SICK FLOWSIC500 Operating Instructions Manual

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Title Page

FLOWSIC500 Ultrasonic Gas Flow Meter with Optional Volume Conversion

Installation

Operation

Maintenance

OPERATING INSTRUCTIONS

Document Information

Glossary

Described Product

Product name: FLOWSIC500

Document ID

Title: Operating Instructions FLOWSIC500 Part No.: 8015391 Document ID: 9186957 Version: 2-3 Release: 2016-10

Manufacturer

SICK Engineering GmbH Bergener Ring 27 · D-01458 Ottendorf-Okrilla · Germany Phone: +49 35205 52410 Fax: +49 35205 52450 E-Mail: info.pa@sick.de

Original Documents

The English version 8015391 of this document is an original document from SICK Engineering GmbH. SICK Engineering GmbH assumes no liability for the correctness of an unauthorized translation. Please contact SICK Engineering GmbH or your local representative in case of doubt.

Legal Information

Subject to change without notice.

AC Alternating Current

Al Aluminium

ATEX ATEX: Atmosphères Explosifs: Abbreviation for Euro-

pean standards that govern safety in potentially explosive atmospheres

CSA Canadian Standards Association (www.csa.ca)

DC Direct Current

HF High frequency, e. g. HF pulses

IEC International Electronical Commission

IECEx IEC system for certification in accordance with stan-

dards for devices for use in potentially explosive atmospheres

IPxy Ingress Protection: Degree of protection of a device

in accordance with IEC/DIN EN 60529; x specifies the protection against contact and impurities, y protection against moisture.

LF Low frequency, e. g. LF pulses

MDR Manufacturer Data Record

NAMUR Abbreviation for "Normen-Arbeitsgemeinschaft für

Mess- und Regeltechnik in der chemischen Industrie", now "Interessengemeinschaft Automatisierungstechnik der Prozessindustrie" (www.namur.de)

pTZ Volume conversion as a function of the pressure,

the temperature and with consideration of the compression factor

TZ Volume conversion as function of the temperature

and a fixed pressure value and with consideration of the compression factor

2 FLOWSIC500 · Operating Instructions · 8015391/Z261/V2-3/2016-10 · © SICK Engineering GmbH

Warning Symbols

Information Symbols

IMMEDIATE HAZARD of severe injuries or death

Hazard (general)

Hazard by electrical voltage

Hazard in potentially explosive atmospheres

Hazard by explosive substances/mixtures

Hazard by unhealthy substances

Hazard by toxic substances

Warning Levels / Signal Words

Information on product condition with regard to protection against explosions (general)

Information on product characteristics related to European Directive ATEX

Information on product characteristics related to explosion protection in accordance with the IECEx scheme.

Important technical information for this product

Important information on electric or electronic functions

Nice to know

Supplementary information

Link referring to information at another place

DANGER

Risk or hazardous situation which will result in severe personal injury or death.

WARNING

Risk or hazardous situation which could result in severe personal injury or death.

CAUTION

Hazard or unsafe practice which could result in personal injury or property damage.

NOTICE

Hazards which could result in property damage

FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH 3

Contents

1 Important Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

1.1 Main hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

1.2 About this document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

1.3 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1.3.1 Purpose of the device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1.3.2 Product identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1.3.3 Operation in potentially explosive atmospheres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

1.3.4 Combustible gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

1.3.5 Restrictions of use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

1.3.6 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

1.4 Responsibility of user . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

1.5 Additional documentation/information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

2 Product Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

2.1 Operating principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

2.1.1 Gas flow meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

2.1.2 Volume conversion (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

2.2 FLOWSIC500 measuring system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

2.2.1 Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

2.2.2 Gas flow meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

2.3 Meter sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

2.4 Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

2.5 Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

2.5.1 Pulse and status outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

2.5.2 Encoder totalizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

2.5.3 Serial data interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

2.5.4 Optical data interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

2.6 Device option: Volume conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

2.6.1 Volume conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

2.6.2 Integrated pressure and temperature transmitters . . . . . . . . . . . . . . . . . . . . . . . . . . 21

2.6.3 External pressure and temperature transmitters . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

2.7 Totalizers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

2.7.1 Device status and totalizers used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

2.7.2 Reverse flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

2.8 Logbooks and Archives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

2.9 Parameter protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

2.9.1 Parameter locking switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

2.9.2 Metrology logbook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

2.10 Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

3.1 Hazards during installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

3.2 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

3.2.1 Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

3.2.2 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

3.3 Mechanical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

3.3.1 Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

3.3.2 Choosing flanges, gaskets and other components . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

3.3.3 Fitting the FLOWSIC500 in the pipeline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

4 FLOWSIC500 · Operating Instructions · 8015391/Z261/V2-3/2016-10 · © SICK Engineering GmbH

Contents

3.4 Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

3.4.1 Requirements for use in potentially explosive atmospheres . . . . . . . . . . . . . . . . . . . 37

3.4.2 Criteria for electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

3.4.3 Opening and closing the electronics cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

3.4.4 Rotating the control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

3.4.5 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

3.4.6 Pin assignment of plug-in connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

3.4.7 Cable specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

3.4.8 Operation with external power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

3.4.9 Operation with batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

3.5 Installing the external pressure and temperature transmitters . . . . . . . . . . . . . . . . . . . 46

3.5.1 Fitting the plug-in connector cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

3.5.2 Installing the pressure transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

3.5.3 Installing the temperature transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

4Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

4.1 Sequence of start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

4.1.1 Start-up of gas flow meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54

4.1.2 Start-up of gas flow meter with device option volume conversion . . . . . . . . . . . . . .54

4.2 Setting the date and time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

4.3 Configuring volume conversion (device option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

4.3.1 Setting fixed values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

4.3.2 Checking the configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

4.3.3 Configuring the gas composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

4.4 Checking the device status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

5Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

5.1 Control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

5.2 Operating using the display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

5.2.1 Display in the symbol bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59

5.2.2 Battery fill level display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

5.2.3 Main screen (without device option volume conversion) . . . . . . . . . . . . . . . . . . . . . . 60

5.2.4 Main display (with device option volume conversion) . . . . . . . . . . . . . . . . . . . . . . . . . 62

5.2.5 Configuration of main display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

5.2.6 FLOWSIC500 menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

5.2.7 Changing the user level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

5.2.8 Setting the language . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

5.2.9 Changing the device mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

5.2.10 Changing parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

5.2.11 Resetting the error volume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

5.2.12 Resetting the event summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73

5.2.13 Confirming battery replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

5.2.14 Checking the external power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

5.2.15 Testing the display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

5.3 Operating using the optical data interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

5.4 FLOWgate500 operating software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75

FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH 5

Contents

6 Clearing Malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

6.1 Contacting Customer Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

6.2 Status messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

6.3 Additional messages in the Event logbook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

7 Maintenance and Meter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 81

7.1 Information on handling lithium batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

7.1.1 Information on storage and transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

7.1.2 Disposal information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

7.2 Maintenance when using external power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

7.2.1 Service life of backup battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

7.2.2 Changing the backup battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

7.3 Maintenance when using battery power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

7.3.1 Service life of battery packs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

7.3.2 Changing the battery packs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

7.4 Meter exchange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

7.4.1 Prerequisites for meter replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

7.4.2 Hazards during meter replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

7.4.3 Sequence of meter replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

7.4.4 Required tools and auxiliary material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

7.4.5 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

7.4.6 Back-up of user-specific configuration of installed gas flow meter . . . . . . . . . . . . . 90

7.4.7 Disconnecting electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

7.4.8 Removing the installed gas flow meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

7.4.9 Installing the replacement gas flow meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

7.4.10 Performing a leak tightness check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

7.4.11 Checking the function of the gas flow meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

7.4.12 Securing metrologically . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

7.5 Function check of a pressure or temperature transmitter . . . . . . . . . . . . . . . . . . . . . . 100

7.6 Exchanging an external pressure or temperature transmitter . . . . . . . . . . . . . . . . . . . 100

7.6.1 Exchanging the pressure transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

7.6.2 Exchanging the temperature transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

8 Accessories and Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

8.1 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

8.1.1 Gas flow meter accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

8.1.2 Volume conversion (device option) accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

8.1.3 Transport accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

8.2 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

8.2.1 Gas flow meter spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

8.2.2 Volume conversion (device option) spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

6 FLOWSIC500 · Operating Instructions · 8015391/Z261/V2-3/2016-10 · © SICK Engineering GmbH

Contents

9 Annex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107

9.1 Conformities and Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108

9.1.1 CE certificate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108

9.1.2 Standards compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

9.1.3 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109

9.1.4 Flow rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

9.1.5 Overload protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111

9.2 Type code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112

9.3 Type plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114

9.3.1 Metrology and electronics type plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114

9.3.2 PED type plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116

9.4 Dimensional drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117

9.5 Internal terminal assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

9.6 Installation examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

9.7 Connection diagrams for operation of the FLOWSIC500 in accordance with CSA .122

9.8 Connection diagrams for operation of the FLOWSIC500 in accordance with

ATEX/IECEx . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129

FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH 7

Contents

8 FLOWSIC500 · Operating Instructions · 8015391/Z261/V2-3/2016-10 · © SICK Engineering GmbH

Important Information

FLOWSIC500

1 Important Information

Main hazards

About this document

Intended use

Responsibility of user

Subject to change w ithout notice

FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH 9

1.1 Main hazards

23 I/O (Interface configurations)

FL5 F

DANGER: Risk of explosion when the gas flow meter is damaged

Natural gas flows with line pressure through the gas flow meter. Natural gas can escape when the gas flow meter is damaged which creates a risk of explosion.

▸

Prevent any possible damage to the gas flow meter. When necessary, fit protection devices.

▸

If the gas flow meter is damaged: Stop natural gas feed immediately and purge the FLOWSIC500 with inert gas.

WARNING: Hazards through leaks

Operation in leaky condition is not allowed and potentially dangerous.

▸

Regularly check leak tightness of equipment.

1.2 About this document

This Manual describes: – Device components – Installation – Operation of the FLOWSIC500. It contains the main safety information for safe operation of the FLOWSIC500.

Important Information

Scope of document

Make sure that your FLOWSIC500 is equipped with optically isolated inputs and outputs:

▸

Check the type code, position 23 "I/O", on the type plate (→ Fig.2) of your FLOWSIC500: –

FLOWSIC500 with interface configurations F, G H, I and J have optically isolated inputs and outputs.

–

For information on FLOWSIC500 with interface configurations A, B, C, D and E, please refer to document "8018707, Addendum to Operating Instructions FLOWSIC500: Interface Configurations".

Fig. 1 Ty pe co d e

▸

For a complete description of the type code refer to → p. 112, §9.2.

NOTICE: Interface Configurations

This document only applies to FLOWSIC500 gas flow meters with optically isolated inputs and outputs.

2523 24

10 FLOWSIC500 · Operating Instructions · 8015391/Z261/V2-3/2016-10 · © SICK Engineering GmbH

Subject to change w ithout notice

Important Information

1 Type plate, metrological and electrical parameters

(metrology and electronics)

4 Type plate, electrical parameters (electronics)

2 Pin assignment of plug-in connectors 5 Type plate, metrological parameters (metrology) 3 Type plate PED

Labelling according to CSA

Labelling according to ATEX/IECEx

1.3 Intended use

1.3.1 Purpose of the device

The FLOWSIC500 serves for measuring the gas volume, volume flow rate and gas velocity of natural gas in pipelines.

The FLOWSIC500 with optional volume conversion serves for measuring the gas volume and converting the gas volume measured to base conditions as well as registering data on meter readings, maximums and other data.

1.3.2 Product identification

Product name: FLOWSIC500

Manufacturer:

The type plates for metrological and electrical parameters are located on the gas flow meter. The type plate for the Pressure Equipment Directive is located on the adapter.

Examples for the type plates see → p. 114, § 9.3.

SICK Engineering GmbH Bergener Ring 27 01458 Ottendorf-Okrilla Germany

Fig. 2 Location of type plates

Subject to change w ithout notice

FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH 11

1.3.3 Operation in potentially explosive atmospheres

The FLOWSIC500 is suitable for use in potentially explosive atmospheres: ATEX: II 2G Ex ia [ia] IIB T4 Gb, II 2G Ex ia [ia] IIC T4 Gb, IECEx: Ex ia [ia] IIB T4 Gb, Ex ia [ia] IIC T4 Gb, US/C: Class I Division 1, Groups C, D T4, Ex/AEx ia IIB T4 Ga

Further information on potentially explosive atmospheres → p. 37, § 3.4.1.

1.3.4 Combustible gas

▸

The FLOWSIC500 is suitable for measuring combustible and occasionally ignitable gases corresponding to zones 1 and 2.

1.3.5 Restrictions of use

▸

Refer to the type plate for the configuration of your FLOWSIC500.

▸

Check the FLOWSIC500 is suitably equipped for your application (e.g. gas conditions).

WARNING: Hazard through material fatigue

The FLOWSIC500 has been designed for use under mainly static loads.

▸

Maximum allowed gradient of static pressure: 3 bar/s (45psi/sec)

The number of complete pressure application and release processes should be kept low during operation.

▸

Replace the device when 500 cycles have been reached.

Important Information

II 2G Ex op is IIC T4 Gb

Ex op is IIC T4 Gb

NOTICE:

The FLOWSIC500 is designed for measuring clean and dry natural gas.

▸

The operator should install a suitable filter or cone screen ahead of the gas flow meter when the gas is contaminated.

NOTICE:

● The FLOWSIC500 is suitable for use in pressurized lines within the parameters specified in the device. The device complies with Pressure Equipment Directive 2014/68/EU.

● It is the user's responsibility to ensure the maximum values specified for pressure and temperature on the type plate are not exceeded during operation.

12 FLOWSIC500 · Operating Instructions · 8015391/Z261/V2-3/2016-10 · © SICK Engineering GmbH

Subject to change w ithout notice

Important Information

1.3.6 Cleaning

WARNING: Risk of ignition due to electrostatic charge

Under certain extreme circumstances, in Gas Group IIC, exposed plastic and unearthed metal parts of the enclosure may store an ignition-capable level of electrostatic charge.

▸

Implement precautions to prevent the build up of electrostatic charge, e.g. locate the equipment where a charge-generating mechanism (such as wind-blown dust) might occur and clean with a damp cloth.

NOTICE: Cleaning instructions

▸

Only clean the FLOWSIC500 with a damp cloth.

▸

Do not use solvents for cleaning.

▸

Only use materials for cleaning which do not damage the surface of the FLOWSIC500.

1.4 Responsibility of user

▸

Only put the FLOWSIC500 into operation after reading the Operating Instructions.

▸

Observe all safety information.

▸

If anything is not clear: Please contact the SICK Customer Service.

Designated users

The FLOWSIC500 may only be operated by skilled technicians who, based on their technical training and knowledge as well as knowledge of the relevant regulations, can assess the tasks given and recognize the hazards involved.

NOTICE:

Skilled persons are persons in accordance with DIN VDE 0105 or IEC 364, or directly comparable standards.

These persons must have exact knowledge on hazards arising from operation, e.g. through hot, toxic, explosive gases or gases under pressure, gas-liquid mixtures or other media as well as adequate knowledge of the measuring system gained through training.

Correct use

▸

Only use the FLOWSIC500 as described in these Operating Instructions (→ p. 11, § 1.3.1). The manufacturer bears no responsibility for any other use.

▸

Do not carry out any work or repairs on the FLOWSIC500 not described in this manual.

▸

Do not remove, add or change any components in or on the FLOWSIC500 unless such changes are officially allowed and specified by the manufacturer.

Otherwise – Any warranty by the manufacturer becomes void – The FLOWSIC500 can become dangerous – The approval for use in potentially explosive atmospheres is no longer valid – The approval fur use in lines pressurized above 0.5 bar (7.25 psi) bar is no longer

valid.

