rsbp FLEX F Series User manual

Flameless Explosion Venting Device –FLEX
Designer
Technical Manager
Ing. Petr Grygar
Ing. Tomáš Wyka
10. 5. 2016
10. 5. 2016
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INDEX
1. INTRODUCTION ............................................................................................................................................... 4
1.1 IDENTIFICATION OF THE OPERATING AND MAINTENANCE INSTRUCTIONS ........................................ 4
1.2 FLEX CLASSIFICATION ........................................................................................................................... 4
1.3 THE PURPOSE OF THE OPERATING AND MAINTENANCE INSTRUCTIONS............................................ 5
1.4 WARRANTY CONDITIONS ..................................................................................................................... 5
1.5 STORAGE .............................................................................................................................................. 6
1.6 TERMS AND DEFINITIONS .................................................................................................................... 6
2. GENERAL SAFETY INSTRUCTIONS.................................................................................................................... 7
3. PRODUCT DESCRIPTION .................................................................................................................................. 8
3.1 OPERATING PRINCIPLE ......................................................................................................................... 8
3.2 TECHNICAL SPECIFICATIONS ................................................................................................................ 9
3.3 THE PARAMETERS ENSURING THE SAFE USE OF FLEX ACCORDING TO THE ATEX CERTIFICATE ....... 14
3.4 SAFETY ZONE...................................................................................................................................... 14
3.5 FORMATION OF OVERPRESSURE IN SURROUNDING VOLUME ACCORDING TO EN 16009 ............... 16
4. THE INSTALLATION TO THE PROTECTED EQUIPMENT .................................................................................. 17
4.1 THE INSPECTION OF THE FLEX BEFORE INSTALLATION...................................................................... 17
4.2 GENERAL INSTALLATION GUIDELINES................................................................................................ 17
4.3 THE INSTALLATION TO THE PROTECTED EQUIPMENT ....................................................................... 20
5. MEMBRANE OPENING SIGNALLING DEVICE ................................................................................................. 23
5.1 ELECTRICAL CONNECTION.................................................................................................................. 23
5.2 PROHIBITED ACTIVITIES ..................................................................................................................... 24
6. OPERATORS, MAINTENANCE, AND STAFF TRAINING.................................................................................... 25
7. SERVICE AND MAINTENANCE........................................................................................................................ 27
7.1 SERVICE .............................................................................................................................................. 27
7.2 FLEX SERVICE AFTER EXPLOSION OR WHEN THE MEMBRANE IS DAMAGED .................................... 28
8. SPARE PART LIST............................................................................................................................................ 34

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9. ANNEXES ....................................................................................................................................................... 35

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1. INTRODUCTION
1.1 IDENTIFICATION OF THE OPERATING AND M AINTENANCE INSTRUCTIONS
This user manual is drawn up for the flameless explosion venting device - FLEX (hereinafter
referred to as FLEX) of the dimensional series F1 to F3, R1 to R4 and C1 to C5. The original
user manual containing the operating and maintenance instructions is drawn up in the Czech
language; other language versions are the translations of the original manual. If in any
doubts, the original wording of the manual shall be considered decisive.
The following documents concerning FLEX are also supplied with this manual.
✓Delivery note
✓EU Declaration of Conformity under 2014/34/EU
✓FLEX control sheet
✓Operation Log Book
The following can be supplied on request:
✓Drawing of the connecting flanges
✓The data sheet of the intrinsically safe relay (if included in the delivery)
1.2 FLEX CLASSIFICATION
FLEX is designed in accordance with the European Directive 2014/34EU:
Table No. 1 - FLEX Classification
The electrical components (intrinsically safe relays) installed in FLEX must be certified
to the appropriate zone or category.
Equipment group
II
Explosive atmosphere
D
Equipment category, interior/exterior
1 D 3G / 3G D
Zone Interior:
20, 21, 22
Exterior:
2, 22

