SICK FLOWSIC600 Operating Instructions Manual
Title
FLOWSIC600
OPERATING INSTRUCTIONS
Applifoto
74 x 45 mm
(150 dpi: 437 x 266 pixel)
Ultrasonic Gas Flow Meter
Ultrasonic Gas Flow Meter
for Custody Transfer
and Process Applications
MEPAFLOW600 CBM and Firmware V3.4.xx
x = 136 mm y = 58 mm
Document Information
Glossary
Product
Product name: FLOWSIC600
Document ID
Title: Operating Instructions FLOWSIC600
Order No.: 8010458
Version: 2.0
Release: 2010-01
Publisher
SICK MAIHAK GmbH
Nimburger Str. 11 · D-79276 Reute · Germany
Tel.: +49 7641 469-0
Fax: +49 7641 469-11 49
E-mail: info.pa@sick.de
Trademarks
IBM is a trademark of the International Business Machine
Corporation.
MS-DOS is a trademark of the Microsoft Corporation.
Windows is a trademark of the Microsoft Corporation .
Other product names used in this document may also be trademarks and are only used for identification purposes.
Guarantee Information
Specified product characteristics and technical data do not serve
as guarantee declarations.
© SICK MAIHAK GmbH. All rights reserved.
Abbreviations used in this manual
act. actual (under operating/flowing conditions)
AGC Automatic Gain Control
ASCII American Standard Code for Information
Interchange
ANSI American National Standards Institute
ASME American Society of Mechanical Engineers
AWG American Wire Gage
CBM Condition Based Maintenance
CSA Canadian Standards Association
DC Direct Current
DIN Deutsches Institut für Normung (German
Standards Institute)
DN Nominal Diameter (internal)
DSP Digital Signal Processor
EC European Community
EN Euro Norm (European Standard)
EVC Electronic Volume Corrector
Ex Potentially
® Communication interface
HART
IEC International Electrotechnical Commission
LCD Liquid Crystal Display
LED Light Emitting Diode
MEPAFLOW Menu-assisted Parameterisation and Diagno-
MDR Manufacturer Datal Record
NAMUR Normenarbeitsgemeinschaft für Mess- und
norm. normalized/corrected (under standard condi-
OI Operating Instructions (this document)
OIML Organisation Internationale de Metrologie
PC Personal Computer
PTB Physikalisch Technische Bundesanstalt
RTU Remote Terminal Unit
SPU Signal Processing Unit
VDE Verband d
area)
sis for FLOWSIC600
Regeltechnik in der chemischen Industrie
(now "Interessengemeinschaft Prozessleittechnik der chemischen und pharmazeutischen Industrie"; ~ Association for
Instrumentation and
Control Standards in the Chemical Industr y)
tions)
Legale
(~ Federal Metrology Office in Germany)
mationstechnik
(~ Association of German Electrical Engineers)
explosive atmosphere (hazardous
er Elektrotechnik Elektronik Infor-
2 FLOWSIC600 · Operating Instructions · 8010458 V2.0 · © SICK MAIHAK GmbH
Warning Symbols
Hazard (general)
Hazard in potentially explosive atmospheres
Hazard by voltage
Warning Levels / Signal Words
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
Hazard which could result in property damage.
