
Page 147 FLOWSIC100 Flare-XT Commissioning FLOWSIC100 Flare-XT Interface Unit Zone 1/Div.1 The display protective flap of the Interface Unit Zone 1/Div. 1 is closed by a snap lock. ▸ Pull the handle to open the display protective flap. ▸ To close the flap, press on the plate next to the handle.
Page 148 A data connection can be established with the device using the optical data interface and the infrared/USB adapter HIE-04 (Part No. 6050602). This interface serves to configure the FLOWSIC100 Flare-XT. The infrared/USB adapter has a USB 2.0 interface. This interface provides the connection to the PC and transfers the FLOWSIC100 Flare-XT data.
Page 149 7 . 5 The field setup wizard leads step by step through the necessary parameterization of the FLOWSIC100 Flare-XT and ensures no important settings are forgotten. The respective parameters are written to the Interface Unit and the FLSE-XT sender/receiver unit after every step.
Page 150 Commissioning FLOWSIC100 Flare-XT FLOWSIC100 Flare-XT Fig. 100 Path setup (2-path installation) Identification 7.5.2 ▸ Compare the serial numbers with the type plates. ▸ Enter a device name: The device name is freely selectable. ▸ Enter the location. System/archives 7.5.3 Date and time ▸...
Page 151 FLOWSIC100 Flare-XT Commissioning FLOWSIC100 Flare-XT Installation 7.5.4 NOTICE: Systems consisting of Interface Unit, FLSE-XT sender/receiver units and spool piece are preconfigured at the factory. Do not change the configurations for these systems and skip the “Installation”.step. The dimensions of the components can be taken from the report generated during assembly.
Page 152 Commissioning FLOWSIC100 Flare-XT FLOWSIC100 Flare-XT Pressure/temperature sensor 7.5.5 ▸ Select source of pressure and temperature measured values. Table 16 Settings for connected pressure or temperature sensors Selection Parameter Description pT sensor settings Single One sensor connected Single/dual source Dual Two sensors connected...
Page 153 FLOWSIC100 Flare-XT Commissioning FLOWSIC100 Flare-XT I/O configuration 7.5.6 In the I/O configuration step, the parameters can be set for the interfaces available in accordance with the ordered configuration. Depending on the configuration, several modules of one type may be available.
Page 154 Selection Description Checkcycle active Check cycle of the sender/receiver units Warnings active Warnings are active on the FLOWSIC100 Flare-XT Alarms active Alarms are active on the FLOWSIC100 Flare-XT Flow direction of the gas; positive flow direction (0), return Flow direction flow (1) ●...
Page 155 ● Debounce: Debounce time (the time a digital input must be constant without status change) ● Alarm on error: In case of an error of the digital input, an error is displayed in the system status of the FLOWSIC100 Flare-XT ● Test mode: – Off: Test mode not active –...
Page 156 Commissioning FLOWSIC100 Flare-XT FLOWSIC100 Flare-XT FFBUS 7.5.6.5 The status of the FOUNDATION Fieldbus (FF) module is displayed. To view details of the status, click on the “?” symbol. Fig. 106 Status of the FOUNDATION Fieldbus module The FF-related configuration is necessary to read values from the device, e.g., node address and communication relationship of the FF blocks.
Page 157 Path velocity v, the mean value of the flow velocity on the sound path between the two sender and receiver units is determined with the FLOWSIC100 Flare-XT. Especially with small pipe diameters, this is not identical with the area velocity. The correction is done with a polynomial relation k Re CC 0 CC 4...
Page 158 Commissioning FLOWSIC100 Flare-XT FLOWSIC100 Flare-XT Volume flow rate at base conditions The volume flow rate is converted from operating conditions to base or standard conditions based on the gas equation Fig. 107 Calculation of the volume flow at base conditions ...
Page 159 The algorithm requires the adiabatic coefficient κ (mean value) as input value, . Velocity of sound and temperature can be measured by FLOWSIC100 Flare-XT. The algorithm is suitable for all ideal gases with pressures < 5 bar with constant gas composition.
Page 160 If the quantity of flow rate N is known, FLOWSIC100 Flare-XT can subtract this portion from the total quantity. Without this compensation, the purge air share with the measured molar mass of the combustible gases would be added to the total quantity of CO...