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1.3 THE PURPOSE OF THE OPERATING AND MAINTENANCE INSTRUCTIONS
These operating and maintenance instructions are intended for all the staff who are expected
to come into contact with the FLEX device during their work.
The operating and maintenance instructions are an integral part of the product and the
manufacturer cannot be held liable for any damage or injuries caused as a result of
insufficient knowledge of these instructions. Therefore, it is necessary that the user reads
through this manual and any other documents thoroughly and communicates them to the
appropriately qualified personnel (electric, mechanical, technological, safety engineers and
others). The provisions concerning the operation and maintenance should be incorporated
into the operating rules, maintenance schedules and other documents by the user.
If the user is in doubt, he/she should contact the company RSBP spol. s r.o. or its authorized
representative.
The customer should pay increased attention mainly to chapter 4 concerning the
proper installation because FLEX is the device, whose improper installation, operation
and maintenance may endanger the human life.
FLEX can be installed, operated, serviced and repaired only by an authorized person.
The authorized person must be trained and certified either by the company RSBP
spol. s r.o., or by its authorized representative. The certification must be renewed
every 2 years.
1.4 WARRANTY CONDITIONS
This product was manufactured with the most advanced, high-quality materials, and it was
thoroughly inspected before dispatch. However, if any defect or damage occurs during
storage, installation, operation, cleaning or servicing, the user is obliged to notify the
manufacturer immediately and in writing.
The manufacturer shall replace the damaged or missing parts of the products in the shortest
possible time.
This product is covered by a warranty period of 2 years.
The warranty cannot be exercised in the following situations:
✓The user did not familiarize himself/herself with these operating and maintenance
instructions.
✓The product was not used in accordance with these operating and maintenance
instructions.
✓The authorized person performed insufficient or improper installation or maintenance.

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✓Unsuitable spare parts were used (only the genuine spare parts distributed by the
manufacturer can be used).
✓Inappropriate accessories, which had not been approved by the manufacturer, were
used.
The warranty can be exercised only provided that the damaged part, including the
description of the defect and the product serial number, will be sent in to the
manufacturer's address.
1.5 STORAGE
Prior to the installation to the protected technology, the product must be stored in a clean and
dry place, and it must not be exposed to the weather. The product shall be stored in the
original packaging. Under no circumstances can the product be exposed to rain, freeze, dust
or any other weather conditions that affect the functions of the FLEX device.
The operating and maintenance instructions must be kept throughout the life of the product
and it must be readily accessible to all employees.
If the product is removed from service or sold, it must be handed over to the new user
together with these operating and maintenance instructions.
In the event of the loss of these instructions, they can be re-ordered from the manufacturer.
1.6 TERMS AND DEFINITIONS
The flameless explosion venting device - FLEX consists of the equipment for explosion
venting (membrane) and the device for the absorption of the released energy (FLEX), which
spreads during the dust explosion in a confined space. FLEX prevents the transmission of
the explosion pressure and flame through the release opening of the membrane, thereby
protecting people and equipment in its vicinity. FLEX must be used in the event of the
membrane installation inside the building, where the protected equipment is located.
The membrane - is the device protecting a vessel or other closed volumes using the
explosion venting - releasing the explosion pressure to the surrounding space. The
membrane prevents the explosion pressure inside the vessel or any other closed volumes
from exceeding the structural strength of the vessel and reduces the explosion pressure to a
lower value than the allowable pressure load-capacity of the vessel.
The signalling device - is a device monitoring the position of the membrane
(closing/opening). It works on the principle of breaking the wire firmly connected with the
membrane and passed through a cable entry in the FLEX body. Upon breaking, the safety
circuit is interrupted and the membrane opening is indicated.

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2. GENERAL SAFETY INSTRUCTIONS
The user must ensure that the product is used and operated only in a technically perfect
condition. The recommended inspection and maintenance intervals must be observed, and
the required service or repairs performed by the certified person must be provided for.
The activities performed with the product must all be recorded in the Operation Log
Vook, which is included in the delivery, so that the history of these activities can be
traced at any time.

