SICK FLOWSIC500 Operating Instructions Manual

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)

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

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.

●●●

●●●●

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.

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)

Subject to change w ithout notice

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

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

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

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.

Subject to change w ithout notice

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

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).

Subject to change w ithout notice

+ 108 hidden pages

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