Page 161 FLOWSIC100 Flare-XT Commissioning FLOWSIC100 Flare-XT In the Setup wizard, you can select whether the nitrogen quantity should be configured as a constant value or read in via an analog input. Fig. 114 Nitrogen compensation Molar mass in ASC mode A value can be defined for the molar mass with active ASC technology. Either the last good value can be used or a fixed value can be configured.
Page 162 Typically, the CO emissions are determined according to a calculation model, which has also been directly implemented in the FLOWSIC100 Flare-XT. Since the measuring device provides an important calculation variable, the mass flow, the calculation of CO emissions can take place directly in the FLOWSIC100 Flare-XT.
Page 163 FLOWSIC100 Flare-XT Commissioning FLOWSIC100 Flare-XT Algorithm for the calculation of the Net Heating Value (NHV) 7.5.8.3 The volume-based net heating value (NHV) is calculated in operating software FLOWgate as of version 01.23.00 from the measured speed of sound, temperature and pressure.
Page 164 Commissioning FLOWSIC100 Flare-XT FLOWSIC100 Flare-XT User management 7.5.9 User management is only available via an Ethernet connection to the FLOWSIC100 Flare-XT. NOTICE: Endress+Hauser strongly recommends changing the initial password of the device. Please also check your local cybersecurity requirements that may apply.
Page 165 FLOWSIC100 Flare-XT Operation FLOWSIC100 Flare-XT Operation Operating concept Display and operating elements Display in the symbol bar Endress+Hauser O P E R A T I N G I N S T R U C T I O N S 8029806/AE00/V2-4/2025-04...
Page 166 Operation FLOWSIC100 Flare-XT Operating concept 8. 1 The Interface Unit display comprises an LCD display for measuring screens and configuring, 4 buttons for menu navigation and an area to attach an infrared/USB adapter (Part No. 6050602) for data communication. The readability of the display is limited at temperatures below -30°C. The display is poorly legible to not legible at all.
Page 167 FLOWSIC100 Flare-XT Operation Menu navigation 8 . 4 Path Format/unit (metric) Format/unit (imperial) Start settings Network Network status Connected/not connected Network interface IP x.x.x.x Subnet mask Gateway x.x.x.x Mac of onboard Eth. aa:bb:cc:dd:ee:ff Device setup System time dd.mm.yyyy time (format: 24 h)
Page 168 Operation FLOWSIC100 Flare-XT Status LEDs on the mainboard 8. 5 The Status LEDs are located at the bottom left on the mainboard, → Fig. 122. Fig. 122 Position of the Status LEDs Table 22 Status LEDs description Description Supply voltage present.
Page 169 FLOWSIC100 Flare-XT Maintenance FLOWSIC100 Flare-XT Maintenance Safety information General information Routine checks i-diagnostics Software-Plug-in (optional) Cleaning Exchanging the battery Endress+Hauser O P E R A T I N G I N S T R U C T I O N S...
Page 170 Endress+Hauser. These activities must be carried out by qualified persons as described in  p. 42, §5.2.8 and  p. 96, §6.2.7. If desired, Endress+Hauser Service or authorized Service support centers can carry out all maintenance work. Any repairs will be made by specialists on-site whenever possible.
Page 171 FLOWSIC100 Flare-XT Maintenance Function check on the display 9.3.1 If there is a warning or malfunction on the device, the corresponding symbol is shown on the display of the Interface Unit: Table 23 Symbols Symbol Significance Description Device status: Malfunction The device has an error, the measured value is invalid.
Page 172 Maintenance FLOWSIC100 Flare-XT Fig. 123 Validation certificate Trend analysis – predictive maintenance 9.4.2 It is also possible to carry out a trend analysis. With the trend analysis, evaluations of various measurement and diagnostic values at past observation points can be made.
Page 173 WARNING: Hazard for intrinsic safety due to incorrect spare parts Only PANASONIC batteries type BR2032 are permitted as RTC battery, otherwise intrinsic safety is endangered. The battery may only be replaced after a Service training by Endress+Hauser or by Endress+Hauser Service! Endress+Hauser...
Page 174 Maintenance FLOWSIC100 Flare-XT Endress+Hauser O P E R A T I N G I N S T R U C T I O N S 8029806/AE00/V2-4/2025-04...