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3. PRODUCT DESCRIPTION
If the explosive atmosphere in the form of a whirled dust cloud occurs in the technology and
if the atmosphere comes into contact with a source of ignition, there may be immediate
explosion. FLEX protects the technology, operators and the environment from the destructive
effects of such explosions.
The FLEX devices of the F and R series feature the base, therefore the rectangular
membrane. The FLEX devices of the C series feature the base, therefore the round
membrane.
3.1 OPERATING PRINCIPLE
The flameless explosion venting device - FLEX consists of the equipment for explosion
venting (membrane) and the device for the absorption of the released energy (FLEX), which
spreads during the dust explosion in a confined space. FLEX prevents the transmission of
the explosion pressure and flame through the release opening of the membrane, thereby
protecting people and equipment in its vicinity. FLEX must be used in the event of the
membrane installation inside the building, where the protected equipment is located. In the
event of explosion, FLEX captures the explosion energy (flame, pressure) coming from the
open membrane. Any damage to the product may result in the product failure. This could
cause the transmission of the dust explosion from the protected vessel to the operators'
zone. For this reason, it is very important to read through these instructions prior to the
commencement of the installation.
The distances of the installed FLEX devices to the adjacent machinery or walls must be
approved by the manufacturer. This distance is required for the proper function of FLEX. The
minimum distance between FLEX and the nearest machinery (or the building wall) must be at
least 500 mm (see chapter 3.4).

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Fig. 1 - An Example of the Installation of FLEX Devices in the Protected Equipment
(1 - FLEX, 2 - Filter)
3.2 TECHNICAL SPECIFICATIONS
Below, there are listed the dimensions of the designs together with the relevant drawings.
3.2.1 BASIC DIMENSIONS OF ROUND FLEX DEVICES - TYPE C (FLEX-C)
Table No. 2 - Basic Dimensions of the Round FLEX Devices (C-Series)
TYPE
A
[mm]
B
[mm]
C
[mm]
D
[mm])
E
[mm]
F
[mm]
G
[mm]
d - the
diameter
of the
opening
for bolts
[mm]
n - the
number
of
openings
for bolts
[pieces]
Weight
[kg]
FLEX C1
315
580
485
320
350
5
375
11
12
30
FLEX C2
445
795
635
450
486
5
525
13
12
71
FLEX C3
505
990
705
510
550
6
585
13
20
104
FLEX C4
625
1640
825
630
680
6
705
13
20
177
FLEX C5
815
2215
1020
820
860
6
895
13
24
291

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Fig. 2 - The Drawing of the Round FLEX Devices (C1-C5)

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3.2.2 BASIC DIMENSIONS OF THE RECTANGULAR FLEX DEVICES OF THE R AND
F TYPES (FLEX-R / FLEX-F)
Table No. 3 - Basic Dimensions of the Rectangular FLEX Devices (R-Series)
TYPE
A
[mm]
B
[mm]
C
[mm]
D
[mm]
d - the
diameter of
the opening
for bolts [mm]
n - the
number of
openings
for bolts
[pieces]
Weight
[kg]
FLEX R1
390
710
635
410
14
18
40
FLEX R2
540
890
900
580
14
22
74
FLEX R3
666
1000
1130
735
14
34
109
FLEX R4
996
1198
1660
1070
14
42
215
Fig. 3 - The Drawing of the Rectangular FLEX - Pie (R1 - R4)
Table No. 4 - Basic Dimensions of the Rectangular FLEX Devices (F-Series)
TYPE
A
[mm]
B
[mm]
C
[mm]
D
[mm]
d - the
diameter of
the opening
for bolts [mm]
n - the
number of
openings
for bolts
[pieces]
Weight
[kg]
FLEX F1
225
675
265
465
14
20
24
FLEX F2
305
625
335
530
14
18
28
FLEX F3
390
710
420
620
14
18
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Fig. 4 - The Drawing of the Rectangular FLEX - Flat (F1 - F3)
3.2.3 MATERIAL DESIGN
FLEX is normally supplied in the material design of structural steel, with the surface
treatment KOMAXIT RAL 9005 (black). Different colors can be supplied upon the customer's
request.
3.2.4 OPTIONAL ACCESSORIES (INTRINSIC ALLY SAFE RELAY)
a) The intrinsically safe relay forms the interface between the safe and the hazardous
zones (Zone 20). The intrinsically safe relay requires power supply of 230V/50 Hz,
protection with the circuit breaker of at least 1 A (tripping characteristics B or C). The
intrinsically safe relay contains a throw-over contact, where the operational state of
the membrane (closed/opened) is signalled.
Fig. 5 - Intrinsically Safe Relay
The intrinsically safe relay can be supplied as an optional accessory (also separately)
upon the customer's requests. For more details, please refer to chapter No. 5. The
intrinsically safe relay must always be used with the installation of the FLEX device.