Subject to change w ithout notice

FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH 13

Danger identification on device

WARNING: Danger identification on device

The following symbol draws attention to important dangers directly on the device:

▸

Consult the Operating Instructions in all cases where the symbol is attached to the device or shown on the display.

Special local conditions

▸

Follow all local laws, regulations and company-internal operating directives applicable at the installation location.

Retention of documents

These Operating Instructions must be

▸

Kept available for reference

▸

Passed on to new owners.

1.5 Additional documentation/information

Some parameter settings, components and characteristics depend on the individual device configuration. This individual device configuration is described in the device documentation delivered with the device.

● Certificate of conformity/EX certificates (depending on configuration)

● Material certificate

● Inspection certificate

– Device configuration sheet – Encoder test protocol (if configured) – Low-pressure calibration test protocol (if ordered) – Labels according to Pressure Equipment Directive 2014/68/EU, Annex 1 Part 3.3

● Printout of the Data Book

● Product CD with:

– Operating Instructions – Operating program FLOWgate500 – FLOWgate500 Software Manual –Key code – Instructions for Kamstrup test valve BDA04

Important Information

14 FLOWSIC500 · Operating Instructions · 8015391/Z261/V2-3/2016-10 · © SICK Engineering GmbH

Subject to change w ithout notice

Product Description

FLOWSIC500

2 Product Description

Operating principle

Device components

Meter sizes

Power supply

Interfaces

Device option: Volume conversion

Totalizers

Logbooks and Archives

Parameter protection

Sealing

Subject to change w ithout notice

FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH 15

2.1 Operating principle

v= Gas velocity L= Measuring path

 = Angle of inclination in °

= Sound transit time in flow direction

= Sound transit time against flow direction

= Pipe inner diameter

Q= Volume flow



-- -

2 cos

--------------- -

BAtAB

–

ABtBA



----------------------

=

=

Vb= Volume at base conditions C = Conversion factor V

= Volume at measurement conditions

p = Gas pressure at measurement conditions p

= Pressure at base conditions T = Gas temperature at measurement conditions T

= Temperature at base conditions

= Compression factor at base conditions

Z = Compression factor at measurement conditions

-----

----- -

=

2.1.1 Gas flow meter

The FLOWSIC500 works according to the principle of ultrasonic transit time difference measurement.

Fig. 3 Functional principle

Measured signal transit times tAB and tBA are defined by the current sound and gas velocity.

Gas velocity v is determined from the difference between the signal transit times. Therefore changes in the sound velocity caused by pressure or temperature fluctuations do not affect the calculated gas velocity with this measurement method.

The FLOWSIC500 calculates the volume flow rate internally from the gas velocity and the diameter of the measuring section of the gas flow meter.

Product Description

2.1.2 Volume conversion (optional)

The integrated volume conversion converts the measured gas volume from measurement conditions to base conditions.

Calculation according to EN 12405:

The measurement conditions are either determined with pressure and temperature transmitters or entered as fixed value.

The following short forms are used in this document for better readability:

● Volume at base conditions = base volume

● Volume at measurement conditions = measurement volume

16 FLOWSIC500 · Operating Instructions · 8015391/Z261/V2-3/2016-10 · © SICK Engineering GmbH

Subject to change w ithout notice

Product Description

Gas flow meter

Adapter

2.2 FLOWSIC500 measuring system

The FLOWSIC500 measuring system comprises:

● FLOWSIC500 gas flow meter,

● Adapter for installation in pipeline and

● optional p&T sensors for the volume conversion device option.

Fig. 4 FLOWSIC500 components

2.2.1

Adapter

The adapter is available in various flange standards and fitting lengths to connect the gas flow meter to the system pipeline.

Depending on the version, the adapter is designed for assembly on line flanges PN16 in accordance with DIN EN1092-1, CL150 in accordance with ASME B16.5, or 1.6MPa in accordance with GOST 12815-80.

Fitting lengths available: → p. 117, § 9.4.

Subject to change w ithout notice

FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH 17

2.2.2 Gas flow meter

An internal flow conditioner rectifies the gas flow in the gas flow meter so that flow profile disturbances caused by pipe bends in the inlet or outlet sections or components projecting into the pipe (e.g., a thermowell) have no influence on measuring results.

The gas flow meter can be replaced without taking the adapter out of the pipeline. The gas flow meter is fitted with:

● Control unit

● Optical and electrical interfaces

● Measuring cell with ultrasonic transducers

● Electronics.

The product variant with volume conversion and integrated pressure and temperature transmitters also has the calibrated pressure transmitter and calibrated temperature transmitter fitted in the gas flow meter.

2.3 Meter sizes

Available meter sizes → p. 117, §9.4.

2.4 Power supply

The FLOWSIC500 is available with two configurations:

● For operation with external intrinsically safe power supply with backup battery (backup duration: Approx. 3 months).

● Self-sufficient power configuration: 2 internal longlife battery packs (typical service life: At least 5 years).

The second battery pack is activated automatically when the first pack is empty and a message displayed (→ p. 58, § 5.2).

Product Description

2.5 Interfaces

The FLOWSIC500 supports various digital and serial interfaces. The configuration of the interfaces as delivered is described in the delivery documents pro-

vided with the respective device.

Table 1 Interface configurations

Config. 1 (LF) Config. 2 (HF) Config 3 (Encoder + LF) Config. 4 (RS485) Config. 5 (Encoder + HF)

Type code I/O: F Type code I/O: G Type code I/O: H Type code I/O: I or J Type code I/O: K DO_0 - HF pulses Encoder - Encoder DO_1 Normal mode: Diagnosis warning, test mode: Test pulses HF pulses DO_2 LF pulses - - - DO_3 Malfunction Malfunction LF pulses - Malfunction Serial - - RS485 -

● Information on explosion-technical characteristics and rated voltage

→ p. 37, § 3.4.

● Details on standard interface configurations available → p. 42, § 3.4.6.

Subject to change w ithout notice

18 FLOWSIC500 · Operating Instructions · 8015391/Z261/V2-3/2016-10 · © SICK Engineering GmbH

Product Description

2.5.1 Pulse and status outputs

FLOWSIC500 has 4 digital switching outputs. Digital switching outputs DO_0, DO_2 and DO_3 are electrically isolated according to EN 60947-5-6.

Alternatively, digital switching outputs DO_2 and DO_3 can also be configured as Open Collector.

When used as pulse output, maximum 2 kHz can be output on digital switching output DO_0 and maximum 100 Hz on digital switching outputs DO_2 and DO_3. When used as status output, status information "Validity of measurement" or the result of the self-diagnosis can be represented.

Digital switching output DO_1 is not electrically isolated. In normal mode, the diagnosis warning is output on DO_1, test pulses are output in test mode.

The digital switching outputs are updated synchronously once per second.

2.5.2 Encoder totalizer

Alternatively, NAMUR switching output DO_0 can be configured so that the reading of totalizer Vm, the meter status and a meter identification are output via asynchronous serial communication. This allows the connection of volume convertors with a suitable input for encoder totalizers.

NOTICE:

If encoder communication has been configured, ensure that the transferred number of digits and the counter resolution can be processed by a connected volume converter.

When the parameter locking switch is open, a parameter change can be performed at the FLOWSIC500 using the FLOWgate500 operating software.

2.5.3 Serial data interface

The serial interface is designed as externally powered RS485 and requires an external intrinsically safe power supply for operation. The RS485 interface has no internal line termination.

2.5.4 Optical data interface

An optical interface according to IEC 62056-21 with serial bit, asynchronous data transmission is located on the front of the FLOWSIC500.

The interface can be used to read out data and parameter settings and to configure the FLOWSIC500.

Subject to change w ithout notice

FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH 19

2.6 Device option: Volume conversion

2.6.1 Volume conversion

The FLOWSIC500 gas flow meter with volume conversion captures the gas volume under measurement conditions and converts it to a volume under base conditions.

Gas volume conversion can run selectively (set at the factory) as PTZ or TZ volume conversion: The configuration as temperature volume conversion uses the default value for measurement pressure for calculations.

Measurement conditions are recorded with the pressure and temperature transmitters or entered as fixed values.

By default, measured values recording and subsequent conversion to the volume under base conditions are performed every 30 seconds. The update interval can be adjusted → p. 69, § 5.2.6.5, “Calculation”.

Depending on the configuration, the compressibility factor (K-factor) is determined with one of the following calculation methods or can be entered as a fixed value.

● SGERG88,

● AGA 8 Gross method 1

● AGA 8 Gross method 2

● AGA NX-19

● AGA NX-19 mod.

● Fixed value

The FLOWSIC500 checks the permissible entry limits of the parameters for the selected calculation method. If one of the entry values is outside the limit values, the FLOWSIC500 switches to malfunction state and uses the fixed value of the compressibility factor for calculation of the basis volume.

An absolute pressure transmitter EDT 23 (optional: relative pressure transmitter EDT 23) and a temperature transmitter EDT 34 measure current measurement conditions and transfer the transmitter type, measured value as well as the transmitter status via a digital interface.

The FLOWSIC500 reads the valid measuring range automatically and, periodically, the current status and measured value.

A transmitter is only activated for measurement when the configured serial number matches the serial number transferred for the transmitter.

If no transmitter is detected or a transmitter is not functioning correctly, the FLOWSIC500 automatically uses the stored default value (= fixed value) of the state vari-

able. In this case, the FLOWSIC500 switches to malfunction state and, using the default value,

stores the volume under base conditions calculated for pressure or temperature in the error volume counter.

If not specified otherwise, the FLOWSIC500 is supplied with the following standard settings:

Table 2 Standard settings

Unit system SI Imperial T unit °C ° F P unit bar psi Symbols according to EN 12405 API Calculation method SGERG88 AGA 8 Gross method 1 Reference conditions for den-

sity and heating value

(T1/T2/p2)

25 °C/0 °C/1.01325 bar (a) Base pressure 1.01325 bar (a) 14.7300 psi (a) Base temperature 0 °C 60 °F

Product Description

Subject to change w ithout notice

(T1/T2/p2) 60 °F/60 °F/14.7300 psi (a)

20 FLOWSIC500 · Operating Instructions · 8015391/Z261/V2-3/2016-10 · © SICK Engineering GmbH

Product Description

1 Pressure transmitter 2 Kamstrup test valve BDA04 3 Temperature transmitter

2.6.2 Integrated pressure and temperature transmitters

The FLOWSIC500 with volume conversion and integrated pressure and temperature transmitters does not have any external components. The internal pressure and temperature transmitters are already fitted and calibrated at the factory. The measuring ports are located in the gas flow meter.

This means the FLOWSIC500 does not require any additional installation of transmitters to determine the measurement conditions and is immediately ready for operation after volume conversion has been configured.

2.6.3 External pressure and temperature transmitters

The FLOWSIC500 with volume conversion and external transmitters is used at measuring ports where a test/calibration of the pressure or temperature transmitter in the system may be required.

It is recommended to install a three-way test valve that separates the pressure transmitter from the measurement pressure and provides a test connection to test the pressure transmitter.

→ Fig. 5 shows a FLOWSIC500 with external transmitters and Kamstrup test valve BDA04 for gas temperatures to -25°C.

Fig. 5 FLOWSIC500 with external transmitters and Kamstrup test valve BDA04

A three-way test valve (→ Fig. 6) that is fitted next to the FLOWSIC500 is used for gas temperatures to -40°C.

Subject to change w ithout notice

FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH 21

Fig. 6 Three-way test valve with p transmitter and Minimess coupling

1FLOWSIC500 connection 2 Three-way test valve 3 Test connection (Minimess coupling) 4 Pressure transmitter

Product Description

2.7 Totalizers

2.7.1 Device status and totalizers used

Various volume totalizers are fitted on the FLOWSIC500 depending on the configuration. Meter V is used in the configuration as gas flow meter. If the gas flow meter has a malfunc-

tion, the measured volume is also recorded in the error volume counter errV.

Table 3 Device status and totalizers used

Status Totalize r

VerrV Operation Malfunction

●

●●

A gas flow meter Vm, a base volume meter Vb and a total volume meter Vbtot are used in the configuration as gas flow meter with integrated volume conversion (device option). If malfunctions occur, the measured values are not recorded in the base volume meter Vb, but the converted volume is recorded in the error volume meter errVb.

Table 4 Device status and totalizers used (with device option volume conversion)

Status Totalize r

Vb errVb Vbtot Vm errVm Operation Malfunction

Authorized users (user level "Authorized user") can reset the error volume counters → p. 73,

§5.2.11.

●●●

●●●●

22 FLOWSIC500 · Operating Instructions · 8015391/Z261/V2-3/2016-10 · © SICK Engineering GmbH

Subject to change w ithout notice

Product Description

2.7.2 Reverse flow

The FLOWSIC500 is designed as unidirectional type and has a configurable zero-flow cutoff which is factory set to a value of 1 m

The totalizers are stopped during reverse flow and this volume is counted in a separate buffer totalizer. When normal operation resumes, the buffer totalizer is first computed with the flow.

The totalizers are first incremented again after the reverse flow volume has passed through.

During reverse flow, the meter first switches to malfunction when the preconfigured buffer volume has been exceeded. An error message is output on the device.

2.8 Logbooks and Archives

The integrated data registration stores meter readings, maximums and other data in the following archives:

● Measuring period archive Totalizers and data saved after the measuring period elapses (standard = 60 min.). The

measuring period can be adjusted → p. 71, §5.2.6.9.

● Daily archive Totalizers and data saved at the defined gas hour time (standard = 06:00)

● Monthly archive Totalizers and data saved at the defined gas day time (standard = 1st day of month)

(35 ft3) as default.

Explanations on data structure and storage depth are available in Technical Bulletin "Data Registration").

The FLOWSIC500 stores events and parameter changes in the following logbooks:

● Event logbook All events with timestamp, user logged on and totalizer reading, max. number of

entries: 1000 When the Event logbook is 90% full, the FLOWSIC500 changes to device status "Warn-

ing", warning W-2001 is shown on the display. When the Event logbook is full, the FLOWSIC500 changes to device status "Malfunc-

tion", error E-3001 is shown on the display (→ p. 78, § 6.2, “Status messages”).

● Parameter logbook All parameter changes with timestamp, user logged on, totalizer reading and old and

new parameter value, max. number of entries: 250 The oldest entries are overwritten when the Parameter logbook is full.

● Metrology logbook All changes to selected calibration-relevant parameters (→ p. 24, §2.9.2), with parameter

locking switch activated with timestamp, user logged on, totalizer reading and old and new parameter value, max. number of entries: 100

When the Metrology logbook is full, calibration-relevant parameters can be modified only after the parameter locking switch has been opened. The FLOWSIC500 changes to device status "Warning", warning W-2002 is shown on the display (→ p. 78, § 6.2, “Status

messages”).

Subject to change w ithout notice

The data are stored in non-volatile memory. All logbooks can be viewed, stored and reset with operating software FLOWgate500. The Event logbook can be viewed after logon as "User" or "Authorized user" on the device.

FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH 23

The following parameters are displayed:

EXT. POWER

BAT1

N.c.

DO3

DO0

RS485

P1P2T1

SENSORS

DISPLAY

LOCK OFF ON

5..12V

NAMUR

4,5..16V

1.5 mm² (AWG 16)

R :100

2..16V

4074419

DO2

*Optional V see module

OC NAM

2..16V

DO1

BAT2

OC NAM

+- +-

● Event type

● Number of events

● Short description

● Timestamp

2.9 Parameter protection

2.9.1 Parameter locking switch

A parameter locking switch is located on the circuit board to secure the calibration-relevant parameters. This covers all values that influence volume metering and volume conversion.

Fig. 7 Parameter locking switch on the circuit board

Product Description

The parameter locking switch is secured by the terminal compartment cover and a seal.

2.9.2 Metrology logbook

Selected calibration-relevant parameters can be modified when the parameter locking switch is closed and after logging in as authorized user.

To ensure traceability of these parameter changes, an entry is created in the Metrology logbook. This entry contains the timestamp, old and new value of the parameter changed, meter reading V (for gas flow meters) or Vb (for gas flow meters with device option volume conversion) and the logged on user.

