. FCI FLT93 Specifications

User Manual: FCI FLT93 Specifications

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The FLT ® 93 Series with FlexSwitch ® Technology

FCI’s FLT93 Series Switches with FlexSwitch technology represent
the first true technological advance in flow, level, and temperature
sensing and switching in over a decade. A single instrument, easily
field-configured or factory preset, provides unparalleled accuracy,
flexibility, and stability for most flow, level, and temperature sensing
and switching needs.

control circuit satisfies virtually any combination of application
requirements. The FlexSwitch technology can be packaged to meet
most integral, remote, and rack mounted configurations.
Precise Performance Accuracy Leveraged from FCI’s fieldproven thermal dispersion experience, the unique sensor technology
of the FLT93 Series Switches, combined with FlexSwitch temperature compensation circuitry, introduces unparalleled performance
capabilities:
 Exclusive flow accuracy as precise as ±2% of the setpoint
velocity over a ±50°F [±28°C] temperature range;
repeatability of ±0.5% reading.
 Level resolution of ±0.1 inch [±0.5 cm]; repeatability of
±0.05 inch [±0.3 cm].
 Standard temperature accuracy ±2.0°F [±1°C]; repeatability
±1.0˚F [±0.6˚C]. Improved temperature accuracy is available
with factory calibration.
Integrated Technologies–Advanced FlexSwitch Circuitry

Rack or Socket Mounted Control Circuit Electronics

Standardization This sensing and switching breakthrough is

achieved in the FLT93 Series Switches by combining a new, highly
accurate, all-welded sensing element with an advanced, user-friendly
FlexSwitch control circuit.
Sensing Element. Two standard sensing element configurations are
available to meet your most demanding application requirements.
The FLT93-S is designed for use in standard heavy industrial applications and in applications with high velocity liquid setpoint requirements; the FLT93-F is designed for fast response gas applications.
Both sensing elements can be supplied in either standard (-40°
to +350°F [-40° to +177°C]) or medium (-100° to +500˚F [-73° to
+260°C]) temperature configurations. The FLT93-S is also available in
a high temperature (-100° to +850°F [-73° to +454°C]) configuration.
Control Circuit. One standardized, field-configurable FlexSwitch

Available in both standard socket mount or optional rack mount
configurations, FCI’s fail-safe, dual alarm (SPDT) control circuit
provides the FLT93 Series Switches with unmatched field flexibility
and user-friendliness. The FlexSwitch control circuit also provides
the exclusive advantage of one switch that offers the following fieldselectable features:
 Dual, independent SPDT relays for the following alarm
combinations:
– Flow rate and temperature
– High flow and low flow
– Point level and temperature
– Flow rate and low liquid level
– Three-phase level interface
– Fail-safe flow, level, or temperature
 One DPDT relay for single alarm of flow rate, liquid level or
temperature is optionally selectable
Application Flexibility

Easy Field or Factory Preset Configurations. FlexSwitch circuit
features are easily enabled and can be selected either in-situ or
factory preset. Selections include the following:
FLT93-S and FLT93-F Insertion FlexSwitch

Sensing Element Feature Highlights
 No moving parts
 All welded design
 Exotic materials

FLT93-F and FLT93-S Sensing Elements

FLT93-S
 Designed for heavy industrial
environments
 High liquid flow rate sensitivity
 High temperature service
 Retractable packing glands

FLT93-F
 Faster response
 Small process connection
Control Circuit Feature Highlights
 Temperature compensation
 Analog output voltage for flow and temperature
 Calibration mode switch to simulate alarm setpoint
 Fail-safe setup
 Dual alarm, each with SPDT relay/ DPDT optional
 Field selected input power

FLT93-C Sanitary Insertion FlexSwitch

Delivering the same field-tested performance
and reliability as the FLT93-S and F, The FLT93-C
is built to comply with the stringent 3A Sanitary
and general sanitary requirements of the Food,
Beverage, Pharmaceutical and Chemical indutries.