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The power supply and control cabling for the intrinsically safe relay is included in the
delivery and it should be provided for by the customer (if not agreed otherwise in the
contract).
b) The flange packing (gasket) must be used between the flange of the protected
device and the membrane, which is sealed to the flange of the FLEX device. This
gasket can be supplied by the company RSBP spol. s.r.o. according to parameters fit
for the particular installation. However, the customer can get it by himself/herself. The
gasket is shown in fig. 12 and 13. The gasket supplied by the company RSBP spol. s
r. o. is made of the EPDM material, which can be used in all common applications
with the ambient temperature between -40 °C to 80 ° C all the time. For the
application with special requirements for the features of the gasket, we can supply the
gasket made of the material that meets the requirements. In the event that the
operator decides to use his/her own gasket, neither the supplier nor the manufacturer
is responsible for the problems related to the its inappropriate selection.
c) The protective bag is intended to cover the functional area of the FLEX flame filter,
so that any penetration of foreign particles in the filter meshes reducing the
functionality of FLEX is prevented. The protective bag is recommended for the use in
dusty premises with the significant clogging risk of the flame filter. In the event of
explosion, the bag breaks and the energy is absorbed without any disturbance.
However, if the bag is damaged, either during the explosion or otherwise, it must be
replaced with the new one.
Fig. 6 - Protective Bag (1 - Protective Bag, 2 - FLEX)

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3.3 THE PARAMETERS ENSURING THE SAFE USE OF FLEX ACCORDING TO THE
ATEX CERTIFICATE
All relevant parameters are summarized in the Table No. 5. If any other range of ambient
temperatures is required, the manufacturer should be contacted.
Table No. 5 - The Parameters Ensuring the Safe Use of FLEX
Size
Max. Kst
[bar∙m/s ]
Ambient
temperature
[°C]
FLEX - F1
220
-20 to 60
FLEX - F2
FLEX - F3
FLEX - R1
220
FLEX - R2
FLEX - R3
FLEX - R4
FLEX - C1
300
FLEX - C2
FLEX - C3
FLEX - C4
FLEX - C5
In the event of explosion, FLEX must be inspected by the manufacturer or by a trained
person; they should determine the proper servicing, so that the proper function for the
further safe use is ensured.
3.4 SAFETY ZONE
The area in front of the free space of the flame filter at a distance of 1 - 2.5 m from FLEX
must be defined as the safety zone. The specific value is given in the Technical Data Sheet
supplied with each FLEX device. No people can access the zone because there is a
danger of noise, smoke and water steam associated with the explosion. It is recommended
that no equipment which could be destroyed in such an event is located in this zone. The
safety zone for the round FLEX is shown in fig. 7, for the rectangular one in fig. 8.
If the operators must regularly work in the close proximity of FLEX, a flat panel or a welding
curtain for the separation of the personnel and the device can be used; the distance from the
FLEX surface must be at least 500 mm. The specific solution must always be approved by
the manufacturer of the FLEX supplier.