The Metrology logbook can have a maximum of 100 entries. The FLOWSIC500 switches to status "Warning" when the Metrology logbook is full.

The Metrology logbook can be cleared when the parameter locking switch is open. Parameter changes to the following parameters are entered in the Metrology logbook as long as entries are possible

Table 5 Calibration-relevant parameters - gas flow meter

Parameter Description Reverse flow limit Buffer volume for reverse flow Symbols for measured value displays Symbols used on the display (formula symbols)

24 FLOWSIC500 · Operating Instructions · 8015391/Z261/V2-3/2016-10 · © SICK Engineering GmbH

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Product Description

Tab le 6 Calibration-relevant parameters - gas flow meter with volume conversion

Parameter Description Reverse flow limit Buffer volume for reverse flow Symbols for measured value displays Symbols used on the display (formula symbols) Flow - lower warning limit Lower warning limit for the flow which can be set by the cus-

tomer

Flow - upper warning limit Upper warning limit for the flow which can be set by the cus-

tomer Calculation method Calculation method for the compressibility factor Calculation interval Cycle time for updating measured values (pressure, tem-

perature) and calculation of the compressibility factor Standard pressure Standard pressure Standard temperature Standard temperature Reference conditions Reference conditions for density and heating value Atmospheric pressure Ambient pressure K-factor (fixed) Figure for method "Fixed value" when the calculation of the

K-factor is incorrect. CO2 CO H2 H N2 N

proportion in gas

Relative density Relation between gas density and air density under refer-

ence conditions Reference density Gas reference density under reference conditions Heating value Gas heating (under reference conditions) Heating value unit Heating value unit p Default value Fixed value of measurement pressure p Unit Unit for pressure values, used for entry and display p Lower alarm limit Lower warning limit for the pressure which can be set by the

customer p Upper alarm limit Upper warning limit for the pressure which can be set by the

customer p Unit Unit for pressure values T Default value Fixed value of measurement temperature T Unit Unit for temperature values, used for entry and display T Lower alarm limit Lower warning limit for the temperature which can be set by

the customer T Upper alarm limit Upper warning limit for the temperature which can be set by

the customer T Unit Unit for temperature values, used for entry and display Gas hour Billing hour for the day archive Gas day Billing day for month archive Measuring period Period for billing archive

Subject to change w ithout notice

FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH 25

2.10 Sealing

1 Seal position 2 Possible position of the adapter seal 3 Possible position of the electronic cover seal

The FLOWSIC500 is secured at the factory with a seal on the cover. Gas flow meter and adapter can be secured at the joint by a user seal (adhesive label)

glued with approximately equal spread on gas flow meter and adapter. Optionally, the electronics cover can also be protected by the customer after the end of the

installation against unauthorized opening.

Fig. 8 Factory seal of the cover on the gas flow meter

Product Description

In addition, the FLOWSIC500 has seal positions on the terminal compartment cover and the plug-in connector cover.

An adhesive label secures the interfaces and the parameter locking switch by the terminal cover compartment.

During the start-up, the plug-in connector cover must be secured according to national regulations. This can be performed with an adhesive label which is glued with approximately equal spread on the cover and the enclosure or alternatively by using capstan screws and a tensioned sealing wire and a wire seal.

Subject to change w ithout notice

26 FLOWSIC500 · Operating Instructions · 8015391/Z261/V2-3/2016-10 · © SICK Engineering GmbH

Product Description

1Seal position 2 Terminal compartment cover (securing the terminal compartment) 3 Plug-in connector cover 4 Capstan screw, wire and wire seal (securing of plug-in connector cover)

1 Temperature transmitter 2 Locknut 3Wire seal

Fig. 9 Seals on the terminal compartment and plug-in connector cover

NOTICE:

▸

Secure the terminal compartment cover and the plug-in connector cover with at least one verification seal against unauthorized removal of the cover!

Fig. 10 Seal on the temperature transmitter (example)

Subject to change w ithout notice

FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH 27

Fig. 11 Seal on the pressure transmitter (example)

1 Pressure transmitter 2 Kamstrup test valve BDA04 3Wire seal 4 Wire loop

Product Description

NOTICE:

Make sure that the wire loop is placed tight around the pressure transmitter.

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Installation

FLOWSIC500

3 Installation

Hazards during installation

General information

Mechanical installation

Electrical installation

External pressure and temperature transmitters installation

Subject to change w ithout notice

FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH 29

3.1 Hazards during installation

CAUTION: General risks during installation

▸

Observe applicable valid regulations, general standards and guidelines.

▸

Observe local safety regulations, operating instructions and special regulations.

▸

Observe the safety information in → p. 10, §1.1.

▸

Comply with the safety requirements of Pressure Equipment Directive 2014/68/EU or ASME B31.3 when installing pressure devices including connection of various pressure devices.

▸

Persons carrying out installation work must be familiar with the directives and standards applicable for pipeline construction and have the corresponding qualifications, e.g. in accordance with DIN EN 1591-4.

WARNING: Hazards through the gas in the system

The following conditions can increase the risk:

• Toxic gas or gas dangerous to health

•Explosive gas

• High gas pressure

▸

Only carry out installation, pre and repair work when the system is nonpressurized.

Installation

WARNING: Hazards during installation work

▸

Do not carry out any welding work on lines with meters fitted.

▸

Comply exactly with mandatory and approved methods.

▸

Observe and comply with regulations of the plant operator.

▸

Meticulously check completed work. Ensure leak tightness and strength.

Otherwise hazards are possible and safe operation is not ensured.

3.2 General information

3.2.1 Delivery

The FLOWSIC500 is delivered preassembled in sturdy packaging.

▸

Inspect for transport damage when unpacking the device.

▸

Document any damage found and report this to the manufacturer.

NOTICE:

Do not put the FLOWSIC500 into operation if you notice any damage!

▸

Check the scope of delivery for completeness.

The standard scope of delivery comprises:

● FLOWSIC500 (gas flow meter and adapter, already fitted),

● Backup battery (if device is configured for external power supply), or

● 2 battery packs (if device is configured for battery operation).

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Installation

3.2.2 Transport

▸

During all transport and storage work, ensure: – The FLOWSIC500 is always well secured – Measures to prevent mechanical damage have been taken – Ambient conditions are within specified limits.

3.3 Mechanical installation

CAUTION: General risks during installation

▸

Observe applicable valid regulations, general standards and guidelines.

▸

Observe local safety regulations, operating instructions and special regulations.

▸

Observe the safety information in → p. 10, §1.1.

▸

Comply with the safety requirements of Pressure Equipment Directive 2014/68/EU or ASME B31.3 when installing pressure devices including connection of various pressure devices.

▸

The FLOWSIC500 normally does not need straight inlet and outlet sections and can be fitted directly after bends in the pipe.

NOTICE: Requirements on installation

▸

3.3.1 Preparations

▸

Select a suitable mounting location. Ensure adequate mounting clearances (→ Table 9).

▸

The following tools and materials are required to install the FLOWSIC500: – Hoisting equipment (lifting capacity according to the weight specifications → p. 117,

§9.4) – Box wrench with size suitable for flange installation – Torque wrench – Flange gaskets – Anti-seize paste, metal-free or suitable for aluminium, e.g. OKS 235, to prevent

thread mountings seizing up

At a distance up to 5 DN upstream to the adapter, the following elements must not occur:

– a valve which is not always fully open during operation, – a pressure regulator. The temperature sensor must not be disposed more than 5 DN down-

stream of the gas meter. The temperature sensor can be inserted in the optional thermowells at the adapter alternatively.

In concrete application, observe limitations resulting from type approval!

NOTICE:

Do not use copper paste!

– 3 mm Allen key

Subject to change w ithout notice

FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH 31

– Leak detection.

3.3.2 Choosing flanges, gaskets and other components

For flange connections only use pipeline flanges, bolts, nuts and gaskets suitable for the maximum operating pressure, maximum operating temperature as well as ambient and operating conditions (external and internal corrosion).

→ Table 7 contains a list of recommended bolts and → Table 8 contains a list of recom- mended gaskets.

Table 7 Bolts and tightening torques

Device/flange

Bolts Washers Nuts Tightening torque

type PN16 / EN1092-1 DN50/ PN16 4 pc. DIN835-

M16x45-A2-70 DN80/ PN16 8 pc. DIN835DN100/ PN16

M16x45-A2-70

DN150/ PN16 8 pc. DIN835-

M20x55-A2-70

4 pc. DIN125A17-A4

8 pc. DIN125A17-A4

8 pc. DIN125A21-A2

4 pc. ISO4032M16-A4-70

8 pc. ISO4032M16-A4-70

8 pc. ISO4032M20-A2-70

Class 150 / ASME B16.5 2"/ Cl150 4 pc. Double end

3"/ Cl150

4"/ Cl150 8 pc. Double end

6"/ Cl150 8 pc. Double end

Table 8 Gaskets

Device/flange type

threaded stud Ø 5/8",

length 3.5"- ASME

B18.31.2,

ASTM A193 Grade

B8M

threaded stud Ø 5/8",

length 3.5"- ASME

B18.31.2,

ASTM A193 Grade

B8M

threaded stud Ø 3/4",

length 4.0"- ASME

B18.31.2,

ASTM A193 Grade

B8M

[1]

[mm]

Di [mm] S [mm]

4 pc. Type A plain washer (narrow series) Ø 5/8" ANSI B18.22.1, grade 8 stainless steel

8 pc. Type A plain washer (narrow series) Ø 5/8" ANSI B18.22.1, grade 8 stainless steel

8 pc. Type A plain washer (narrow series) Ø 3/4" ANSI B18.22.1, grade 8 stainless steel

4 pc. Hex flat nut (UNC series) Ø 5/8" ANSI B18.2.2, ASTM A194 Grade 8MA

8 pc. Hex flat nut (UNC series) Ø 5/8" ANSI B18.2.2, ASTM A194 Grade 8MA

8 pc. Hex flat nut (UNC series) Ø 3/4" ANSI B18.2.2, ASTM A194 Grade 8MA

Material

PN16 / EN1092-1 DN50/ PN16 107 61 DN80/ PN16 142 90 DN100/ PN16 162 115

2 novapress® FLEXIBLE/815

DN150/ PN16 218 169 Class 150 / ASME B16.5 2"/ Cl150 105 60 3"/ Cl150 137 89 4"/ Cl150 175 114

2 novapress® FLEXIBLE/815

6"/ Cl150 222 168

[1] Da = outer diameter, Di = inner diameter, S = thickness, → Fig. 12

Installation

130 Nm 96 lbf ft

250 Nm 184 lbf ft

140 Nm 103 lbf ft

240 Nm 177 lbf ft

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Installation

Fig. 12 Dimensions of gaskets

Subject to change w ithout notice

FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH 33

3.3.3 Fitting the FLOWSIC500 in the pipeline

Marking for flow direction

Direction of gas flow

NOTICE:

The lifting lug is designed for transporting the measuring device only. Do not lift or transport the FLOWSIC500 with additional loads using this lug.

▸

The FLOWSIC500 must not swing or tilt on the hoisting equipment during transport.

▸

The FLOWSIC500 must not turn during transport otherwise the lifting lug could be screwed out.

NOTICE: Observe the gas flow direction

The prescribed flow direction is marked on the adapter with an arrow. Arrow direction and gas flow direction must match.

▸

Install the FLOWSIC500 in flow direction. The device signals a malfunction when the FLOWSIC500 is installed against the prescribed flow direction.

The FLOWSIC500 can be installed horizontal or vertical. The control unit can be rotated ± 90° (→ p. 40, § 3.4.4).

Fig. 13 Installation examples

Installation

34 FLOWSIC500 · Operating Instructions · 8015391/Z261/V2-3/2016-10 · © SICK Engineering GmbH

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Installation

1 Clearance at the top 2 Clearance at the bottom

3.3.3.1 Mounting clearances

Adequate mounting clearances must be maintained to ensure that sufficient space is available for exchanging the gas flow meter.

The clearance at the top is required for removing the gas flow meter and placing it back on the adapter. The clearance at the bottom is required for loosening and removing or reinserting the screws and applying the tool accordingly.

Fig. 14 Mounting clearances

NOTICE:

Depending on the tools used and the mounting location, sufficient clearances to the left and right must be ensured.

Tab le 9 Required minimum clearance based on the pipe axis

Meter size Clearance at the top,

without lifting lug

Clearance at the top, with lifting lug

Clearance at the bottom

[mm] [in] [mm] [in] [mm] [in] DN50/2" 300 11.81 340 13.39 200 7.87 DN80/3" 460 18.11 510 20.08 250 9.84 DN100/4" 520 20.47 570 22.44 320 12.6 DN100/6" 520 20.47 570 22.44 320 12.6

Subject to change w ithout notice

FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH 35

3.3.3.2 Torque on the pipeline

NOTICE:

If the FLOWSIC500 is installed so that the gas flow meter projects sideways from the pipeline, the gas flow meter weight creates a torque on the pipeline.

▸

Make sure the pipeline is capable of holding the gas flow meter → p. 36, Table 10.

Table 10 Pipeline torque

Meter size Torque

DN50/2" 6 5 DN80/3" 16 12 DN100/4" 31 23 DN150/6" 31 23

3.3.3.3 Installation in pipeline

1 Select suitable bolts.

Recommended bolts → Table 7.

2 Use the hoisting equipment to position the FLOWSIC500 in the desired location in the

pipeline. Lay the pipelines without tension to the device to be installed!

3 Insert and align the gaskets. 4 Apply anti-seize paste to the bolts. 5 First screw the bolts by hand into the adapter to the stop.

– Screw in the bolts according to DIN835 with the shorter thread end. – The bolts according to ASME B18.31.2 can be screwed in with any end.

6 Check the thread length in the adapter is fully utilized. 7 Then install the washers and nuts, and tighten them by hand. 8 Check whether the thread length of the nut is fully utilized.

If necessary, use a different bolt length.

9 Check correct positioning of flange gaskets. 10 Tighten nuts evenly and crosswise in small steps until the specified tightening torque is

reached (→ Table 7). Make sure the flange sits free of tension.

11 Slowly increase the pressure in the pipeline.

Gradient: Max. 3bar/min (45psi/min)

12 Carry out a leak tightness check on the pipeline (in accordance with the pipeline manu-

facturer's specifications).

Installation

[Nm] [lbf ft]

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Installation

3.4 Electrical installation

3.4.1 Requirements for use in potentially explosive atmospheres

For a FLOWSIC500 used in potentially explosive atmospheres:

▸

Installation, start-up, maintenance and inspection may only be carried out by skilled persons having knowledge of the relevant rules and regulations for potentially explosive atmospheres, especially:

– Ignition protection types – Installation regulations – Category classification

▸

Comply with all valid IEC standards.

The FLOWSIC500 is suitable for measuring combustible and occasionally ignitable gases corresponding to zones 1 and 2.

Basic requirements

▸

The documentation for zone categorization in accordance with IEC60079-10 must be available

▸

The FLOWSIC500 must have been checked for suitability for the actual installation location and the Ex marking on the device must match the requirements.

▸

After installation and before initial start-up, the complete equipment and the system must be inspected in compliance with IEC 60079-17.

II 2G Ex op is IIC T4 Gb

Ex op is IIC T4 Gb

WARNING: Risk of explosion

All electrical connections of the FLOWSIC500 are approved for connection to the certified intrinsically safe power circuits only.

▸

Proof of the intrinsic safety in compliance with IEC 60079-14 must be presented for interconnection with the associated intrinsically safe equipment.

Otherwise the intrinsic safety of the FLOWSIC500 can be endangered, i.e. the ignition protection for the FLOWSIC500 can no longer be ensured.

Subject to change w ithout notice

FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH 37

Operating conditions for the ultrasonic sensors

● The pipeline contains a nonexplosive mixture. The gas mixture can be combustible.

● Gas pressure and gas temperature can be within the range specified on the type plate of the gas flow meter.

Case 2:

● The area inside the pipeline is classified as potentially explosive atmosphere Zone 1 or 2.