Flow Ranges for FLT93S, FLT93F, or FLT93C
Water-Based Liquids

Hydrocarbon-Based Liquids

Gases

.01

.1

Common Applications
 Pump protection
 Additive verification
 Gas/steam injection monitoring
 Analyzer flow monitoring
 Syrup flow monitoring
 Low flow detection
 Level/Interface

The instrument’s no moving parts design
makes it ideal for monitoring the flow of syrups,
fillings and other viscous media and product
slurries. The FLT93-C is suitable for both
clean-in-place and steam-in-place applications.

FLT93-C Sanitary Sensing Element

.001

Control Circuit Feature Highlights
 Refer to FLT93-F and S on previous page

1

10

100

1000

Typical Monitoring Applications
 High/low pump flow
 Relief valve and flare gas flow or leakage detection
 HVAC flow monitoring
 Monitoring heat exchanger and filter fouling
 Drain line flow detection
 Pump seal leak and lubricant detection
 Wet /dry and sump seal detection
 High/low level alarm and control
 Interface control in separation vessels
 High and low temperature alarm

Velocity (ft./sec.) For meters per second, multiply by 0.3048

Typical Liquid Flow Curves

Typical Level and Interface Output Signals
7

Note: Output signal will vary with heater power selection.

30 wt. Oil
Output Signal (DC volts)

Output Signal (DC volts)

6

3
Air

5
4
3

30 wt.
Oil

Detergent
Foam

Demineralizer/
Resin Slurry
Diesel

2

Kerosene
Water

2

Water
1

1
0

0.01

0.1

1

10

Velocity (ft./sec.) For meters per second, multiply by 0.3048

The “Temperature Compensated Flow Curves” graph (right)
illustrates how “temperature compensated” flow switches will
not experience signal drift during temperature changes. Whereas
a “non-temperature compensated” flow switch experiences signal
drift (as indicated by the red arrow) causing alarm failure.

Temperature Compensated Flow Curves
2.00

51˚F [10.6˚C]
76˚F [24.4˚C]
139˚F [59.4˚C]

1.75

Voltage Output, Vdc

Accuracy and Temperature Compensation FLT93 Series
switches are “precision temperature compensated” to insure
the accuracy of factory and field set alarms when installed
in dynamic process applications. Accuracy combined with
temperature compensation results in:
 Preventing false alarms or alarm failure
 Maximizing operator and process safety
 Having the option to set alarms within a narrow set point range

1.50

signal drift
without temperature
compensation

1.25

1.00

signal stability
with temperature compensation
0.75
0

1

2

3

4

Velocity (ft./sec.) For meters per second, multiply by 0.3048

5

Field Selectable Feature

Advantage/Benefit

5294 Control Circuit Functional Diagram

Input Power Jumpers

Maximizes voltage source flexibility
and emergency power operations.
Application / Heater Power Optimizes signal level or best
Selection Jumpers
configuration for changing application conditions.
Relay Configuration
Enables easy field selection of
and Logic Jumpers
SPDT or DPDT configurations
and relay energization modes.
Calibrate /Operate Mode
Selects field verification, pre-check,
calibration or general operation
modes.
Maximized Instrument Life Simple reconfiguration allows
the instrument to be further utilized in new service applications or
easily adjusted as specific application requirements change.

Sensing
Element
Reference
RTD

Active
RTD
Heater

9

8
7

1
0

Input Power 1
2

1

Sensor
Current
Source

Temp Comp
Adjustment

Power
Supply &
Selector

2

5

3

Calibration
Switch

Signal
Conditioner

Heater Power
Selector/
Temp Control

Alarm Setpoint 1
Adjustment

Flow/Level or
Temperature
Selector

Calibration
Adjustment

Out +
Out Temp +
Temp -

6 NC2

4 4 NO2
5 COM2

1
Alarm Setpoint 2
Adjustment

2

5

11 NC1

3
1
2
3
4

4

12 NO1
3 COM1

Operation Verification and /or Pre-Check Alarm setpoint

and fail-safe verification is easily performed before installation or
in-situ. The dual alarms are field-configured to fail-safe when
used exclusively for flow rate, liquid level, or temperature alarm.
Resulting from FCI’s historically proven durability, pre-check
capability and fail-safe operation, operators will be protected
from any unforeseen failure. This combination of features gives
the FLT Series Switches unrivaled reliability. Setpoints may be
configured to provide failure information of sensing element
assembly as well as control circuit electronic failure.