Page 175 FLOWSIC100 Flare-XT Troubleshooting FLOWSIC100 Flare-XT Troubleshooting Detecting malfunctions Error signaling on the display Contacting Customer Service Starting a diagnostic session Endress+Hauser O P E R A T I N G I N S T R U C T I O N S...
Page 176 Pending errors or warnings are signaled on the display,  p. 170, §9.3. Contacting Customer Service 10 . 3 Contact Endress+Hauser Customer Service for any malfunctions you cannot clear yourself. To help Customer Service to understand malfunctions that have occurred, the...
Page 177 FLOWSIC100 Flare-XT Troubleshooting Fig. 126 Diagnostic recording completed 4 Click “OK” to confirm the message. 5 Select the storage location for the diagnostic session: – Click “Close” to leave the file at the standard storage location. – Click “Save as” to select a storage location for the diagnostic recording.
Page 178 Troubleshooting FLOWSIC100 Flare-XT Endress+Hauser O P E R A T I N G I N S T R U C T I O N S 8029806/AE00/V2-4/2025-04...
Page 179 FLOWSIC100 Flare-XT Decommissioning FLOWSIC100 Flare-XT Decommissioning Safety information on decommissioning Returning Disposal information Endress+Hauser O P E R A T I N G I N S T R U C T I O N S 8029806/AE00/V2-4/2025-04...
Page 180 11 . 3 Materials 11.3.1 ● The FLOWSIC100 Flare-XT mainly consists of steel, aluminum and plastic materials. ● It does not contain any toxic, radioactive or other environmentally harmful substances. ● Substances from the pipeline can possibly penetrate, or deposit on seals.
Page 181 FLOWSIC100 Flare-XT Technical data FLOWSIC100 Flare-XT Technical data System FLOWSIC100 Flare-XT FLSE100-XT sender/receiver units Interface Unit Dimension drawings Endress+Hauser O P E R A T I N G I N S T R U C T I O N S...
Page 182 Only the metrological parameters described in the Application Evaluation Datasheet apply. If the delivery documentation of your FLOWSIC100 Flare-XT does not include an Application Evaluation Datasheet, contact your Endress+Hauser partner! Example of an Application Evaluation Datasheet:  p. 191, §12.4...
Page 183 FLOWSIC100 Flare-XT Technical data Depending on the capabilities of the selected flow test rig. Additional uncertainty of measurement. In the range of 100% ... 130% of the last gas velocity measured with ultrasonic transit time difference measurement . FLSE100-XT sender/receiver units 1 2.
Page 184 Technical data FLOWSIC100 Flare-XT F1F-S 12.2.1 Table 27 Technical data F1F-S Measuring conditions Operating pressure: CL150 device flange: 20 bar (g) PN25 device flange (optional): 20 bar (g) CL300 device flange (optional). 20 bar (g) Gas temperature –196 °C ... +280 °C...
Page 185 FLOWSIC100 Flare-XT Technical data F1F-M 12.2.2 Table 28 Technical data F1F-M Measuring conditions Operating pressure: CL150 device flange: 20 bar (g) PN25 device flange (optional): 20 bar (g) CL300 device flange (optional). 20 bar (g) Gas temperature –196 °C ... +280 °C...
Page 186 Technical data FLOWSIC100 Flare-XT F1F-P 12.2.4 Table 30 Technical data F1F-P Measuring conditions Operating pressure: CL150 device flange: ATEX/IECEx: 20 bar(g) CSA: 16 bar(g) PN25 device flange (optional): ATEX/IECEx: 20 bar(g) CSA: 16 bar(g) CL300 device flange (optional): ATEX/IECEx: 20 bar(g)
Page 187 FLOWSIC100 Flare-XT Technical data Interface Unit 1 2. 3 Table 31 Technical data of Interface Unit Ambient conditions Ambient temperature -40 °C … +60 °C -40 °C … +65 °C optional (maximum number of I/O interfaces available is limited) Storage temperature -40 °C ...
Page 188 Technical data FLOWSIC100 Flare-XT ✔ Serial RS232 Quantity: 1 For firmware updates Supported signals: TXD, RTS, RXD, CTS, COM Data protocol: Modbus RTU/ASCII Baud rate: 2400…57600 (default: 9600) ✔ HART ® HART ® -compatible Host (for connection of external pressure and temperature sensors) ®...