● The gas pressure must be within the range 0.8 (11.6 psi) to 1.1 bar (15.95 psi) (normal atmospheric conditions).

● Gas temperature must be within the permitted ambient temperature range specified by the type plate on the gas flow meter

Zone 1 or 2

Case 1:

Zone 1 or 2

Non-explosive gas mixture

Zone 1 or 2

The FLOWSIC500 is designed for use in potentially explosive atmospheres solely under normal atmospheric conditions within the following limits.

– Ambient pressure range 0.8 bar (11.6 psi) to 1.1 bar (15.95 psi) – Air with normal oxygen content, normally 21 percent by volume The ambient temperature must be within the range specified on the type plate. The gas flow meter becomes part of the pipeline as soon as the FLOWSIC500 is installed in

the pipeline. The walls of the pipeline and the gas flow meter then serve as zone-separating barrier. The

following Figure shows the different situations for a possible application and the operating conditions that apply.

Fig. 15 Ex zones

Installation

WARNING: Risk of ignition due to impact on the ultrasonic transducers

he ultrasonic transducers are manufactured from titanium. The pipeline adaptor and part of the electronic enclosure may be made from aluminium. In rare cases, ignition sources due to impact and friction sparks could occur.

The maximum piezo-electric energy released by impact on the ultrasonic transducers exceeds the limit for Gas Group IIC specified in Clause 10.7 of EN60079-11:2012.

▸

For this reason, the ultrasonic transducers may only be used in zone 1 when risks of ignition arising from impacts or friction on the sensor housing can be ruled out within the application.

▸

Only ultrasonic transducers provided by SICK may be used!

38 FLOWSIC500 · Operating Instructions · 8015391/Z261/V2-3/2016-10 · © SICK Engineering GmbH

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Installation

4 screws

3.4.2 Criteria for electrical connection

Installation work → p. 31, § 3.3 must be completed.

WARNING: Risk of explosion - hazard for intrinsic safety

▸

The following work may only be carried out by skilled technicians familiar with the special characteristics of the intrinsic safety of the ignition protection type and who have knowledge of the relevant standards and regulations for interconnection of intrinsically safe power circuits.

3.4.3 Opening and closing the electronics cover

The Ex i terminal compartment of the FLOWSIC500 can be accessed after the electronics cover has been opened. The cover may also be opened in the hazardous area when under voltage. However, safe separation between the various intrinsically safe power circuits must not be breached.

Opening the electronics cover

1 Loosen the 4 screws (captive) on the electronics cover using a 3 mm Allen key.

Fig. 16 Position of electronics cover screws

2 Open the electronics cover.

Closing the electronic cover

1 Close the electronics cover.

▸

Make sure no battery and display cables are pinched.

2 Screw the electronics cover tight again.

Tightening torque: 2.0 Nm (18 lbf in)

Subject to change w ithout notice

FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH 39

3.4.4 Rotating the control unit

4 display screws

1 Open the electronics cover (→ p. 37, § 3.4) 2 Loosen the 4 display screws with a 3 mm Allen key, → Fig. 17.

Fig. 17 Position of display screws

Installation

3 Rotate the display in the desired direction. 4 Tighten the display screws evenly.

Tightening torque: 1.0 Nm (9 lbf in)

5 Close the electronics cover again.

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Installation

1 2 3 4

1 Plug-in connector 1 (B-coded): External power supply and signal output 2 Plug-in connector 2 (A-coded): Signal output 3 Ground screw 4 Connections for pressure/temperature transmitters (optional)

Plug-in connector 1 (B-coded)

Plug-in connector 2 (A-coded)

3.4.5 Electrical connections

The FLOWSIC500 interfaces are accessible from the outside via external plug-in connectors.

Fig. 18 Connections

Fig. 19 M12 plug-in connector coding

NOTICE:

Safety relevant parameters are valid for connecting all pins of a plug-in connector.

Plug-in connector 2 (A-coded) can be configured when ordered, configuration options → p. 42, §3.4.6.

The respective configuration is printed on the type plate ( → p. 43).

The external power supply need not be connected when the FLOWSIC500 is operated with internal batteries.

Subject to change w ithout notice

FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH 41

3.4.6 Pin assignment of plug-in connectors

3.4.6.1 Plug-in connector 1: External power supply and signal output

Table 11 Pin assignment for M12 plug-in connector 1 (male/B-coded, 4-poles)

M12 pin Input/output Function/signal Operating parameters

Safety relevant parameters

1 PWR- Voltage supply Rated input voltage 4.5 … 16 V Ui = 20 V

= 667 mA

Pi = 753 mW U

= 8.2 V

2PWR+

3 DO_1- Diagnosis warning,

pulse output in test mode (→ Table 1) and in config-

4DO_1+

3.4.6.2 Plug-in connector 2: Signal output

Table 12 Pin assignment for M12 plug-in connector 2 (male/A-coded, 4-poles)

M12 pin Input/output Function/signal Operating parameters

Pin assignment configuration 1 LF pulses and malfunction (electrically isolated), Type code I/O: F

uration K, f

= 2 kHz at 120 %

max

1DO_2+ LF pulses

Passive, not electrically isolated

Max. 16 V Max. 100 mA R

< 110 Ω

> 1 MΩ

off

Passive, electrically isolated, configurable as:

configurable up to

2DO_2-

max

100 Hz at 120 % Q

3 DO_3- Malfunction

OC (Open Collector)*: Max. 16 V

max

Rated current 20 mA

= 0.83 mA

Po = 1.7 mW C

= 7,6 μF

= 100 mH

Safety relevant parameters

= 20 V

= 753 mW

or NAMUR:

4DO_3+

Pin assignment configuration 2 : HF pulses and malfunction (electrically isolated), Type code I/O: G

1 DO_0+ HF pulses

configurable up to

2DO_0-

max

2 kHz at 120 % Q

max

Rated input voltage 8.2 V I

= 3.4 mA

= 0.7 mA

off

NAMUR, electrically isolated, optically isolated Rated input voltage 8.2 V I

= 3.4 mA

= 0.7 mA

off

= 20 V

= 753 mW

3 DO_3- Malfunction Passive, electrically isolated, configu-

rable as OC (Open Collector)* or

4DO_3+

NAMUR, see Configuration 1 for operating parameters

Installation

Pin assignment configuration 3 : Encoder and LF pulses (electrically isolated), Type code I/O: H

1 DO_0+ Encoder protocol NAMUR, electrically isolated, optically

isolated

2DO_0-

Rated input voltage 8.2 V I

= 3.4 mA

= 0.7 mA

off

= 20 V

= 753 mW

3 DO_3- LF pulses Passive, electrically isolated, configu-

rable as OC (Open Collector)* or

4DO_3+

NAMUR, see Configuration 1 for operating parameters

* Standard configuration

42 FLOWSIC500 · Operating Instructions · 8015391/Z261/V2-3/2016-10 · © SICK Engineering GmbH

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Installation

(1) PWR+ (2) Data+ (3) GND (4) Data-

Sensor

(1) (2) DO_2(3) DO_3(4)

Power

Signal output

(1) (2) (3) (4)

PWRPWR+ DO_1DO_1+

A coded

B coded

DO_2+

DO_3+

Tab le 1 2 Pin assignment for M12 plug-in connector 2 (male/A-coded, 4-poles)

M12 pin Input/output Function/signal Operating parameters

Safety relevant parameters

Pin assignment configuration 4: RS485 module (externally powered), Standard Version: Type code I/O: J, Low voltage version: Type code I/O: I

1 PWR+ RS485 module

(externally powered)

2 Data A

3PWR-

Electrically isolated

Standard version: Rated input voltage 4 … 16 V

Low voltage version:

= 20 V

= 1.1 W

IIC: C IIB: Ci = 1.35 μF L

= 0.03 mH

Rated input voltage 2.7 ... 10 V

4 Data B

Pin assignment configuration 5 : Encoder and HF pulses (not electrically isolated), Type code I/O: K

The HF pulses are output via plug-in connector 1 (DO_1), → Table 11.

= 0.22 μF

1 DO_0+ Encoder protocol NAMUR, electrically isolated, optically

isolated

2DO_0-

Rated input voltage 8.2 V I

= 3.4 mA

= 0.7 mA

off

3 DO_3- Malfunction Passive, electrically isolated, configu-

rable as OC (Open Collector)* or

4DO_3+

NAMUR, see Configuration 1 for operating parameters

* Standard configuration

Fig. 20 Identification on the electronics type plate (example)

Internal terminal assignment→ p. 118, § 9.5

3.4.7

Cable specifications

When the plugs available from SICK are used, a shielded control cable with 4x0.25 mm cross-section, with PVC insulation and approx. 5 mm outer diameter is required.

= 20 V

Pi = 753 mW

Subject to change w ithout notice

WARNING: Requirements on cables and installation

▸

Pay attention to the requirements in EN 60079-14 when selecting the cables and during installation!

▸

Further legal requirements must be observed for use in explosive atmospheres.

SICK recommends the ready-made cables available as accessories (→ p. 104, §8.1).

FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH 43

3.4.8 Operation with external power supply

1 External power supply and signal output

The FLOWSIC500 is designed electrically intrinsically safe.

▸

After correct installation has been checked, the plug connections in the hazardous area can be connected and disconnected under voltage as well.

3.4.8.1 Connecting the external power supply

1 Connect the external intrinsically safe power supply to the M12 plug-in connector of the

FLOWSIC500. Safety-relevant parameters → p. 42, §3.4.6.

Fig. 21 Connection for external power supply underneath the gas flow meter

Installation

2 Switch the power supply on.

The FLOWSIC500 is initialized.

3 Measurement starts and the current measured value for the gas volume appears. 4 Set the date and time (→ p. 54, §4.1).

3.4.8.2 Connecting the backup battery

1 Open the electronics cover (→ p. 39, 3.4.3). 2 Connect the back-up battery (part No. 2065928) to connection BAT2 in the terminal

compartment (→ Fig. 22).

3 Close the electronics cover again.

Fig. 22 Connected back-up batteries

Subject to change w ithout notice

44 FLOWSIC500 · Operating Instructions · 8015391/Z261/V2-3/2016-10 · © SICK Engineering GmbH

Installation

3.4.9 Operation with batteries

WARNING: Risk of of ignition due to electrostatic charge

Make sure to minimize electrostatic risks when handling the plastic portable battery packs.

▸

When a static-generating mechanism is identified, such as repeated brushing against clothing, take suitable precautions, e.g.the use of anti-static footwear.

▸

Activities such as placing the item in a pocket or on a belt, operating a keypad or cleaning with a damp cloth, do not present a significant electrostatic risk.

The FLOWSIC500 and the delivered battery packs are designed intrinsically safe.

▸

Only the exchangeable battery packs from SICK with part no. 2064018 and the backup battery with part no. 2065928 may be used.

▸

The battery packs can be connected and disconnected in the hazardous area as well.

▸

Only connect the battery packs to the connections marked for this purpose in the terminal compartment of the FLOWSIC500.

▸

Modifying the electrical connection parts is not allowed.

1 Open the electronics cover (→ p. 39, 3.4.3) 2 Insert the battery packs as shown and connect to connections BAT1 and BAT2 in the

terminal compartment. The FLOWSIC500 is initialized.

Fig. 23 Connected battery packs

3 Close the electronics cover again. 4 Set the date and time (→ p. 54, §4.1).

Subject to change w ithout notice

FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH 45

3.5 Installing the external pressure and temperature transmitters

1 Pressure measuring port 2 Alternative temperature measuring ports

The adapter of FLOWSIC500 has measuring ports for pressure and temperature.

NOTICE:

▸

The pressure measuring port to be used for measurement is marked “PM”. On meters with flow direction “left-right” (→), the marked pressure measuring port is on the rear of the adapter, on meters with flow direction “rightleft” (←), it is on the front.

▸

Pressure and temperature transmitters can only be exchanged when the parameter locking switch is open.

Fig. 24 Pressure and temperature measuring ports (front and rear side)

Installation

NOTICE: Ensure sufficient assembly clearance!

Ensure sufficient clearance to the wall or other components at the rear measuring ports when installing the transmitters.

The recommended minimum clearance to the wall is 0.3 m.

3.5.1

Fitting the plug-in connector cover

Fit the plug-in connector cover before installing the transmitters. 1 Guide the transmitter plugs through the openings in the plug-in connector cover.

Fig. 25 Plug-in connector cover

Subject to change w ithout notice

46 FLOWSIC500 · Operating Instructions · 8015391/Z261/V2-3/2016-10 · © SICK Engineering GmbH

Installation

1 Connections for pressure and temperature transmitters

1 Capstan screw 2 Plug-in connector cover

2 Connect the plugs to the planned connections.

For meter sizes DN50 and DN80, it is recommended to connect the pressure transmitter to the right M8 connection and the temperature transmitter to the left M8 connection.

The FLOWSIC500 automatically detects whether a pressure or temperature transmitter has been connected to a connection.

Fig. 26 Connections for pressure and temperature transmitters

3 Push the plug-in connector cover over the plugs and fasten with both capstan screws.

Fig. 27 Fastening the plug-in connector cover

Subject to change w ithout notice

FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH 47

3.5.2 Installing the pressure transmitter

1 Pressure transmitter 2 Kamstrup test valve BDA04

A three-way test valve is normally fitted to be able to test the pressure transmitter.

NOTICE: Fitting information

It is recommended to connect the pressure transmitter with the three-way test valve or with the FLOWSIC500 so that there is a downward slope from the pressure transmitter to the connection point and from the three-way test valve to the FLOWSIC500.

Variant 1: Installation with Kamstrup test valve BDA04 (up to -25 °C)

For details on installation with Kamstrup test valve BDA04, see Kamstrup Operating Instructions.

You will find the document on the delivered product CD.

Installation

1 Remove the dummy plug on the pressure measuring port marked “P 2 Fit the Kamstrup test valve BDA04.

Pay attention to the alignment of the connection for the pressure transmitter.

3 Fit the pressure transmitter on the Kamstrup test valve BDA04 (→ Fig. 28).

Fig. 28 Kamstrup test valve BDA04 with pressure transmitter fitted

”.

48 FLOWSIC500 · Operating Instructions · 8015391/Z261/V2-3/2016-10 · © SICK Engineering GmbH

Subject to change w ithout notice

Installation

FLOWSIC500

Pressure transmitter

FLOWSIC500

Test pressure

Pressure transmitter

Tab le 1 3 Kamstrup test valve BDA04 positions

Measuring position

Test position

Subject to change w ithout notice

FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH 49

Variant 2: Installation with three-way test valve (to -40 °C)

1FLOWSIC500 connection 2 Three-way test valve 3 Test connection (Minimess coupling) 4 Pressure transmitter

Test pressure

FLOWSIC500

Test pressure

FLOWSIC500

Test pressure

FLOWSIC500

Here, a conventional three-way test valve is used. Install the three-way test valve with pressure transmitter fitted at a suitable location next to

the FLOWSIC500. A pressure line serves to connect the pressure measuring connection of the FLOWSIC500 to the three-way test valve.

1 Fasten the three-way test valve at a suitable location. 2 Remove the dummy plug on the pressure measuring port marked “P 3 Fit the supplied screw fitting. 4 Install the pressure line between the FLOWSIC500 and the three-way test valve. 5 Fit the pressure transmitter to the three-way test valve.

Fig. 29 Pressure transmitter installation on the three-way test valve (-40 °C)

Installation

”.

Table 14 Three-way test valve positions

Measuring position

Test position

Closed position

Subject to change w ithout notice

50 FLOWSIC500 · Operating Instructions · 8015391/Z261/V2-3/2016-10 · © SICK Engineering GmbH

Installation

1 Pressure transmitter

Variant 3: Installation without a three-way test valve

Here, the pressure transmitter is connected directly to the FLOWSIC500.

1 Remove the dummy plug on the pressure measuring port marked “P 2 Fit the pressure transmitter.

Fig. 30 Installation without three-way test valve

”.

Subject to change w ithout notice

FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH 51

3.5.3 Installing the temperature transmitter

1 Temperature transmitter

NOTICE:

SICK recommends to install the temperature transmitter on the temperature measuring port which is on the same side as the display.