Simple, Accurate, Field Set Alarms Field calibrations and set-

point adjustments are easily performed. Voltage readings at critical
setpoint values can easily be recorded for reference purposes or
for optimized monitoring.
Field Selectable Input Power The FLT93 Series’ FlexSwitch
circuit is field configurable for compatibility with the most commonelectrical power. Selection of 24 Vdc, 115 Vac or 230 Vac by
simple jumper selection is a standard feature.

FLT93-L Inline FlexSwitch

Sensing Element Feature Highlights
 Ideal for extremely low flow
(down to .015 cc/sec)
 316L stainless steel or Hastelloy C-276
wetted parts, all welded.
 Process temperatures to 500°F [+260°C]
 Process pressures to 2000 psig [138 bar(g)]
 Temperature compensation results in accurate and stable setpoints and output signals.
 Hazardous location system approvals: FM,
CSA, CENELEC, CE Mark and CRN.

FLT93-L Inline Sensing Element

Control Circuit Feature Highlights
 Refer to FLT93-F and S on previous page
Common Applications
 Chemical additive verification
 Coolant and lubrication seal leakage
 Lube flow detection
 Seal water flow
 Analyzer flow detector
 Air flow purge monitoring
 Spray nozzle monitoring

Setpoint Adjustment Ranges for Typical Media
FO

S

Water

FO
F

Sensing Element
Configurations2
FO=F-style sensors with orifice*
F =F-style sensors without orifice
SO=S-style sensors with orifice*
S =S-style sensors without orifice

SO
S
FO

Motor Oil

Media at ambient temperature

Air

F
SO

*0.094 inch (2.4 mm) orifice diameter

F
SO

Conversion Factors
To Convert
gal/min
gal/min
gal/hr
gal/day
gal/day
L/min
L/hr
L/hr
L/day
33
ftft /min
/min
m3/hr

into

cc/sec

Multiply By
63.1
1.05
0.0438
16.7
0.278
0.0116
472.0
278.0

S

.01

0.1

1.0

10

Flow Rate (cc/second)

100

1,000

10,000 20,000

FlexSwitch FLT93 Series General Specifications
Application
Flow rate and /or level /interface and temperature sensing in liquid,
gas and slurry applications.
Sensing Elements
 Process Connection
Models S and F
3/4 inch male NPT standard; optional 1 inch BSP, 1 inch male
NPT, 3/4 inch Male NPT (FLT93-F only); flanges, spool pieces,
sanitary fittings or retractable sensing element optional.
Model L
1 inch male NPT or 3/4 inch female NPT, both ends with orifice;
flanges optional.
Model C
Sanitary flange
 Insertion Length
Models S and F
Available in standard lengths of 1.2 inch [30 mm], 2 inches
[51 mm], 4 inches [102 mm], 6 inches [152 mm], 9 inches
[229 mm], 12 inches [305 mm], 18 inches [457 mm] and
custom-specified lengths.
Model L
3.375 inch [86 mm] in-line body length
Model C
Please see chart on outline dimensional.
 Sensing Element

Models S and F
All wetted surfaces are 316L stainless steel with all-welded
construction. Hastelloy C, Monel 400, electro-polished
stainless steel and titanium (FLT93-S only) are optionally
available. Other spray coatings are available on special
request (i.e., tantalum, chromium carbide).
Model L
All wetted surfaces are 316L stainless steel with all-welded
construction. Hastelloy C, Monel 400 and titanium are
optionally available.
Model C
All wetted surfaces are 316L stainless steel with all-welded
construction electro-polished to 20 Ra.
 Operating Temperature