Page 189 FLOWSIC100 Flare-XT Technical data Digital outputs Switching output Optionally configurable as digital input 2 per module, up to 6 available when using I/O modules Electrically isolated Max. current: 70 mA Max. switching frequency: 50 Hz Max. input voltage: 30 V DC...
Page 190 Technical data FLOWSIC100 Flare-XT Output supply voltage - 24V-OUT (to supply external sensors) AC version DC version Output voltage 24 VDC ± 5% Equivalent to supply voltage of the Interface Unit, no internal filtering Max. power output ≤ 2 W Depending on external supply ≤...
Page 191 FLOWSIC100 Flare-XT Technical data Application Evaluation Datasheet (example) 1 2. 4 Application Evaluation Datasheet Page 1 (example) Fig. 128 Endress+Hauser O P E R A T I N G I N S T R U C T I O N S...
Page 192 Technical data FLOWSIC100 Flare-XT Application Evaluation Datasheet Page 2 (example) Fig. 129 Endress+Hauser O P E R A T I N G I N S T R U C T I O N S 8029806/AE00/V2-4/2025-04...
Page 193 When correctly designed and applied, Endress+Hauser's ultrasonic flow technology meets or exceeds most regulatory performance requirements. Please contact your Endress+Hauser representative to find out about the right flare measurement solution that meets the currently applicable regulatory requirements. Application limits 1 2. 6 Fig.
Page 194 Technical data FLOWSIC100 Flare-XT Fig. 131 with 20% uncertainty of 1-path and 2-path solutions depending on the speed of sound (SOS) Welded / dry calibrated / flow calibrated 0.19 0.18 0.17 0.16 0.15 0.14 0.13 0.12 0.11 0.10 0.09 0.08 0.07...
Page 195 FLOWSIC100 Flare-XT Technical data Derating pressure resistance 1 2. 7 NOTICE: The diagrams apply to the standard variants of the FLSE100-XT sender/ receiver units. Deviations in other versions are possible. Observe the maximum permissible design values shown on the type plates of the devices.
Page 196 Technical data FLOWSIC100 Flare-XT Fig. 135 F1F-P 38 °C 100 °C -200 -150 -100 Temperature [°C] Temperature [°C] F1F-P (ATEX) F1F-P (CSA) F1F-P (ATEX) F1F-P (CSA) Endress+Hauser O P E R A T I N G I N S T R U C T I O N S...
Page 197 FLOWSIC100 Flare-XT Technical data Dimension drawings 1 2. 8 Dimension drawings of FLSE100-XT sender/receiver units 12.8.1 Dimensions for F1F-S/-M/-H CL150, 2" Fig. 136 F1F-S/-M/-H Pushed-in position Withdrawn position Table 32 Extended version FLSE100-XT Dimensions of extended version F1F-S 1055.5 F1F-M...
Page 198 Technical data FLOWSIC100 Flare-XT Dimensions for F1F-P, CL150, 2" Fig. 137 F1F-P 1508 Pushed-in position 1527 Withdrawn position Endress+Hauser O P E R A T I N G I N S T R U C T I O N S...
Page 199 FLOWSIC100 Flare-XT Technical data Dimension drawings Interface Unit 12.8.2 Interface Unit Zone 2/Div 2 resp. Non-Ex version Fig. 138 Interface Unit Zone 2 (dimensions in mm (in)) (14.09) (13.15) (12.05) (7.99) Fig. 139 Interface Unit Cl. 1 Div. 2 (dimensions in mm (in)) (14.09)
Page 200 Technical data FLOWSIC100 Flare-XT Interface Unit Zone 1/Div 1 Fig. 140 Interface Unit Zone 1 Ex d (dimensions in mm (in)) Fig. 141 Interface Unit Zone 1 Ex d e (dimensions in mm (in)) 293 (11.54) 245 (9.65) Endress+Hauser O P E R A T I N G I N S T R U C T I O N S...
Page 201 FLOWSIC100 Flare-XT Spare parts FLOWSIC100 Flare-XT Spare parts Recommended spare parts for FLSE100-XT sender/receiver units Recommended spare parts for Interface Unit Endress+Hauser O P E R A T I N G I N S T R U C T I O N S...