The temperature transmitter can be greased with heat-conductive oil or paste to improve its performance.

1 Insert the temperature transmitter into the immersion sleeve to the stop. 2 Tighten the locknut. 3 Have the wire seal attached by a calibration inspector (→ Fig. 10).

Fig. 31 Installing the temperature transmitter

Installation

52 FLOWSIC500 · Operating Instructions · 8015391/Z261/V2-3/2016-10 · © SICK Engineering GmbH

Subject to change w ithout notice

Start-up

FLOWSIC500

4 Start-up

Sequence of start-up

Setting the date and time

Configuring volume conversion (device option)

Checking the device status

Subject to change w ithout notice

FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH 53

4.1 Sequence of start-up

4.1.1 Start-up of gas flow meter

FLOWSIC500 start-up is normally performed in the following sequence:

▸

Log on as "Authorized user" (→ p. 72, § 5.2.7).

▸

Set the date and time (→ p. 54, § 4.2).

▸

Check the device status (→ p. 56, § 4.4).

4.1.2 Start-up of gas flow meter with device option volume conversion

▸

Log on as "Authorized user" (→ p. 72, § 5.2.7).

▸

Set the date and time (→ p. 54, §4.2).

▸

Activate the configuration mode (→ p. 72, § 5.2.9).

▸

Set fixed values for pressure and temperature (→ p. 55, §4.3.1).

▸

Set reference values (already configured: → Table 2).

▸

Select the calculation method (already configured: → p. 69, §5.2.6.5)

▸

Set the fixed value of the compressibility factor (→ p. 69, §5.2.6.5).

▸

Check the configuration (→ p. 56, §4.3.3).

▸

Configure the gas composition (→ p. 56, § 4.3.3).

▸

Adapt alarm limits for pressure and temperature (→ p. 70, §5.2.6.6 and → p. 70, § 5.2.6.7).

Start-up

The alarm limits are set in the factory to the measuring range of the selected transmitter

▸

Terminate configuration mode (→ p. 72, § 5.2.9).

▸

Check the device status (→ p. 56, § 4.4).

4.2 Setting the date and time

Date and time must be set after the power supply has been connected. The FLOWSIC500 displays error E-3007 ("Time" invalid) until the time has been set.

Detailed information on operating using the display and on menu navigation → p. 58, § 5.2.

● The time zone function adapts the time to the new time zone.

If you want to change date and time as well as the time zone, change the time zone first.

● Date and time can be changed without starting configuration mode.

1 Log on as "Authorized user" (→ p. 72, § 5.2.7). 2 Switch to the "System settings” submenu in the FLOWSIC500 menu. 3 Call up "Date". 4 Press ENTER to start the edit mode.

The cursor now blinks under the first position of the date.

5 Use the arrow buttons to increment or decrement the selected position by 1 until the

correct digit is shown.

6 Confirm with ENTER.

The cursor now blinks under the second position of the date.

7 Repeat for the remaining positions of the date.

The date is saved when you confirm the last position with ENTER.

Subject to change w ithout notice

54 FLOWSIC500 · Operating Instructions · 8015391/Z261/V2-3/2016-10 · © SICK Engineering GmbH

Start-up

8 Switch to "Time". 9 Use the arrow buttons to increment or decrement the first position of the time by 1 until

the correct digit is shown.

10 Confirm with ENTER. 11 Repeat for the remaining positions of the time.

The time is saved when you confirm the last position with ENTER.

4.3 Configuring volume conversion (device option)

4.3.1 Setting fixed values

The fixed values must be set to the average measurement conditions of pressure and temperature:

1 Log on as "Authorized user" (→ p. 72, § 5.2.7). 2 Start the configuration mode → p. 72. 3 In the FLOWSIC500 menu, switch to submenu "Pressure parameters" or "Temperature

parameters"

4 Select the view "p Fixed value" or "T Fixed value". 5 Press ENTER to start the edit mode.

The cursor now blinks under the first position of the parameter.

6 Use the arrow buttons to increment or decrement the selected position by 1 until the

correct digit is shown.

7 Confirm with ENTER.

The cursor now blinks under the second position of the parameter. 8 Repeat for all remaining positions of the parameter. The fixed value is saved when you confirm the last position with ENTER.

4.3.2 Checking the configuration

The FLOWSIC500 is delivered already configured according to customer specifications. It is recommended to check the calibration-relevant parameters and settings. The calibra-

tion-relevant parameters are shown in the Data Book printout and can be compared against the current configuration on the display.

A new printout of the Data Book can be created using the FLOWgate500 operating software.

Subject to change w ithout notice

FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH 55

4.3.3 Configuring the gas composition

1 Log on as "Authorized user" (→ p. 72, § 5.2.7). 2 Start the configuration mode (→ p. 72). 3 Switch to submenu "Conversion/Gas composition" in the FLOWSIC500 menu. 4 Enter the following parameters according to the gas used and for the calculation

method selected: – Rel. density or reference density –H2 [mol%] –CO2 [mol%] –N2 [mol%] –Heating value

Parameter changes are saved in the Metrology logbook when the parameter locking switch is closed.

The Metrology logbook can be viewed using the FLOWgate500 operating software.

4.4 Checking the device status

Make sure the FLOWSIC500 is in error-free operating status:

1 Log on as "Authorized user" (→ p. 72, § 5.2.7). 2 Check whether warnings or errors are shown in the symbol bar on the display.

The device has a warning. The FLOWSIC500 is in "Warning" status.

Start-up

The device has an error. The FLOWSIC500 is in "Malfunction" status.

3 If warnings or malfunctions exist, change to view "Current events" on the main display:

– Clear existing malfunctions (→ p. 78, §6.2, “Status messages”). – Contact SICK Customer Service for any malfunctions you cannot clear yourself

(→ p. 78, § 6.1, “Contacting Customer Service”).

4 The event overview can be reset when all warnings and errors have been cleared

(→ p. 73, § 5.2.12).

Subject to change w ithout notice

56 FLOWSIC500 · Operating Instructions · 8015391/Z261/V2-3/2016-10 · © SICK Engineering GmbH

Operation

FLOWSIC500

5 Operation

Control unit

Operating using the display

Operating using the optical data interface

FLOWgate500 operating software

Parameter protection

Subject to change w ithout notice

FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH 57

5.1 Control unit

1Display 2 Buttons 3 Optical data interface

Fig. 32 Operating and display elements

Operation

5.2

Table 15 Buttons

Operating using the display

▸

Press any button to switch the display on.

Esc





ENTER Calls a submenu, starts edit mode. Confirms an input.

In battery operation, the display and the optical data interface have a timeout and switch off after approx. 60 seconds (default setting) when no button has been pressed and no data transmission takes place.

The display and the optical interface are permanently active when an external power supply is connected.

In menu In Edit mode

Returns to next higher level of the operator menu

Toggles between single menu entries on one level

Aborts input of new value and returns to the next higher level of the operator menu.

Increments or decrements a parameter by 1, toggles between several selection options.

58 FLOWSIC500 · Operating Instructions · 8015391/Z261/V2-3/2016-10 · © SICK Engineering GmbH

Subject to change w ithout notice

Operation

5.2.1 Display in the symbol bar

Tab le 1 6 Symbols

Symbol Significance Description

External power supply Only displayed when the device is configured with external

Battery fill level, battery 1 Displayed when the FLOWSIC500 is configured for battery

Battery fill level, battery 2 With external power supply: Backup battery status.

Device status: Malfunction The device has an error, the measured value is invalid.

Device status: Warning The device has a warning, the measured value is still valid.

Registered events Events have occurred since the last event summary reset.

power supply.

operation: Status of the first battery pack Details on the battery fill level → p. 59, § 5.2.2.

With battery operation: Second battery pack status. Details on the battery fill level → p. 59, § 5.2.2.

Parameter locking switch closed

Parameter locking switch open

Configuration mode Device parameters can be changed.

NOTICE:

In device status “Malfunction” or “Warning”, the respective symbols are shown blinking on the display.

5.2.2 Battery fill level display

The battery symbol changes as the battery is discharged.

Tab le 1 7 Battery fill level display

Battery fill level > 75%

Battery fill level > 50%

Battery fill level > 25%

Metrologically relevant parameters are protected against changing; modifications are registered in the Metrology logbook → p. 24, § 2.9.2.

Metrologically relevant parameters can be changed; the modifications are not saved in the Metrology logbook.

Battery almost empty but still in use

● The last segment of the battery symbol starts to blink when the battery fill level drops

below 10%.

● When the battery is completely empty, the empty battery symbol blinks and the

FLOWSIC500 has switched to the second battery.

Subject to change w ithout notice

FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH 59

5.2.3 Main screen (without device option volume conversion)

▸

Use buttons  and  to toggle between the menu entries on a level.

▸

Press ENTER to go down one menu level.

Main display

The following information is displayed on the top display menu level:

Main display Description

Operation

000000000 m

20.08.2012 10:30:52

V = Volume absolute, cannot be reset

 Pressing ENTER opens the FLOWSIC500 menu.

err

000000000 m

20.08.2012 10:30:52

err

V = Error volume: Volume counted during a malfunction, can be

reset

 Pressing ENTER opens the action "Reset error volume”.

→ "Resetting the error volume" (p. 73).

Q = Volume flow

Q 0.000 m3/h VOG 0.000 m/s

Current events 1 Event

VOG = Gas velocity

Current events (1 event is reported)

 Pressing ENTER opens a list of current reported events.

Use the arrow buttons to toggle through the reported events.

Stored status messages: Events since the last time the event

Event Summary 2 Events

summary was reset (2 events have occurred).

 Pressing ENTER opens a list of stored events.

Use the arrow buttons to toggle through the stored events.

Last Event Reset

20.08.2012 10:30:52

Last reset of event summary

 Pressing ENTER opens the action "Reset Event Summary”.

→ "Resetting the event summary" (p. 73).

NOTICE:

A parameter with Malfunction status is shown on the display by a blinking exclamation mark after the parameter (e. g. Q!).

60 FLOWSIC500 · Operating Instructions · 8015391/Z261/V2-3/2016-10 · © SICK Engineering GmbH

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Operation

Menu navigation (without device option volume conversion)

Some menu functions are only available when you are logged in with user level "User" or "Authorized User":

User level: G Guest (standard) U User (1)

Access rights: - Hidden ○ View ● Star t/edit

Path G U A2+3 A1 Explanation

Main display: Volume under measurement conditions V ○○ ○ ○

FLOWSIC500 menu: User ○○ ○ ○

Logged in user level ●● ● ●→p. 67, §5.2.6.1

FLOWSIC500 menu: Device mode ○○ ○ ○→p. 67, §5.2.6.2

Calibration mode ○○ ● ● Configuration mode ○○ ● ●

FLOWSIC500 menu: Device information ○○ ○ ○→p. 67, §5.2.6.3

Measuring port ○○ ○ ○ Serial number ○○ ○ ○ Firmware Version ○○ ○ ○ Firmware Date ○○ ○ ○ Firmware CRC ○○ ○ ○ Metrology CRC ○○ ○ ○ Min. oper. pressure ○○ ○ ○ Max. oper. pressure ○○ ○ ○ Meter factor ○○ ○ ○ Frequency at Qr [Hz] ○○ ○ ○

FLOWSIC500 menu: System settings ○○ ○ ○→p. 68, §5.2.6.4

Power supply (1) [%] ○○ ● ● Power supply (2) [%] ○○ ● ● Date ○○ ● ● Time ○○ ● ● Timezone ○○ ● ● Language ○● ● ● Symbols ○○ ○ ○ LCD test ○● ● ●

FLOWSIC500 menu: Logbooks ○○ ○ ○

Event logbook ○○ ○ ○

List of stored events - ○○○ Parameter logbook ○○ ○ ○ Metrology logbook ○○ ○ ○

FLOWSIC500 menu: Archives ○○ ○ ○→p. 71, §5.2.6.9

Gas hour ○○ ● ● Gas day ○○ ● ● Measuring period ○○ ● ●

Main display: Error volumes errV ○○ ● ●

Main display: Volume flow under measurement

conditions/ gas velocity

Main display: Current Events ○○ ○ ○

List of current events ○○ ○ ○

Main display: Event Summary ○○ ○ ○

Subject to change w ithout notice

Main display: Last Event Reset ○○ ● ●→p. 73, §5.2.12

List of stored events ○○ ○ ○

User (2) User (3)

○○ ○ ○

Authorized user (1)

Authorized user (2)

Authorized user (3)

FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH 61

5.2.4 Main display (with device option volume conversion)

▸

Use buttons  and  to toggle between the menu entries on a level.

Press ENTER to go down one menu level.

The symbols on the display are shown as standard in accordance with

EN12405.

Symbols with regional deviations can be configured. These Operating Instructions use symbols in accordance with EN12405.

Main display (with device option volume conversion)

The following information is displayed on the top display menu level:

Main display Description

Operation

000000000 m

20.08.2012 10:30:52

Vb= Volume at base conditions, uninterrupted

 Pressing ENTER opens the FLOWSIC500 menu.

err

000000000 m

20.08.2012 10:30:52

err

Vb = Error volume at base conditions

 Pressing ENTER opens the action "Reset error volume”.

→ "Resetting the error volume" (p. 73).

totalV

20.08.2012 10:30:52

err

20.08.2012 10:30:52

000000000 m

totalV

= Total volume at base conditions = Vb +

Vm = Total volume at measurement conditions

err

Vm = Error volume

Volume counted at measurement conditions, during a malfunction, can be reset

err

Q = Volume flow at measurement conditions

Q 0.000 m3/h Qb 0.000 m3/h

Qb = Volume flow at base conditions

SOS = Sound velocity currently measured

SOS 430.00 m/s VOG 0.000 m/s

62 FLOWSIC500 · Operating Instructions · 8015391/Z261/V2-3/2016-10 · © SICK Engineering GmbH

VOG = Gas velocity currently measured

Subject to change w ithout notice

Operation

Main display Description

p = Pressure currently used for volume conversion

p 3.532 bar T 25.42 °C

T = Temperature currently used for volume conversion

C = Conversion factor

C 25.7368 K 0.9541

K = Compressibility factor

Z = Compression factor at measurement conditions currently used for volume conversion

Z 0.99830 Zb 0.99812

Z = Compression factor at base conditions currently used for volume conversion

Current events 1 Event

Current events (1 event is reported)

 Pressing ENTER opens a list of current reported events.

Use the arrow buttons to toggle through the reported events.

Stored status messages: Events since the last time the event

Event Summary 2 Events

summary was reset (2 events have occurred).

 Pressing ENTER opens a list of stored events.

Use the arrow buttons to toggle through the stored events.

Last Event Reset

20.08.2012 10:30:52

Last reset of event summary

 Pressing ENTER opens the action "Reset Event Summary”.

→ "Resetting the event summary" (p. 73).

NOTICE:

A parameter with Malfunction status is shown on the display by a blinking exclamation mark after the parameter (e. g. Q!).