Sensing Element:
All Models
Standard temperature configuration:
-40° to +350°F [-40° to +177°C]
Medium temperature configuration:
-100° to +500°F [-73° to +260°C]
Model S Only
High temperature configuration:
-100° to +850°F [-73° to +454°C]
Control Circuit:
All Models
Ambient -40° to +140°F [-40° + 60°C]

 Operating Pressure

Models S, F and L
Hydrostatically proof pressure tested to 3500 psig [241 bar(g)]
at 70°F [21°C]. Derated with temperature, the maximum
recommended operation service is 2350 psig [162 bar(g)] at
500°F [260°C].
Model C
To 2000 psig [138 bar(g)]
Higher ratings available with special construction and test certification.
Control Circuit Features

 Control Circuit

Available in both standard socket mount, single channel, dual alarm,
epoxy sealed relays and in rack mounted configurations (card cage
or enclosure not included).
 Output Signal
Analog DC voltage related to flow or level / interface signal and
proportional to temperature, standard.
 Input Power
Field selected or pre-configured in the factory to 115 Vac (±15),
230 Vac (±30, 50 to 60 Hz), 24 Vdc (+4, -3) or 24 Vac (+2, -6);
100 Vac ±10 optionally available. LED indicates power on.
 Power Consumption

AC units, 13 VA maximum; DC units, 7 watts maximum.
 Heater Power

Field or factory selected to optimize switching performance and rangeability and selectable for specific fluid service requirements. 7 watts
power consumption, 230 mA maximum.
Typical Service
Gas or Air

Sensing Element
S-Style
F-Style
S-Style

Liquids

Power (W)
0.75
0.25
3.0

The above typical service power selections are for reference only.
Depending on application requirements, surface temperature rating
requirements, and rangeability expectations, alternate power selections
may be recommended. Other intermediate power selections can be
made. Consult installation manual for recommendations in your service.
 Relay Rating

Dual SPDT or single DPDT field configurable 6 amp resistive at 115
Vac, 240 Vac or 24 Vdc; hermetically sealed relay configurations
optionally available.
 Electrical Enclosure

Aluminum (epoxy coated) or optional stainless steel. Enclosures are
rated for hazardous location use (Class I and II, Division 1 and 2,
Group B, C, D, E, F and G; and EEx d IIC) and resists the effect of
weather and corrosion (NEMA and CSA Type 4X and equivalent to IP66).
[specifications continued on next page]

FlexSwitch FLT93 Series General Specifications [continued]
For Flow Service
 Setpoint Range
Model S
Water-based Liquids:
0.01 to 0.5 FPS [0.003 to 0.15 MPS]with 0.75 watt heater;
0.01 to 3.0 FPS [0.003 to 0.9 MPS] with 3.0 watt heater.
Hydrocarbon-based Liquids:
0.01 to1.0 FPS [0.003 to 0.3 MPS] with 0.75 watt heater;
0.01 to 5.0 FPS with [0.003 to 1.5 MPS] with 3.0 watt heater.
Air/ Gas:
0.25 to 120 SFPS [0.08 to 37 NMPS] with 0.75 watt heater at
standard conditions; 70°F [21.1°C], 14.7 psia [1.013 bar(g)].
Other Fluids: Contact the factory for approximate rangeability.
Model F
Air/Gas:
0.25 to 120 SFPS [0.08 to 37 NMPS] 0.75 watt heater at standard
conditions; 70°F [21.1°C], 14.7 psig [1.013 bar(g)].
Model L
Water-based Liquids: 0.015 to 50 cc/sec
Hydrocarbon-based Liquids: 0.033 to 110 cc/sec
Air/ Gas: 0.6 to 20,000 cc/sec
Model C
Water-based Liquids: 0.01 to 3.0 FPS [0.003 to 0.9 MPS]
Syrup: to 5.0 FPS [0.0003 to 1.5 MPS]
Air/Gas: 0.25 to 120 SFPS [0.08 to 36.6 NMPS]
 Factory Calibrated Switch Point Accuracy
Any flow rate within the instrument flow range may be selected as a
setpoint alarm. A factory-calibrated setpoint adjustment may be optimally
preset with accuracy of ±2% of setpoint velocity over an operating
temperature range of ±50°F [±28°C].
 Monitoring Accuracy