Page 202 Spare parts FLOWSIC100 Flare-XT Recommended spare parts for FLSE100-XT sender/receiver units 13 . 1 Part No. Description 2108048 Assembly kit ANSI150 2Z SS ET 2108049 Assembly kit ANSI300 2Z SS ET 2108050 Assembly kit DN50 PN16 M16 SS ET Replacement cover for aluminum EXD M20 housing...
Page 203 FLOWSIC100 Flare-XT Spare parts Recommended spare parts for Interface Unit 1 3. 2 Interface Unit, Zone 2/Div. 2 13.2.1 Part No. Description Fuse kit mainboard 2104408 – for all Interface Units with 24 V DC power supply – 2A5 250V D5*20...
Page 204 Spare parts FLOWSIC100 Flare-XT Interface Unit, Zone 1/Div. 1 13.2.2 Part No. Description Fuse kit mainboard 2104408 – for all Interface Units with 24 V DC power supply – 2A5 250V D5*20 Fuse kit power supply 2105350 – for all Interface Units with 115/230 VAC power supply –...
Page 205 Accessories for Interface Unit Further accessory parts (cable screw fittings, ball valves, nozzles, etc.) are available on request from Endress+Hauser Endress+Hauser O P E R A T I N G I N S T R U C T I O N S...
Page 206 Accessories (optional) FLOWSIC100 Flare-XT Accessories for FLSE100-XT sender/receiver units 14 . 1 Part No. Description Weather/sun protective cover for electronics of the active 2105581 ultrasonic sensor 2108210 Venting/drain valve for ultrasonic sensor Accessories for Interface Unit 14 . 2 Part No.
Page 207 FLOWSIC100 Flare-XT Annex FLOWSIC100 Flare-XT Annex Compliances Installation examples Connection diagrams Type code Relationship between IECEx marking and Interface Unit Gasket installation Endress+Hauser O P E R A T I N G I N S T R U C T I O N S...
Page 208 Annex FLOWSIC100 Flare-XT Compliances 15 . 1 NOTICE: Applied European standards and harmonized standards are listed in the valid version of the manufacturer‘s CE conformity declaration. Compliances of FLSE100-XT sender/receiver units 15.1.1 CE declaration 15.1.1.1 The FLSE100-XT sender/receiver units have been developed, built and tested according to the following EU Directives: ●...
Page 209 FLOWSIC100 Flare-XT Annex Compliances of Interface Unit 15.1.2 CE declaration 15.1.2.1 The Interface Unit has been developed, manufactured and tested in accordance with the following EU Directives: ● ATEX Directive 2014/34/EU ● EMC Directive 2014/30/EC Conformity with the above Directives has been determined and the CE label attached to the device.
Page 210 Annex FLOWSIC100 Flare-XT Interface Unit Zone 1 resp. Div. 1 The Interface Unit Zone 1 resp. Div. 1 version conforms to the following standards or recommendations: ● CAN/CSA-C22.2 No. 0-10 (r 2015) ● CSA C22.2 No. 213/ISA 12.12.01: 2017 ● CAN/CSA C22.2 No. 94.1-15 Second Edition & ANSI/UL 50-15 (Edition 13) ●...
Page 211 FLOWSIC100 Flare-XT Annex Installation examples 1 5. 2 Fig. 142 Interface Unit Zone 2 AC version (example) Endress+Hauser O P E R A T I N G I N S T R U C T I O N S 8029806/AE00/V2-4/2025-04...
Page 212 Annex FLOWSIC100 Flare-XT Fig. 143 Interface Unit Zone 2 DC version (example) Endress+Hauser O P E R A T I N G I N S T R U C T I O N S 8029806/AE00/V2-4/2025-04...
Page 213 FLOWSIC100 Flare-XT Annex Fig. 144 Interface Unit Zone 1 AC version (example, Ex d version; see delivery documentation for Ex d e versions) Endress+Hauser O P E R A T I N G I N S T R U C T I O N S...
Page 214 Annex FLOWSIC100 Flare-XT Fig. 145 Interface Unit Zone 1 DC version (example, Ex d version; see delivery documentation for Ex d e versions) Endress+Hauser O P E R A T I N G I N S T R U C T I O N S...