Subject to change w ithout notice

FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH 63

Operation

Menu navigation (with device option volume conversion)

Some menu functions are only available when you are logged in with user level "User" or "Authorized User":

User level: G Guest (standard) U User (1)

User (2) User (3)

Access rights: - Hidden ○ View ● Start/edit

Path G U A2+3 A1 Explanation

Main display: Base volume Vb ○○ ○ ○

FLOWSIC500 menu: User ○○ ○ ○ →p. 67, §5.2.6.1

Logged in user level ●● ● ●

FLOWSIC500 menu: Device mode ○○ ○ ○ →p. 67, §5.2.6.2

Calibration mode ○○ ● ● Configuration mode ○○ ● ●

FLOWSIC500 menu: Device information ○○ ○ ○p. 67, §5.2.6.3

Measuring port ○○ ○ ○ Serial number ○○ ○ ○ Firmware version ○○ ○ ○ Firmware date ○○ ○ ○ Firmware CRC ○○ ○ ○ Metrology CRC ○○ ○ ○ Min. oper. pressure ○○ ○ ○ Max. oper. pressure ○○ ○ ○ Meter factor ○○ ○ ○ Frequency at Qr ○○ ○ ○

FLOWSIC500 menu: System settings ○○ ○ ○ →p. 68, §5.2.6.4

Power supply (1) ○○ ● ● Power supply (2) ○○ ● ● Date ○○ ● ● Time ○○ ● ● Timezone ○○ ● ● Language ○● ● ● Symbols ○○ ○ ○ LCD test ○● ● ●

FLOWSIC500 menu: Conversion ○○ ○ ○ →p. 69, §5.2.6.5

Conversion: References ○○ ○ ○

Standard pressure ○○ ● ● Standard temperature ○○ ● ● Ref. conditions ○○ ● ● Atmospheric pressure ○○ ● ●

Conversion: Calculation ○○ ○ ○

Calc. methods ○○ ● ● Calc. interval ○○ ● ● K-factor (fixed) ○○ ● ●

Conversion: Gas composition ○○ ○ ○

Density entry type ○○ ● ● Reference density ○○ ● ● Relative density ○○ ● ● CO2 [mol%] ○○ ● ● N2 [mol%] ○○ ● ● H2 [mol%] ○○ ● ● Heating value ○○ ● ● Heating value unit ○○ ● ●

FLOWSIC500 menu: Pressure parameters ○○ ○ ○→p. 70, §5.2.6.6

p Sensor type ○○ ○ ○

Authorized user (1)

Authorized user (2)

Authorized user (3)

Subject to change w ithout notice

64 FLOWSIC500 · Operating Instructions · 8015391/Z261/V2-3/2016-10 · © SICK Engineering GmbH

Operation

Path G U A2+3 A1 Explanation

p Sensor serial number ○○ ○ ○ p Lower alarm limit ○○ ● ● p Upper alarm limit ○○ ● ● p Default value ○○ ● ● p Unit ○○ ● ● p Adjust offset ○○ ● ● p Adjust factor ○○ ● ●

FLOWSIC500 menu: Temperature parame-

○○ ○ ○ →p. 70, §5.2.6.7

ters

T Sensor type ○○ ○ ○ T Sensor serial number ○○ ○ ○ T Lower alarm limit ○○ ● ● T Upper alarm limit ○○ ● ● T Default value ○○ ● ● T Unit ○○ ● ● T Adjust offset ○○ ● ● T Adjust factor ○○ ● ●

FLOWSIC500 menu: Logbooks ○○ ○ ○

Event logbook ○○ ○ ○

List of stored events - ○○ ○ Parameter logbook ○○ ○ ○ Metrology logbook ○○ ○ ○

FLOWSIC500 menu: Archives ○○ ○ ○→p. 71, §5.2.6.9

Gas hour ○○ ● ● Gas day ○○ ● ● Measuring period ○○ ● ●

Main display: errVb ○○ ● ●→p. 73, §5.2.11

Main display: totalVb ○○ ○ ○

Main display: Vm ○○ ○ ○

Main display: errVm ○○ ○ ○

Main display: Q/Qb ○○ ○ ○

Main display: SOS/VOG ○○ ○ ○

Main display: p/T ○○ ○ ○

Main display: C-factor ○○ ○ ○

Main display: Z/Zb ○○ ○ ○

Main display: Current Events ○○ ○ ○

List of current events ○○ ○ ○

Main display: Event Summary ○○ ○ ○

List of stored events ○○ ○ ○

Main display: Last Event Reset ○○ ● ●→p. 73, §5.2.12

Subject to change w ithout notice

FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH 65

5.2.5 Configuration of main display

The configuration of the main display can be performed via the operating program FLOWgate500.

The following contents are available:

● Blank (line 1 – SICK standard)

● Date, time (line 2 – SICK standard)

● Pressure p

● Temperature T

● Conversion factor C

● Compressibility factor K

● Volume flow rate Q

● Base flow Qb

● VOG

● SOS

Operation

66 FLOWSIC500 · Operating Instructions · 8015391/Z261/V2-3/2016-10 · © SICK Engineering GmbH

Subject to change w ithout notice

Operation

5.2.6 FLOWSIC500 menu

5.2.6.1 User

User Logged in user level, without login: Guest

5.2.6.2 Device mode

Calibration mode Display whether calibration mode for the flow check is switched on or off,

→ "Changing the user level" (p. 72)

Logged in as:

● User (1)

● User (2)*

● User (3)*

● Authorized user (1)

● Authorized user (2)*

● Authorized user (3)*

* when activated

start and end calibration mode

In calibration mode, message "CALIBRATION MODE" blinks on the main display with the meter factor now effective for the calibration (set at the factory). The FLOWSIC500 outputs test pulses with a maximum possible frequency of 2 kHz at 120% Q (→ p. 42, § 3.4.6.1).

.on digital switching output DO_1

max

Configuration mode Display whether configuration mode is switched on or off,

5.2.6.3 Device information

Measuring port Measuring port identifier Serial number Device serial number Firmware Version Firmware version installed on the device Firmware Date Firmware release date Firmware CRC Firmware check sum Metrology CRC Check sum of metrologically relevant parameters Min. oper. pressure Minimum operating overpressure

Max. oper. pressure

Meter factor Pulse valency, relation between frequency and flow [Imp/m Frequency at Qr Frequency for overload flow Qr=1.2 Qmax

For flow check and calibration, see document "E_86770: Calibration Instructions for the Ultrasonic Gas Flow Meter FLOWSIC500"

Starting and terminating configuration mode

→ "Start configuration mode" (p. 72)

Maximum operating overpressure

]

Subject to change w ithout notice

FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH 67

5.2.6.4 System settings

Gas flow meter:

Gas flow meter with volume conversion

EN12405 PTB GOST API

Volume (measurement) V V V Vf

Flow (measurement) Q Q Q Qb

Velocity of Gas VOG VOG VOG VOG

Speed of Sound SOS SOS SOS SOS

EN12405 PTB GOST API

Volume (measurement) Vm Vm V Vf

Volume (base) Vb Vb Vc Vb

Flow (measurement) Q Q Q Qb

Flow rate (base) Qf Qf Qc Qf

Pressure (measurement) p p P Pf

Pressure (base) pb pb Pc Pb

Temperature (measurement) T T T Tf

Temperature (base) Tb Tb TC Tb

Velocity of Gas VOG VOG VOG VOG

Speed of Sound SOS SOS SOS SOS

K-factor (fixed) K K K s

Conversion factor C C C C

Z (measurement) Z Z Z Zf

Z (base) Zb Zb Zc Zb

Power supply (1)

Power supply (2)

Date Device date → "Sequence of start-up" (p. 54) Time Device time → "Sequence of start-up" (p. 54) Timezone Time zone set on device Language Language for displays

Operation

● For battery operation:

– Fill level for battery pack 1 [%], – Confirm battery exchange for battery pack 1.

→ "Confirming battery replacement" (p. 74)

● With external power supply:

– Display: 100%

→ "Checking the external power supply" (p. 74)

● For battery operation:

– Fill level for battery pack 2 [%], – Confirm battery exchange for battery pack 2.

● With external power supply:

– Fill level for backup battery – Confirm battery exchange for backup battery.

→ "Confirming battery replacement" (p. 74)

Available: English, German, Russian

Symbols according to Symbols for mesured value displays

LCD test Display test → "Testing the display" (p. 74)

→ "Setting the language" (p. 72)

The setting can be changed with the FLOWgate operating software.

Subject to change w ithout notice

Operation

T1 T2 p2 Set 1 25 °C 0 °C 1.01325 bar (a) Set 2 0 °C 0°C 1.01325 bar (a) Set 3 15 °C 15 °C 1.01325 bar (a) Set 4 60 °F 60 °F 14.7347 psi (a) Set 5 60 °F 60 °F 14.7300 psi (a) Set 6 25 °C 20°C 1.01325 bar (a)

5.2.6.5 Conversion (only for device types with volume conversion)

References

Standard pressure Standard pressure [unit acc. to display] Standard temperature Standard temperature [unit acc. to display] Ref. conditions Reference conditions for density and heating value

Display: T1/T2/p2

T1 = Reference temperature, heating value T2 = Reference temperature, rel. density/reference density p2 = Reference pressure, rel. density/reference density

Atmospheric pressure Ambient pressure [unit acc. to display]

Input requried for version with relative pressure transmitter

Calculation

Calculation method Calculation method for the compressibility factor

Select from:

● SGERG88,

● AGA 8 Gross method 1

● AGA 8 Gross method 2

● AGA NX-19

● AGA NX-19 mod.

● AGA NX-19 mod. GOST

● GERG91 mod.

● Fixed value

Calculation interval Cycle time for updating measured values (pressure, temperature), calcu-

lation of the compressibility factor

Select from: 3 s, 10 s, 20 s, 30 s, 60 s

K-factor (fixed) Entry of K factor for method "Fixed value" when the calculation of the K-

factor is incorrect.

Subject to change w ithout notice

Gas composition (only for device option volume conversion)

Density entry type Select from:

Reference density, relative density Either menu item "Reference density" or menu item "Relative density"

is displayed depending on the selection. Reference density Gas reference density under reference conditions Relative density Relative density, relation between gas density and air density under refer-

ence conditions CO2 CO N2 H2

- proportion in gas [mol%]

Heating value Gas heating (under reference conditions) Heating value unit Heating value unit

Select from: Default, MJ/m³, kWh/m³, BTU/ft³

Default = Standard setting according to selected unit system (SI or US),

configured in accordance with the order

The calculation method selected determines the permissible entry limits for gas proportions as well as pressure and temperature.

Operation

5.2.6.6 Pressure parameters (only for device option volume conversion)

p Sensor type Display of configured pressure transmitter p Sensor serial number Pressure transmitter serial number expected by the device, preset p Lower alarm limit Lower alarm limit for pressure transmitter p Upper alarm limit Upper alarm limit for pressure transmitter p Default value Fixed value for measurement pressure [unit acc. to display]

The entry value is used as fixed value for configuration as TZ conversion

and for pressure measurement malfunctions.

p Unit Unit for pressure values, used for entry and display

Select from:

Default, bar, psia, kPa, MPa, kg/cm

, psig Default = Standard setting according to selected unit system (SI or Imperial), configured in accordance with the order

p Adjust offset Calibration offset for pressure transmitter [unit acc. to display] p Adjust factor Calibration factor for pressure transmitter

5.2.6.7 Temperature parameters (only for device option volume conversion)

T Sensor type Display of configured temperature transmitter T Sensor serial number Temperature transmitter serial number expected by the device, preset T Lower alarm limit Lower alarm limit for temperature transmitter T Upper alarm limit Upper alarm limit for temperature transmitter T Default value Fixed value for measurement temperature [unit acc. to display]

The entry value is used as fixed value for malfunctions of temperature measurement.

T Unit Unit for temperature values, used for entry and display

Select from: Default, °C, °F, K, °R

Default = Standard setting according to selected unit system (SI or Imperial), configured in accordance with the order

Subject to change w ithout notice

Operation

5.2.6.8 Logbooks

5.2.6.9 Archives

T Adjust offset Calibration offset for temperature transmitter [unit acc. to display] T Adjust factor Calibration factor for temperature transmitter

Event logbook Number of entries currently stored/max. number

Pressing ENTER opens the detailed view.

The detailed view shows the event type, a short text and the timestamp. Parameter logbook Number of entries currently stored/max. number Metrology logbook Number of entries currently stored/max. number

Gas hour Billing hour for the day archive

Entry range: 00:00 ... 23:59

Default: 06:00 Gas day Billing day for month archive

Measuring range: 1 ... 28

Default: 1 Measuring period Defines the period for the billing archive

Select from: 3 min, 5 min,15 min, 30 min, 60 min

Default: 60 min

Subject to change w ithout notice

5.2.7 Changing the user level

1 Call up menu function "User". 2 Press ENTER to start the edit mode. 3 Use the arrow buttons to select the desired user level. 4 Confirm with ENTER.

The cursor now blinks under the first position of the password.

5 To enter the password:

– Use the arrow buttons to increment or decrement the first position of the password

by 1 until the correct digit is shown.

–Confirm with ENTER.

The cursor now blinks under the second position of the password. – Repeat for the remaining positions of the password. – You are logged in with the selected user level after the last position of the password

is confirmed.

The following users are set at the factory:

● User (1), password: 1111

● Authorized user (1), password: 2222

Operation

▸

Change the password after the first logon via the FLOWgate operating software.

5.2.8 Setting the language

1 Switch to the "System settings” submenu in the FLOWSIC500 menu. 2 Call up "Language". 3 Press ENTER to start the edit mode. 4 Use the arrow buttons to select the desired language. 5 Confirm with ENTER.

The display texts are now shown in the selected language.

5.2.9 Changing the device mode

On the FLOWSIC500, the device modes Configuration and Calibration can be activated independently from each other.

5.2.9.1 Starting and terminating configuration mode

Start configuration mode

1 Switch to the "Device mode” submenu in the FLOWSIC500 menu. 2 Call up "Configuration mode". 3 Press ENTER to start the edit mode. 4 Use the arrow buttons to select ON. 5 Confirm with ENTER.

The configuration mode is started. Symbol is displayed in the symbol bar.

Terminate configuration mode

1 Call up "Configuration mode". 2 Use the arrow buttons to select OFF. 3 Confirm with ENTER.

The configuration mode is terminated.

Subject to change w ithout notice

Operation

5.2.9.2 Starting and terminating calibration mode

Calibration mode can be started and terminated in the same manner as the configuration mode (→ p. 73, §5.2.9.2).

In calibration mode, message "CALIBRATION MODE" blinks on the main display with the meter factor now effective for the calibration (set at the factory).

The FLOWSIC500 outputs test pulses with a maximum possible frequency of 2 kHz at 120% Q max.on digital switching output DO_1 (→ p. 42, §3.4.6.1).

5.2.10 Changing parameters

Numerical values

1 Start the configuration mode → p. 72. 2 Select the desired parameter in the menu. 3 Press ENTER to start the edit mode.

The cursor now blinks under the first position of the parameter.

4 Use the arrow buttons to increment or decrement the selected position by 1 until the

correct digit is shown.

5 Confirm with ENTER.

The cursor now blinks under the second position of the parameter.

6 Repeat for all remaining positions of the parameter.

Selection lists

1 Start the configuration mode → p. 72. 2 Select the desired parameter in the menu. 3 Press ENTER to start the edit mode. 4 use the arrow buttons to switch to the desired selection. 5 Confirm with ENTER.

5.2.11 Resetting the error volume

1 Switch to the error volume display on the main screen. 2 Press ENTER to start the edit mode. 3 Use the arrow buttons to select OK. 4 Confirm with ENTER.

The error volume is reset.

5.2.12 Resetting the event summary

1 Switch to the "Event Summary " display on the main display. 2 Press ENTER to open a list of the stored events. 3 Press ENTER to start the edit mode. 4 Use the arrow buttons to select OK. 5 Confirm with ENTER.

The event summary is reset.

Subject to change w ithout notice

5.2.13 Confirming battery replacement

Confirm battery replacement on the display after you have changed a battery.

1 Switch to the "System settings” submenu in the FLOWSIC500 menu. 2 Switch to the status indicator of the replaced batteries, e.g. "Power Supply (1)”. 3 Press ENTER to start the edit mode. 4 Use the arrow buttons to select OK. 5 Confirm with ENTER.

5.2.14 Checking the external power supply

An external power supply connected to the meter can be checked as follows:

1 Switch to the "System settings” submenu in the FLOWSIC500 menu. 2 Select “Power supply (1)” with the arrow buttons and confirm with ENTER. 3 Select “Check ext.power supply” and confirm with ENTER.

5.2.15 Testing the display

1 Switch to the "System settings” submenu in the FLOWSIC500 menu. 2 Call up "LCD Test”. 3 Press ENTER to start the display test.

All display segments on the display are activated and deactivated three times. Defective display segments can thus be detected.