Based on a measured output voltage over the entire flow range, an
operating temperature range of ±50°F [±28°C], and an operating
pressure range of ±100 psig [±7 bar(g)]:
Liquids: ±5% reading or ±0.04 SFPS [±0.012 NMPS],
whichever is larger
Gases: ±5% reading or ±2 SFPS [±0.06 NMPS], whichever is larger
 Repeatability

For Temperature Service

 Accuracy

±2.0°F [±1°C] with field setpoint adjustment. Monitoring accuracy
±3.5°F [±2°C] with standard curve fit output voltage operation
across the selected instrument temperature range. Higher accuracy
available with factory calibrations.
 Repeatability

±1.0°F [±0.6°C]
The above accuracy is based on liquid or slurry service and in
gas service with a minimum 1 sfps (0.3 nmps) velocity past the
sensing element or with the heater deactivated for temperature
sensing service only.
Factory Application-Specific Set-up and
Setpoint Calibration
Standard instrument factory default setting, unless otherwise selected at
order entry, will be as follows:
 115 Vac input power for all FM Approved units. 230 Vac for all
other agency approval units.
 Dual SPDT alarms set for:
Alarm No. 1: Preset for flow or level and to de-energize
with decreasing conditions.
Alarm No. 2: Preset to de-energize for increasing temperature
at 10°F [5°C] below the maximum instrument process.
temperature.
 Heater power at 0.25 watt on Model F or 0.75 watt on Model S.
 Calibration switch set at “operate”.
Factory calibration including set-up for specific service, process
fluid and alarm conditions optionally available. Contact factory for
fluid handling capabilities.
Agency Approvals
FM, CSA, CENELEC,
T4 Rated (System approval),
ATEX, CE Mark and CRN
IEC Ex d IIC

±0.5% reading

SIL-2 Compliant

For Level /Interface Service
 Accuracy
Model S
±0.25 inch [±6.4 mm]
Model F
±0.1 inch [±2.5 mm]

Shipping Weight (approximate)
Integral: 8 lbs. [3.6 kgs]
Remote: 13 lbs. [5.9 kgs]

 Repeatability

Model S
±0.125 inch [±3.2 mm]
Model F
±0.05 inch [±1.3 mm]

REF

FLT93-S and FLT93-F FlexSwitch, Insertion

Mounting
Reference “

Active RTD
and Heater

REF

”

1.50± .50 [38 ±13]

4.63 [118]

4.73 [120]

U-Length

1.85 [47]

.63 [16] Max

4.30
[109]

Reference RTD

0.875 [22] OD
FLT93-S
(Extended U-Length 3/4 inch Male NPT
Configuration Shown)

Enclosure used as wire terminal
junction box or to house local
switch electronics.
Instrument certified to:
Class I, Division 1 and 2, Groups B, C and D
Class II, Division 1, Groups E, F and G
NEMA and CSA Type 4X (equivalent to IP66)
and/or EEx d IIC. T4 (or T3a) rated.

External ground lug
and cover lock
provided on
CENELEC
approved enclosure

Notes:
1. For best performance, the sensing element should be
installed into a vertical section of pipe. Liquids should flow
up through the sensing element and gases should flow
down through the sensing element.

4.73
[120]

2. The time response of the F-style sensors is faster than
the S-style sensors. However, the S-style sensors can
withstand higher fluid forces (drag) than the F-style sensors.

Note 3
1" Male MNPT

Local Enclosure (see FLT-S above)
or
Cable PIigtail

3. Refer to the FlexSwitch product brochure
(Doc. No. 02MK011288) for additional information and
complete specifications.