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The safety zone can be accessed only for the purpose of service or device maintenance.
However, only provided that the entire technology has been shut down, the explosive
atmosphere has been vented and if there is no explosion risk inside the protected
technology.
Fig. No. 7 - Safety Zone for the Round FLEX Devices
Fig. No. 8 - Safety Zone for the Rectangular FLEX Devices

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3.5 FORMATION OF OVERPRESSURE IN SURROUNDING VOLUME ACCORDING TO
EN 16009
When using the flameless venting device for explosion venting, rises the pressure inside the
room where is such device installed. This effect is obvious especially for installations inside
small rooms. In such situation is necessary to check, if is the room volume according to the
volume of protected vessel large enough, to avoid a damage of this room. Generally, is
necessary to consider a reinforcement of the room if the room is 300x smaller than protected
vessel. This is valid for buildings and rooms with common constructional strength 0,01 bar.
This is described within following formula:
V0
V= α ∙ p0 ∆p
Where
p0is the ambient pressure;
∆p is the maximum pressure rise in the room or building;
αis the expnasion constant, empirical derived from the gas volume and temperature outside
protected vessel;
V0is the volume of the room or building;
𝑉is the volume of the protected vessel;

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4. THE INSTALLATION TO THE PROTECTED EQUIPMENT
FLEX is supplied assembled. The membrane is sealed and bolted to FLEX. These bolts must
be removed prior to the installation (see chapter 4.3). The installation of the device shall be
carried out according to the manufacturer's documents concerning the specific use.
4.1 THE INSPECTION OF THE FLEX BEFORE INSTALLATION
Immediately after the delivery and then before the commencement of FLEX installation, the
following basic checks must be performed:
✓Check the integrity of the original packaging of FLEX.
✓Check the integrity and flawlessness of the top coat of FLEX.
✓Check the integrity of the membrane.
✓Check whether no fasteners (bolts, nuts, washers) holding the top lid (cover) of FLEX
are missing.
✓Check the integrity of the cabling.
After successful inspection, FLEX is ready to be installed. In the event of any defects or
deficiencies, contact the manufacturer or the distributor immediately.
4.2 GENERAL INST ALL ATION GUIDELINES
A) Only lifting eyes can be used for the transport and handling FLEX. The lifting eyes of
the FLEX devices of the C and F series are firmly welded to the FLEX structure; as to
the FLEX devices of the R series, they are bolted between the FLEX body and its lid.
B) The flange of the vessel must have the same connecting dimensions as the FLEX
flange and it must be located, if possible, on the lowest possible branch extrusion,
ensuring easy installation and sufficient strength for carrying the FLEX weight. The
pressure resistance of the device must comply with the legislation relating to the
device for explosion venting and flameless explosion venting devices.
C) Both the sealing faces, both on the FLEX device and on the connecting flange of the
vessel, must be thoroughly cleaned and degreased. The material for the flange
gasket (packing) must be fit for the respective operation and meet all necessary
requirements (temperature, chemical resistance, tightness and others). The
recommended gasket is the gasket supplied by the company RSBP spol. s r.o., which
is made of EPDM for common operations. For special requirements, the gasket
meeting the special requirements of the customer can also be supplied.

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D) The FLEX devices can be installed vertically, horizontally or at an angle. The goal
consists in the prevention of sticking an excessive amount of dust and dirt from the
technology on the membrane. The allowed positioning of the installation is shown in
fig. 9.
Fig. 9 - The Allowed Positioning of the Installation
E) If FLEX C3, C4 or C5 is positioned otherwise than vertically, the end of the device
must be fixed in the way that the load from the FLEX weight is distributed evenly
between both the ends of the device. The end of FLEX must be hung by the welded
eyes on the FLEX cover (lid) using a suitable structure. An example of such
suspension is shown in fig. 10. The specific fastening method must be discussed with
the manufacturer or the supplier. The dimension of the structure as well as all
suspension components must be fit for the load from the FLEX weight for all FLEX
types and sizes. In the event of installation, the device must also be sufficiently sized
to withstand the weight of the FLEX device.
Fig. 10 - The Proper Positioning of FLEX