Operation

Subject to change w ithout notice

Operation

Correct alignment Wrong alignment

5.3 Operating using the optical data interface

A data connection can be established with the device using the optical data interface and the infrared/USB adapter HIE-04 (part no. 6050502).

This interface serves to configure the FLOWSIC500. The infrared adapter has a USB 2.0 interface. This interface provides the connection to the PC and transfers the FLOWSIC500 data.

A driver must first be installed to operate the adapter on a PC. You will find the driver on the delivered product CD.

1 Do not connect the USB connector yet. First install the driver. 2 Connect the USB connector to the PC. 3 Fit the infrared adapter to the infrared interface as shown (→ Fig. 33); a magnet inte-

grated in the reading head retains the adapter.

Fig. 33 Alignment of the infrared adapter

4 Press any button on the display to activate the optical data interface on the

FLOWSIC500.

5 Start the connection on the PC.

When a connection has been established, the optical data interface on the FLOWSIC500 remains active until the adapter is removed.

The display and the optical interface remain active during the connection.

5.4 FLOWgate500 operating software

For information concerning the FLOWgate500 operating software, see "Software Manual FLOWgate500”.

The Software Manual is on the delivered Product CD. The Software Manual is also available using the Help function of the

FLOWgate500 operating software.

If the user is not an administrator, the following entries in the registry must exist or be configured for installation of the system:

● AlwaysInstallElevated = 1

Subject to change w ithout notice

● EnableUserControl = 1

Support: http://msdn.microsoft.com/en-us/library/aa367561(v=vs.85).aspx

Operation

Subject to change w ithout notice

Clearing Malfunctions

FLOWSIC500

6 Clearing Malfunctions

Contacting Customer Service

Status messages

Additional messages in the Event logbook

Subject to change w ithout notice

6.1 Contacting Customer Service

Contact SICK Customer Service for any malfunctions you cannot clear yourself.

A diagnosis file can be created with the FLOWgate operating software which helps Customer Service to better understand malfunctions that occur. For information concerning the FLOWgate500 operating software, see "Software Manual FLOWgate500”.

6.2 Status messages

Table 18 Information messages

Status message Description/clearance I-1017 The device firmware has been changed. I-1018 The device has been started. I-1019 Configuration mode is active. → p. 72, §5.2.9.1, “Starting and terminating configu-

ration mode”

I-1020 The parameter locking switch is open.→ p. 24, §2.9.1,“Parameter locking switch”

Table 19 Warning messages

Status message Description/clearance W-2001 The Event logbook is up to 90% full.

The Event logbook can be viewed, stored and reset with operating software FLOWgate500.

W-2002 The Metrology logbook is full.

Calibration-relevant parameters can only be modified after the parameter locking switch has been opened. The Metrology logbook can be reset using the operating software FLOWgate500. → p. 77, § 6 “Clearing Malfunctions”

W-2003 More pulses than permissible should be output on the pulse output.

Check whether the current flow rate is higher than the max. flow. If the flow is within the permissible range, check whether the selected output scaling (= pulse factor) is correct. → p. 78, § 6.1 “Contacting Customer Service”

W-2008 Flow measurement is in status "Warning".

Have the device checked by Customer Service. → p. 78, § 6.1 “Contacting Customer Service”

W-2009 The measured flow rate is outside the set warning limits.

Check the current measuring conditions or adjust the limits. The warning limits can be set using the operating software FLOWgate500.

W-2010

W-2009 = flow rate below warning limit, W-2010 = flow rate above warning limit.

W-2016 Battery 1 failure.

→ p. 85, § 7.3.2 “Changing the battery packs”

Clearing Malfunctions

W-2017 Battery 2 failure.

● With external power supply:

→ p. 84, § 7.2.2 “Changing the backup battery”

● For battery operation:

→ p. 85, § 7.3.2 “Changing the battery packs”

W-2018 External power supply failure.

Check the connection and function of the external power supply. → p. 44, § 3.4.8 “Operation with external power supply”.

Subject to change w ithout notice

Clearing Malfunctions

Tab le 2 0 Error messages

Status message Description/clearance E-3001 The Event logbook is full.

Check the Event logbook. The Event logbook can be reset using the operating software FLOWgate500.

E-3006 Checksum error

→ p. 78, § 6.1 “Contacting Customer Service”.

E-3007 Time invalid

→ p. 54, § 4.1 “Sequence of start-up”.

E-3009 The FLOWSIC500 is in calibration mode.

→ p. 73, § 5.2.9.2, “Starting and terminating calibration mode”.

E-3010 Temperature transmitter failure.

The FLOWSIC500 uses the default value specified.

→ p. 100, § 7.6 “Exchanging an external pressure or temperature transmitter” → p. 78, § 6.1 “Contacting Customer Service”.

E-3012 Pressure transmitter failure.

The FLOWSIC500 uses the default value specified.

→ p. 100, § 7.6 “Exchanging an external pressure or temperature transmitter” → p. 78, § 6.1 “Contacting Customer Service”.

E-3013 Device is outside the permissible measurement pressure range.

Check Pmin/Pmax vs. pressure.

E-3014 Flow measurement is in status "Malfunction",

→ p. 78, § 6.1 “Contacting Customer Service”.

E-3017 The K-factor cannot be calculated.

Check the values entered for gas composition against the reference conditions and the base conditions. → p. 62, § 5.2.4 “Main display (with device option volume conversion)”.

E-3018 Reverse flow

The measured creep volume (reverse flow) is larger than the preconfigured buffer volume.→ p. 19 If larger reverse flows occur regularly, contact Customer Service to have the preconfigured volume adapted. → p. 78, § 6.1 “Contacting Customer Service”.

E-3019 The measured gas temperature/gas pressure is outside the permissible limits.

E-3019 = Gas temperature is below the alarm limit

E-3020

E-3020 = Gas temperature is above the alarm limit E-3021 = Gas pressure is below the alarm limit

E-3021

E-3022 = Gas pressure is above the alarm limit

E-3022

Subject to change w ithout notice

Check the set alarm limit values. → p. 70, § 5.2.6.7 "Temperature parameters"

6.3 Additional messages in the Event logbook

The FLOWSIC500 saves all status messages (→ p. 78, §6.2) as well as further supplemen- tary messages concerning events and status changes in the Event logbook.

Each message code is supplemented with a (+) or (-) to identify an incoming message = (+) or an outgoing message = (-).

Table 21 Information messages in the Event logbook

Status message Description/clearance I-1001 Event logbook has been reset I-1002 Parameter logbook has been reset. I-1003 Metrology logbook has been reset. I-1004 Measuring period archive has been reset. I-1005 Daily archive has been reset. I-1006 Monthly archive has been reset. I-1010 Event overview has been reset. I-1011 Time has been reset.

I-1012 Totalizers have been reset. I-1013 Error volume totalizers have been reset.

I-1014 All parameters have been reset or a group of parameters have been reset. I-1021 Battery (1) has been replaced. I-1022 Battery (2) has been replaced. I-1023 Totalizers have been preset.

Clearing Malfunctions

Table 22 Warning messages in the Event logbook

Status message Description/clearance W-2011 The number of valid measurements (performance of flow measurement) is signifi-

cantly lower than normal. W-2012 Flow measurement is performed at reduced speed. W-2013 Flow rate higher than 120% Q

Table 23 Error messages in Event logbook

Status message Description/clearance E-3002 Check sum of totalizers is invalid. E-3003 Check sum of firmware is invalid. E-3004 Parameter is invalid. E-3005 Check sum of logbooks/archives is invalid. E-3015 Hardware error in flow measurement. E-3016 Number of valid measurements (performance of flow measurement) is not suffi-

cient.

In the Event logbook, additional data, e.g. status, meter levels, measured values and parameters at the time of certain events are saved.

These events or messages are identified with operating software FLOWgate500 (→ p. 75, § 5.4).

max

. The data can be viewed and saved with

Subject to change w ithout notice

Maintenance and Meter Replacement

FLOWSIC500

7 Maintenance and Meter Replacement

Information on handling lithium batteries

Maintenance when using external power supply

Maintenance when using battery power supply

Meter exchange

Function check of a pressure or temperature transmitter

Exchanging an external pressure or temperature transmitter

Subject to change w ithout notice

7.1 Information on handling lithium batteries

Date

Variable

Description

QR-Code Order No. +

Serial No.

00 01 02

WARNING: Fire, explosion, and servere burn hazard. Do not recharge, disassemble,heat above 100°C, incinerate or expose contents to water.

Date:

Backup battery 2S-P1

Disposal in EU: Batteries shall be properly disposed and recycled according to guideline 2006/66/EC. Upon request a disposal service is offered by Tadiran Germany.

Disposal in US: Spent batteries shall be treated by an authorized, professional disposal company. It is recommended to contact the local EPA office.

Refer to FLOWSIC500 user manual for further information.

cell type: TADIRAN SL-860

SICK Part no.: 2065928 Serial no.:

WARNING: Fire, explosion, and servere burn hazard. Do not recharge, disassemble, heat above 100°C, incinerate or expose contents to water.

SICK Part no.:2064018 Serial no.: Date:

Battery pack 2S-P1 cell type: TADIRAN SL-2880

Disposal in EU: Batteries shall be properly disposed and recycled according to guideline 2006/66/EC. Upon request a disposal service is offered by Tadiran Germany.

Disposal in US: Spent batteries shall be treated by an authorized, professional disposal company. It is recommended to contact the local EPA office.

Refer to FLOWSIC500 user manual for further information.

WARNING: Risk of of ignition due to electrostatic charge

Make sure to minimize electrostatic risks when handling the plastic portable battery packs.

▸

When a static-generating mechanism is identified, such as repeated brushing against clothing, take suitable precautions, e.g.the use of anti-static footwear.

▸

Activities such as placing the item in a pocket or on a belt, operating a keypad or cleaning with a damp cloth, do not present a significant electrostatic risk.

WARNING: Risk of explosion - hazard for intrinsic safety

▸

Only the exchangeable battery packs from SICK with part no. 2064018 and the backup battery withy part no. 2065928 may be used.

▸

Do not use damaged batteries; they must be disposed of correctly!

WARNING:

Do not transport used battery packs by air freight!

▸

Always remove used battery packs before shipment of the complete FLOWSIC500 measuring systems or the gas flow meter.

▸

For weight reasons, the battery packs should always be removed before transport by air.

Maintenance and Meter Replacement

The battery packs are marked with important information concerning storage and disposal.

Table 24 Marking

Symbol Significance

Do not dispose with household trash.

Recycling

Fig. 34 Identification of battery packs

Subject to change w ithout notice

Maintenance and Meter Replacement

7.1.1 Information on storage and transport

▸

Prevent a short circuit of the battery terminals: – Store and transport the batteries in their original packaging – or tape the battery terminals.

▸

Store cool (under 21 °C (70 °F)), dry and without major temperature fluctuations.

▸

Protect against permanent sunlight.

▸

Do not store near the heating.

7.1.2 Disposal information

In the EU

▸

Dispose of lithium batteries in accordance with the Battery Directive 2006/66/EU.

▸

In Germany, you can hand in the batteries at your local recycling center. Alternatively, the battery manufacturer Tadiran Germany offers a return service on

request. Contact data: Phone: +49 (0)6042/954-122 Fax: +49 (0)6042/954-190 www.tadiranbatteries.de

In the USA

▸

Batteries have to be disposed of by an authorized waste disposal company. Identification of lithium batteries: – Proper shipping name: Waste lithium batteries – UN number: 3090 – Label requirements: MISCELLANEOUS, HAZARDOUS WASTE – Disposal code: D003

▸

If anything is unclear, contact the local office of the Environmental Protection Agency (EPA).

In other countries:

Please observe national regulations for the disposal of lithium batteries.

Subject to change w ithout notice

7.2 Maintenance when using external power supply

7.2.1 Service life of backup battery

When new, the capacity of the backup battery has been calculated for bridging up to 3 months failure of the supply voltage. When voltage supply is not interrupted, the service life is at least 10 years when stored at approx. 25 °C (77 °F).

Repeated, even short-time voltage failure reduces the remaining buffer capacity of the battery so that exchange is recommended.

If both the supply voltage and the backup battery fail, the clock setting is lost and the FLOWSIC500 does not measure anymore. Meter readings determined until then and parameter settings remain permanently stored.

7.2.2 Changing the backup battery

WARNING: Risk of explosion - hazard for intrinsic safety

▸

Only the exchangeable battery packs from SICK with part nos. 2064018 and the backup battery with part no. 2065928 may be used.

1 Ensure external voltage supply. 2 Open the electronics cover (→ p. 39, § 3.4.3) 3 Loosen the connection of the backup battery. 4 Remove the backup battery. 5 Insert a new backup battery and connect the battery to connection BAT2. 6 Close the electronics cover (→ p. 39, § 3.4.3) 7 Confirm battery replacement on the display (→ p. 74, § 5.2.13).

Maintenance and Meter Replacement

NOTICE:

The battery symbol on the display shows full straight away after the battery change.

The check whether the battery is really operational then takes 20 minutes.

Subject to change w ithout notice

Maintenance and Meter Replacement

7.3 Maintenance when using battery power supply

7.3.1 Service life of battery packs

Under typical operating conditions, the expected total service life of both battery packs is 5 years.

The FLOWSIC500 needs more power

● when the display is used frequently,

● when the infrared interface is used,

● when the encoder output is frequently used (scanning cycles < 15 min).

When the electrically isolated NAMUR output (DO_0) is used, an external voltage supply is recommended due to the significantly higher power requirement.

The capacity of the batteries is reduced in unfavorable climatic conditions, for example when the temperatures are significantly higher or lower than 25°C

The complete failure of both battery packs results in the loss of the clock settings and the FLOWSIC500 does not measure anymore.

Meter readings determined until then as well as the parameter settings remain permanently stored.

7.3.2 Changing the battery packs

(77° F).

WARNING: Risk of explosion - hazard for intrinsic safety

▸

The charge level of the battery packs is shown as a symbol on the display.

Tab le 2 5 Battery fill level

Symbol Significance Description

Battery pack 1 fill level (connection BAT1)

Battery pack 2 fill level (connection BAT2)

The second battery pack is activated automatically when the first pack is completely empty. When one battery pack is empty, at least this battery pack should be changed. Both battery

packs must be changed at the latest when the second battery pack is running low.

1 Check on the display which battery pack is empty. 2 Open the electronics cover (→ p. 39, § 3.4.3) 3 Loosen only the respective terminal connection of the empty battery pack.

Only the exchangeable battery packs from SICK with part no. 2064018 and the backup battery with part no. 2065928 may be used.

Details on the battery fill level → p. 59, § 5.2.2.

NOTICE:

Only loosen one connection at a time to ensure continuous voltage supply! If both battery packs are to be exchanged at the same time, first replace

the empty battery pack and then the still used battery pack.

Subject to change w ithout notice

Fig. 35 Battery connections on the circuit board

4 Remove the battery pack and replace by the new one. 5 Reconnect the electrical system.

The FLOWSIC500 now continues to use the second battery pack and then switches back to the new battery pack.

6 Close the electronics cover (→ p. 39, § 3.4.3) 7 Confirm battery replacement on the display (→ p. 74, § 5.2.13).

Maintenance and Meter Replacement

NOTICE:

The battery symbol on the display shows full straight away after the battery change.

The check whether the battery is really operational then takes 20 minutes.

Subject to change w ithout notice

Maintenance and Meter Replacement

7.4 Meter exchange

7.4.1 Prerequisites for meter replacement

NOTICE:

Ensure that the meter replacement is carried out according to the national regulations for Ex and pressure applications of your country.

7.4.2 Hazards during meter replacement

WARNING: Hazards due to combustible gases or high pressure

Natural gas under line pressure flows through the gas flow meter during running operation. The gas flow meter may only be replaced when the equipment is at a standstill.

Before commencing installation work:

▸

Ensure the pipeline is free from pressure and free from combustible gases.

▸

Purge the pipeline with inert gas if necessary.

▸

Observe the safety information in §1.1 (→ p. 10) and §3.1 (→ p. 30).