.75 Inch Male NPT

1 Inch Male NPT
Opptional
Both Ends

FLOW

.75 Inch Female NPT
Optional Both Ends

2.06
[52]

FLT93-L FlexSwitch, Inline

1 Inch Female
NPT Customer
Conduit Port

1.750
[44]
Max

Available U-lengths:
1.2 inch [30]
2.0 inch [51]
4.0 inch [102]
6.0 inch [152]
9.0 inch [229]
12 inch [305]
18 inch [457]

Earth
Grounding
Lug

1 inch Female NPT
Customer Conduit Port

4.30
[109]

Ø .156 Thru
[4]

Available wetted surface
material of construction:
316 stainless steel
Monel 400
Hastelloy C
Titanium (“S” configuration
only)

1 Inch SCH 160 Pipe
3.375 [86] MAX
(A - Length)

4. Use the Model FLT93L Ordering Information Sheet (OIS
Doc. No. 01SA011426) to configure the complete instrument
part number.
5. Sensing element A-length is 12.0 inches (305 mm) if
flanges are specified for the process connection.

Other end connections available.

[millimeters]

FLT93-C FlexSwitch, Sanitary Insertion
E

Local Enclosure Meets Explosion Proof
(See FLT93-S above)

A

3/
4

B

3/
4

1
1
1/ 2 111/
/2
11/
2
2
1/ 2
2
21/
2
3
2
4

C

5.25
4.75
5.50
7.00
5.68
6.18
8.12

D

1.12
1.06
1.37
1.62
1.87
2.12
2.62

E

1.50
2.12
2.12
2.12
2.12
2.12
2.12

To Convert To Millimeters Multiply by 25.4

F

N.A.
1.50
1.75
2.00
2.25
2.50
3.00

U-Lgth
1.43
1.25
1.93
1.93
1.93
2.75
2.75

Flat Indicates
Flow Direction

ø4.63
[118]

4.83
[123]

Gasket
(Customer)
Approx 1/16
Except 3/4”
SIZE=D

U Length

A Tube &

FlangeSize

D

Clamp

C/
2

4.30
[109]

Earth
Ground
ø2.06
[52]

1 Inch Female NPT Port

B

Tube &FlangeSize

F

Short Leg Tee
(Optional)

C

Test and Calibration Laboratory

Fluid Components
International maintains an extensive, instrument test and calibration
laboratory at its headquarters in San Marcos, California. Utilizing
the latest in advanced, computerized data acquisition systems and
calibration test equipment, this facility permits comprehensive product development, testing, and calibration. Any FCI product can be
calibrated in accordance with customer specifications. Laboratory
standards are maintained with NIST (National Institute of Standards
and Technology) traceable Cavitating Venturis (CVs) and precisely
calibrated, pressure and temperature corrected turbine flowmeters.
Combustible and non-combustible gas calibration flow stands
allow for the calibration of FCI products in a wide range of gases
and gas mixtures in flow stand line sizes as small as 1/8 inch to
30 inches [3 to 760 mm] in diameter. A variety of flow profiles

from laminar to turbulent conditions are generated to duplicate
actual field conditions. Flow rates from 0 to 20,000+ SCFM [0 to
34,000 NCMH], velocities from 0 to 800 SFPS [0 to 240 NMPS],
pressures from vacuum to 3000 psig [200 bar(g)], and temperatures from -100º to +900ºF [-70º to +480ºC] are available.
On-Site Calibration and Training In-situ calibration is avail-

able from FCI’s Field Service engineers where precise test and
calibration is accomplished in actual media conditions.
FCI’s Training Department can provide on-site or at the factory
Product Knowledge Workshops for our customers. The workshops cover installation, setup, and troubleshooting skills, and
include hands-on exercises using real products, under actual
operating conditions.

24 Hour Customer Service Access Available

Web: www.fluidcomponents.com
1755 La Costa Meadows Drive, San Marcos, California 92078 USA | Phone: 760-744-6950 | Toll free: 800-854-1993 | Fax: 760-736-6250
European Office: Persephonestraat 3-01 5047 TT Tilburg, The Netherlands | Phone: 31-13-5159989 | Fax: 31-13-5799036
ISO 9001:2000 and AS9100 certified
©Copyright 2008 by Fluid Components International LLC. All rights reserved. Subject to change without notice.
0407 5K

Doc. No. 02MK011288N



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