Page 215 FLOWSIC100 Flare-XT Annex Connection diagrams 1 5. 3 Fig. 146 Connection diagrams, FLSE-XT (page 1 of 5) Endress+Hauser O P E R A T I N G I N S T R U C T I O N S 8029806/AE00/V2-4/2025-04...
Page 216 Annex FLOWSIC100 Flare-XT Fig. 147 Connection diagrams, FLSE-XT (page 2 of 5) Endress+Hauser O P E R A T I N G I N S T R U C T I O N S 8029806/AE00/V2-4/2025-04...
Page 217 FLOWSIC100 Flare-XT Annex Fig. 148 Connection diagrams, FLSE-XT (page 3 of 5) Endress+Hauser O P E R A T I N G I N S T R U C T I O N S 8029806/AE00/V2-4/2025-04...
Page 218 Annex FLOWSIC100 Flare-XT Fig. 149 Connection diagrams, FLSE-XT (page 4 of 5) Endress+Hauser O P E R A T I N G I N S T R U C T I O N S 8029806/AE00/V2-4/2025-04...
Page 219 FLOWSIC100 Flare-XT Annex Fig. 150 Connection diagrams, FLSE-XT (page 5 of 5) Endress+Hauser O P E R A T I N G I N S T R U C T I O N S 8029806/AE00/V2-4/2025-04...
Page 220 Annex FLOWSIC100 Flare-XT Type code 15 . 4 Type code, FLSE-XT, sender/receiver units 15.4.1 Fig. 151 FLSE-XT, sender/receiver units (overview) 1 Ultrasonic sensor 2 Meter layout 3 Meter length 4 Ex approval 5 Ex classification / temperature class 6 Sensor electronics...
Page 221 FLOWSIC100 Flare-XT Annex Fig. 152 FLSE-XT, sender/receiver units (explanation) Ultrasonic sensor 13 Sensor contour material FLSE100-XT Stainless steel Meter layout PTFE 14 Sensor retraction Cross-duct H Retractable Cross-duct M 15 Sensor process connection Cross-duct S ASME B16.5, CL150 2" RF Probe ASME B16.5, Cl150 3"...
Page 222 Annex FLOWSIC100 Flare-XT Type code, Interface Unit 15.4.2 Fig. 153 Type code, Interface Unit (overview) 1 Device type 2 Ex approval 3 Ex classification 4 Material electronics housing 5 Painting electronics housing 6 Cable entries 7 Display 8 Terminal 9 Tropicalization...
Page 223 FLOWSIC100 Flare-XT Annex Fig. 154 Type code, Interface Unit (explanation) 13 Analog Module Type 1 (2AI+2AO+2HA) Device type Flare-XT Interface Unit 1 x Analog Module Type 1 (2AI+2AO+2HA) Ex approval 2 x Analog Module Type 1 (2AI+2AO+2HA) ATEX/IECEx/UKEX 3 x Analog Module Type 1 (2AI+2AO+2HA)
Page 224 Annex FLOWSIC100 Flare-XT Relationship between IECEx marking and Interface Unit 15 . 5 Fig. 155 Interface Unit Zone 1 Ex d IIC T4 Gb Ex ia Electronics Display Interconnection Ex ia Display Unit Ex db Enclosure Ex db Field Wiring...
Page 225 FLOWSIC100 Flare-XT Annex Gasket installation 1 5. 6 Fig. 158 Gasket installation (developed by ”pikotek”) Endress+Hauser O P E R A T I N G I N S T R U C T I O N S 8029806/AE00/V2-4/2025-04...
Page 226 Annex FLOWSIC100 Flare-XT Fig. 159 Gasket installation (developed by ”pikotek”), screw tightening torques for comb profile gasket B9A and polymer gasket GYLON Endress+Hauser O P E R A T I N G I N S T R U C T I O N S...
Page 227 FLOWSIC100 Flare-XT Annex Endress+Hauser O P E R A T I N G I N S T R U C T I O N S 8029806/AE00/V2-4/2025-04...
Page 228 8029806/AE00/V2-4/2025-04 www.addresses.endress.com...

Endress+Hauser FLOWSIC100 Flare-XT Operating Instructions Manual

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