NOTICE:

The gas flow meter may only be replaced by skilled persons who, based on their technical training and knowledge in pipeline construction as well as knowledge of the relevant regulations, can assess the tasks given and recognize the hazards involved.

▸

Observe the information in §1.4 (→ p. 13).

▸

In case of doubt, please contact the local SICK Customer Service.

7.4.3 Sequence of meter replacement

To exchange the gas flow meter, proceed as follows:

1 Download the user-specific configuration of the installed gas flow meter (→ p. 90,

§7.4.6).

2 Disconnecting electrical connections (→ p. 90, §7.4.7). 3 Removing the installed gas flow meter (→ p. 91, § 7.4.8). 4 Installing the replacement gas flow meter (→ p. 95, § 7.4.9). 5 Performing a leak tightness check (→ p. 97, §7.4.10). 6 Connect the new gas flow meter to the electric system ( → p. 37, §3.4). 7 Upload the user-specific configuration of the previously installed gas flow meter to the

new gas flow meter (→ p. 90, § 7.4.6).

8 Check the function of the gas flow meter (→ p. 99, § 7.4.11). 9 If necessary, secure metrologically (→ p. 99, § 7.4.12).

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7.4.4 Required tools and auxiliary material

● Meter replacement set (item numbers → p. 106, § 8.2.1 ) with: – Test cap for the respective meter size (→ Fig. 36, component no. 9) –Socket wrench –Allen key

Table 26 Openings

Meter size Socket wrench Allen key DN50/2" 19 8 DN80/3" 24 10

DN100/4" 30 14 DN150/6"

● Torque wr ench

● Transport protection for the gas flow meter with a safety strap (item numbers → p. 105,

§8.1.3)

● Silicone grease

● Leak detection spray

● Anti-seize paste, metal-free or suitable for aluminium, e.g. OKS 235, to prevent thread

mountings seizing up

Maintenance and Meter Replacement

NOTICE:

Do not use copper paste!

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Maintenance and Meter Replacement

1 Securing screws 6 Connecting pieces with seals 2 Ripplock washers 7 Adapter 3 Center bolt 8 Locking cap 4 Ripplock washer 9 Test cap 5 Gas flow meter

7.4.5 Overview

Fig. 36 Components for meter replacement using DN50/2" as example

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Maintenance and Meter Replacement

EXT. POWER

BAT1

N.c.

DO3

DO0

RS485

P1P2T1

SENSORS

DISPLAY

LOCK OFF ON

5..12V

NAMUR

4,5..16V

1.5 mm² (AWG 16)

R :100

2..16V

4074419

DO2

*Optional V see module

OC NAM

2..16V

DO1

BAT2

OC NAM

+- +-

7.4.6 Back-up of user-specific configuration of installed gas flow meter

▸

Use the operating software FLOWGate500 to download the customer-specific configuration of the installed gas flow meter and to save it as file.

You can use the file later to set user-specific configurations in the new gas flow meter.

▸

After installation of the replacement gas flow meter, upload the user-specific configuration of the previously installed gas flow meter to the new gas flow meter (see Software Manual FLOWGate500, §13, “Meter replacement”).

7.4.7 Disconnecting electrical connections

Observe the safety information in §3.4 (→ p. 37)! Depending on the configuration of your FLOWSIC500, proceed as follows: 1 Disconnect the potential equalization line at the outer ground terminal (on the right of

the M12 plug-in connections) of the electronic housing (→ Fig. 18, p. 41).

2 If installed, remove the plug-in connector cover. To do so, loosen the capstan screws

(→ Fig. 27, p. 47).

3 If installed, manually loosen and remove the M12 plug-in connectors for external power

supply and the signal output (→ Fig. 18, p. 41).

4 If installed, manually loosen and remove the plug-in connectors of the pressure and

temperature transmitters ( → Fig. 18, p. 41).

5 Open the electronics cover (→ p. 39, § 3.4.3).

▸

Configuration with external power supply and back-up battery: Switch the back-up battery to “N.c.”.

Fig. 37 Switching the back-up battery

▸

Self-sufficient power configuration with battery packs: Remove the battery packs and dispose of or store properly according to → p. 82, § 7.1.

SICK recommends inserting new batteries during every meter replacement.

6 Close the electronics cover again (→ p. 39, § 3.4.3).

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Maintenance and Meter Replacement

7.4.8 Removing the installed gas flow meter

1 Ensure safe conditions.

WARNING: Hazards due to combustible gases or high pressure

Natural gas under line pressure flows through the gas flow meter during running operation. The gas flow meter may only be replaced when the equipment is at a standstill.

Before commencing installation work:

▸

Ensure the pipeline is free from pressure and free from combustible gases.

▸

Purge the pipeline with inert gas if necessary.

▸

Observe the safety information in §1.1 and §3.1.

WARNING: Hazard due to the gas flow meter falling down

▸

Secure the gas flow meter before loosening the screw fitting, e.g. by supporting the gas flow meter or with the help of another person holding the gas flow meter.

2 Unscrew the closure cap.

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3 Remove securing screws (1) with the

1 2

Meter size Number of securing screws

DN50 2

DN80 3 DN100 4 DN150 4

approx. 5

Allen key

4 Loosen center bolt (2) five to six

turns.

5 Instead of the closure cap, at first

manually screw the test cap for the respective meter size in until the test cap touches the center bolt.

Maintenance and Meter Replacement

6 Keep on screwing the test cap in with

the socket wrench against the resistance of the center bolt until the test cap is completely screwed in.

The center bolt pushes the seals upwards and lifts the gas flow meter up.

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Maintenance and Meter Replacement

7 Unscrew the test cap and the center

bolt completely with the socket wrench.

8 Pull the gas flow meter straight

upwards and remove it.

9 Ensure that the connecting pieces

with the O-rings are still on the gas flow meter.

10 Ensure that the gas flow meter can

not be contaminated or damaged at any time.

11 Secure the removed gas flow meter

with the transport protection before shipping:

– Fit the gas flow meter on the

transport protection.

– Secure the gas flow meter with

the strap provided.

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12 Check the sealing surfaces on the

adapter (marked green): – When the sealing surfaces are

contaminated, clean carefully.

– Ensure that the sealing surfaces

are undamaged. They have to be free of scratches or grooves.

WARNING: Hazard of leaks

There is a risk of the installation becoming leaky when the sealing surfaces of the adapter are damaged. Operation in leaky condition is not allowed and potentially dangerous.

▸

In this case, the adapter has to be exchanged.

▸

Please contact your local SICK Customer Service.

Maintenance and Meter Replacement

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Maintenance and Meter Replacement

1 2

7.4.9 Installing the replacement gas flow meter

NOTICE:

When the sealing surfaces of the adapter have been cleaned with a detergent, let it evaporate completely.

1 Carefully remove the transport pro-

tection of the new gas flow meter. Pay attention to the arrangement of O-ring seals (1) and support plates (2).

2 Check the outside of the replace-

ment gas flow meter for transport damage.

Only undamaged gas flow meters may be installed.

3 Ensure that flat sealing (1) and the

O-rings on connection pieces (2) are not damaged.

4 Check all threads on the compo-

nents for damage.

5 Apply silicone grease to the sealing surfaces of the adapter. 6 Apply silicone grease to the O-rings on the connection pieces.

7 Carefully fit the gas flow meter on the

adapter. Pay attention to the correct orienta-

tion of the gas flow meter. The position of the center bolt allows only one fitting direction.

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8 Carefully plug the connection pieces

Meter size Tightening torque [Nm) DN50 45 DN80 100 DN100

145

DN150

Meter size Tighenting torque [Nm]

DN50 20

DN80 45 DN100

100

DN150

with the O-rings into the openings of the adapter.

9 First screw the provided new center

bolt with Ripplock washer in manually.

SICK recommends using anti-seize paste.

10 Then tighten the center bolt with the

socket wrench to the specified tightening torque.

Maintenance and Meter Replacement

11 First screw the provided securing

12 Then tighten the securing screws

13 Check the leak tightness, → p. 97,

screws with Ripplock washers in manually.

with the Allen key to the specified tightening torque.

Subject to change w ithout notice

§7.4.10.

Maintenance and Meter Replacement

14 After a successful leak tightness check, connect the replacement gas flow meter to

the electric system, see §3. 4 “Electrical installation”.

15 If desired, upload the configuration of the previously installed gas flow meter to the

replacement gas flow meter (→ p. 90, §7.4.6).

16 Checking the function of the gas flow meter, → p. 99, § 7.4.11.

17 Securing metrologically, → p. 99, §7.4.12, if necessary.

7.4.10 Performing a leak tightness check

After each replacement of the gas flow meter, the correct installation of the gas flow meter and the leak tightness of the measuring device has to be checked.

To check the leak tightness, the corresponding test cap for the respective meter size is needed (→ p. 88, §7.4.4).

1 First screw the test cap for the

respective meter size in manually.

2 Then tighten the test cap with the

socket wrench until the test cap is completely screwed in.

3 Slowly increase the pressure in the device (max. gradient 3 bar/min or 45 psi/min) up

to the line pressure.

4 Apply leak detection spray to the opening of the test cap. 5 Check for at least 15 min. whether gas escapes from the opening of the test cap

– When no gas escapes from the opening of the test cap, see → p. 98, §7.4.10.1 – When gas escapes from the opening of the test cap, see → p. 98, §7.4.10.2.

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7.4.10.1 Leak tightness check successful

Meter size Item number

DN50 2076394

DN80 2076395 DN100

2076396

DN150

1 Remove the test cap with the socket

wrench.

2 Screw in the closure cap. 3 Then connect the replacement gas

flow meter to the electric system, see

§3. 4 “Electrical installation”.

7.4.10.2 Leak tightness check not successful

1 Close the line and depressurize the device. 2 Vent the environment. 3 Remove the gas flow meter from the adapter as described, see → p. 91, § 7.4.8.

4 Check flat seal (1) and the O-rings on

connections pieces (2) for completeness, intactness and correct installation. When the sealing elements are damaged, a new seal set is available as spare part.

Maintenance and Meter Replacement

Subject to change w ithout notice

Maintenance and Meter Replacement

5 Check the sealing surfaces on the

adapter (marked green) for contamination and damage.

6 When the sealing surfaces are dam-

aged, e.g. due to corrosion or external force, the adapter has to be exchanged.

7 When the adapter is damaged, it has to be removed and a new adapter installed

→ p. 31, § 3.3. Then install the gas flow meter anew, → p. 95, § 7.4.9.

8 When the components do not seem to be damaged but leak tightness can not be

established, please contact SICK Customer Service (→ p. 78, § 6.1).

7.4.11 Checking the function of the gas flow meter

▸

Record the diagnosis parameters (see Software Manual FLOWGate500, §11, “Field verification”).

▸

Check on the display if there are any malfunctions or warnings:

Device status: Malfunction The device has an error, the measured value is invalid.

Device status: Warning The device has a warning, the measured value is still valid.

▸

When malfunctions or warnings exist, clear the cause (→ p. 77, § 6).

7.4.12 Securing metrologically

▸

Gas flow meter and adapter can be secured at the joint by a user seal (adhesive label) (→ p. 26, § 2.10).

▸

When the parameter locking switch has been opened during the meter replacement, secure the parameter locking switch anew metrologically (→ Fig. 9, p. 27).

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Maintenance and Meter Replacement

7.5 Function check of a pressure or temperature transmitter

The error status of a transmitter is displayed on the device as an event.

1 Switch to main display "Current events". 2 Check the list for a current event with type 'E-3010' (temperature transmitter failure) or

'E-3012' (pressure transmitter failure). Exchange the transmitter involved when one of these errors is displayed → p. 100, § 7.6.

Replace the gas flow meter in the device configuration with internal pressure and temperature transmitters.

If an error is not displayed, the transmitter function can be checked by comparing the measured value on the FLOWSIC500 with the measured value of a reference transmitter.

7.6 Exchanging an external pressure or temperature transmitter

WARNING: Hazard through wrong spare parts

The FLOWSIC500 and the delivered pressure and temperature transmitters are designed intrinsically safe.

▸

Only pressure and temperature transmitters from SICK may be used → p. 106, § 8.2.2.

▸

The pressure and temperature transmitters can be connected and disconnected in the hazardous area as well.

▸

The pressure and temperature transmitters may only be connected using the M8 plug-in connectors marked accordingly on the FLOWSIC500.

▸

Modifying the electrical connection parts is not allowed.

NOTICE:

Pressure and temperature transmitters can only be exchanged when the parameter locking switch is open.

7.6.1 Exchanging the pressure transmitter

1 Three-way test valve: Move the knob to the test position (→ Table 14).

Kamstrup test valve: Fit the adapter on the test connection (part no. 2071841).

2 Unscrew the transmitter from the three-way test valve.

Here, loosen the screw fitting slowly so that any overpressure can escape under control.

3 Loosen the plug-in connector cover. 4 Disconnect the plug. 5 Connect the plug to the M8 connection on the FLOWSIC500. 6 Screw the plug-in connector cover tight. 7 Install a new pressure transmitter on the pressure measuring port marked “P

§3.5.2.

8 Enter the serial number of the new transmitter in the FLOWSIC500 with the operating

software FLOWgate500.

9 Check the function by comparing the operating point or checking the display value

(remove adapter on test connection) against a reference measurement.

NOTICE: Leak tightness check

SICK recommends a leak tightness check after transmitter replacement.

” → p. 48,

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SICK FLOWSIC500 Operating Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Title Page

Glossary

Warning Symbols

Information Symbols

Contents

1 Important Information

1.1 Main hazards

1.2 About this document

Fig. 1 Ty pe co d e

1.3 Intended use

1.3.1 Purpose of the device

1.3.2 Product identification

Fig. 2 Location of type plates

1.3.3 Operation in potentially explosive atmospheres

1.3.4 Combustible gas

1.3.5 Restrictions of use

1.3.6 Cleaning

1.4 Responsibility of user

1.5 Additional documentation/information

2 Product Description

2.1 Operating principle

2.1.1 Gas flow meter

Fig. 3 Functional principle

2.1.2 Volume conversion (optional)

Adapter

2.2 FLOWSIC500 measuring system

Fig. 4 FLOWSIC500 components

2.2.2 Gas flow meter

2.3 Meter sizes

2.4 Power supply

2.5 Interfaces

2.5.1 Pulse and status outputs

2.5.2 Encoder totalizer

2.5.3 Serial data interface

2.5.4 Optical data interface

2.6 Device option: Volume conversion

2.6.1 Volume conversion

2.6.2 Integrated pressure and temperature transmitters

2.6.3 External pressure and temperature transmitters

Fig. 5 FLOWSIC500 with external transmitters and Kamstrup test valve BDA04

Fig. 6 Three-way test valve with p transmitter and Minimess coupling

2.7 Totalizers

2.7.1 Device status and totalizers used

2.7.2 Reverse flow

2.8 Logbooks and Archives

2.9 Parameter protection

2.9.1 Parameter locking switch

Fig. 7 Parameter locking switch on the circuit board

2.9.2 Metrology logbook

2.10 Sealing

Fig. 8 Factory seal of the cover on the gas flow meter

Fig. 9 Seals on the terminal compartment and plug-in connector cover

Fig. 10 Seal on the temperature transmitter (example)

Fig. 11 Seal on the pressure transmitter (example)

3 Installation

3.1 Hazards during installation

3.2 General information

3.2.1 Delivery

3.2.2 Transport

3.3 Mechanical installation

3.3.1 Preparations

3.3.2 Choosing flanges, gaskets and other components

Fig. 12 Dimensions of gaskets

3.3.3 Fitting the FLOWSIC500 in the pipeline

Fig. 13 Installation examples

3.3.3.1 Mounting clearances

Fig. 14 Mounting clearances

3.3.3.2 Torque on the pipeline

3.3.3.3 Installation in pipeline

3.4 Electrical installation

3.4.1 Requirements for use in potentially explosive atmospheres

Fig. 15 Ex zones

3.4.2 Criteria for electrical connection

3.4.3 Opening and closing the electronics cover

Fig. 16 Position of electronics cover screws

3.4.4 Rotating the control unit