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F) FLEX must be installed in the way that the membrane is facing the free volume of the
protected vessel. For instance, the space in front of the membrane must not be
blocked with filter cartridges or any other elements.
G) The membrane opening signalling device must be properly connected in each FLEX,
so that the operators can surely distinguish, whether no membrane is opened. The
opening signalling device must always be connected to the intrinsically safe relay.
H) The outdoor installation is allowable only provided that the FLEX device is under the
roof, so that the penetration of water, snow, ice and other particles in the flame filter
meshes of FLEX is avoided. The protective bag must also be used in this situation. In
the event of intrusion of any particles into the meshes of FLEX due to climatic effects,
the manufacturer or the distributor of FLEX cannot be held liable for the functionality
of the device.
I) FLEX grounding must be made using the appropriate grounding element (earth
termination, earth wire), by means of which the earth bolt with one of the flange bolts
connecting FLEX with the protected device is connected. The contact faces for the
placement of the earth element must be cleaned appropriately and their coating must
be removed. The fasteners used for attaching the grounding element to the FLEX
earth bolt must be galvanized. Specifically, the nut M8 (ISO 4032), property class 8,
and serrated lock washer (DIN 6798) and plain washer (ISO 7090) - both of them with
the size 8. First, the serrated lock washer should be put on the earth bolt, then the
grounding element, the plain washer; finally the nut should be tightened with a torque
15 Nm. The other end of the grounding element should be placed under the head of
one of the FLEX flange bolts. Between the grounding element and the actual FLEX,
the serrated lock washer (DIN 6798) of the same size as the flange bolts FLEX must
be inserted; tighten with the same tightening torque as the other flange bolts. The
example of the proper grounding is shown in Fig. 11. The grounding must comply
with the legislative requirements of the country where FLEX is installed.
Fig. No. 11 - Flex Grounding
J) FLEX should be connected to the prepared flange on the vessel using the fasteners
listed in table No. 6. In this table, all types of bolts, nuts and washers necessary for
1 - Fasteners
2 - Grounding element (earth
terminal/wire)
3 - Fasteners of FLEX and
and the protected vessel

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the proper installation must be listed. All fasteners must be galvanized, the property
class of bolts must be 8.8 (ISO 4017) and the property class of nuts must be 8 (ISO
7040). The washers (ISO 7090) should be put under the nut. The table also shows
the specific tightening torques for individual bolts.
Table No. 6 - Fasteners for the Installation of FLEX
FLEX
Number of
bolts, nuts
and washers
[pcs]
Bolt ISO
4017 - 8.8 -
A3L
Nut ISO
7040 - 8 -
A3L
Washer ISO
7090 - A3L
Tightening
torque [N∙m]
F1
20
M10 x 35
M10
10
21
F2
18
M10 x 35
M10
10
21
F3
18
M10 x 35
M10
10
21
R1
18
M10 x 35
M10
10
21
R2
22
M10 x 35
M10
10
21
R3
34
M10 x 35
M10
10
21
R4
42
M10 x 35
M10
10
21
C1
12
M8 x 30
M8
8
15
C2
12
M10 x 35
M10
10
21
C3
20
M10 x 35
M10
10
21
C4
20
M10 x 40
M10
10
21
C5
24
M10 x 40
M10
10
21
4.3 THE INSTALLATION TO THE PROTECTED EQUIPMENT
The installation of the FLEX device can be summarized in the following steps:
1) Removing the transport bolts (ISO 10642) which, together with the sealant, hold the
membrane firmly on the FLEX body.
2) Cleaning and degreasing of the flange contact face on the vessel and the FLEX
device (the underside of the membrane). Do not remove the membrane! Leave it
intact, sealed to the underside of FLEX.
3) The installation of the appropriate flange gasket, either the gasket supplied by the
company RSBP spol. s r.o., or the customer's own gasket.
4) For FLEX C3, C4, C5 or any other type or size, for which it was decided that the
following procedure is required due to the total size of the protected device, the FLEX
devices should be supported (suspended); see chapter 4.2 (E).