Information Symbols
Information about the use in potentially explosive
atmospheres
Important technical information for this product
Important information on electric or electronic functions
Supplementary information
Link to information at another place
FLOWSIC600 · Operating Instructions · 8010458 V 2.0 · © SICK MAIHAK GmbH 3
Contents
Contents
1 Important Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.1 About this Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.2.1 Intended Use of the Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.3 Authorized Staff. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.4 General Safety Instructions and Protective Measures . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.5 Dangers due to hot, corrosive and explosive gases and high pressure . . . . . . . . . . . . 10
1.6 Dangers due to heavy loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.7 Environmental information and instructions for disposal . . . . . . . . . . . . . . . . . . . . . . . . 11
2 Product Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.1 System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.1.1 Meter body. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.1.2 Ultrasonic transducers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.1.3 Signal processing unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.2 Operating Modes, Meter States and Signal Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.2.1 Operation Mode and Configuration Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.2.2 Meter States . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.2.3 Pulse output and status information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.3 MEPAFLOW600 CBM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.3.1 Software Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.3.2 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.1 General Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.1.1 Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.1.2 Transport and storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.2.1 Measuring location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.2.2 Installation configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.3 Mechanical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.3.1 Choosing flanges, seals and other parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.3.2 Mounting the FLOWSIC600 in the piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.3.3 SPU alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.4 Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.4.1 General information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.4.2 Cable specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.4.3 Checking the cable loops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.4.4 Terminal enclosure on the SPU. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.4.5 Operating the FLOWSIC600 in safe areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3.4.6 Operation in hazardous areas (Directive 94/9/EC (ATEX)) . . . . . . . . . . . . . . . . . . . . 39
4 FLOWSIC600 · Operating Instructions · 8010458 V2.0 · © SICK MAIHAK GmbH
Contents
4 Commissioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4.1 General Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
4.2 Connecting the FLOWSIC600 to a PC or Laptop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4.2.1 Connecting the FLOWSIC600 via RS485 / RS232 cable . . . . . . . . . . . . . . . . . . . . . .45
4.2.2 Connecting the FLOWSIC600 via RS485/USB converter . . . . . . . . . . . . . . . . . . . . . . 46
4.3 Connecting to the FLOWSIC600 with MEPAFLOW600 CBM . . . . . . . . . . . . . . . . . . . . . . 47
4.3.1 Starting MEPAFLOW600 CBM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
4.3.2 Choosing an User Access Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
4.3.3 Creating a new meter entry in the meter database . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
4.3.4 Online Connection: Direct Serial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
4.3.5 Online Connection: Ethernet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
4.4 Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
4.4.1 Checking identification, operation / design data and firmware version . . . . . . . . . 52
4.5 Field Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
4.5.1 Disconnecting from the Meter and Closing the Session . . . . . . . . . . . . . . . . . . . . . . . 54
4.6 Function Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
4.6.1 Function test on FLOWSIC600 with LCD front panel . . . . . . . . . . . . . . . . . . . . . . . . . . 55
4.6.2 Function test on FLOWSIC600 with LED front panel . . . . . . . . . . . . . . . . . . . . . . . . . . 55
4.6.3 Function test with MEPAFLOW600 CBM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
4.7 Activation of Path Compensation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
4.8 Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
5Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
5.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
5.2 Routine Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
5.2.1 Comparing theoretical and measured Speed of Sound (SOS) . . . . . . . . . . . . . . . . . . 63
5.2.2 Checking the Meter Health . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
5.2.3 Time Synchronization. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
5.2.4 Battery Lifetime / Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
5.3 Maintenance Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
5.4 Optional Data Download . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
5.4.1 Logbook Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
6 Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
6.1 General Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
6.2 Indication of Meter States, System Alarms and Warnings . . . . . . . . . . . . . . . . . . . . . . . . 72
6.2.1 Checking the “Meter Status“ Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
6.2.2 Checking the User Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
6.2.3 Battery Lifetime / Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
6.3 Generation of a Diagnosis Session . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
6.4 Meter Connection Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
FLOWSIC600 · Operating Instructions · 8010458 V 2.0 · © SICK MAIHAK GmbH 5
Contents
7 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
7.1 Conformities and Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
7.1.1 CE certificate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
7.1.2 Standard compatibility and type approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
7.1.3 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
7.2 Logbooks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
7.2.1 Overview of event entries in logbooks and MEPAFLOW600 CBM . . . . . . . . . . . . . . 86
7.3 Connection Diagrams for Operating the FLOWSIC 600 in Hazardous Areas in
Accordance with North American Guidelines (CSA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
7.4 Wiring Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
7.4.1 Intrinsically safe installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
7.4.2 Non-intrinsically safe installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
7.5 Sealing Plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
6 FLOWSIC600 · Operating Instructions · 8010458 V2.0 · © SICK MAIHAK GmbH
Important Information
FLOWSIC600
1 Important Information
About this Document
Safety Instructions
Authorized staff
General Safety Instructions and Protective Measures
Dangers Due to Hot, Corrosive and Explosive Gases and High Pressure
Dangers Due to Heavy Loads
Environmental Information and Instructions for Disposal
FLOWSIC600 · Operating Instructions · 8010458 V 2.0 · © SICK MAIHAK GmbH 7
Important Information
1.1
About this Document
This manual describes the FLOWSIC600 measuring system, which is used to determine the
volumetric flow rate, volume and the speed of sound in gases transported in pipelines. It
provides general information on the measuring method employed, design and function of
the entire system and its components, and on planning, assembly, installation, calibration
commissioning, maintenance and troubleshooting. Also included is a detailed description
of the various system capabilities, options and settings which will assist in optimizing the
meter configuration for a specific application.
This manual covers standard applications which conform with the technical data specified.
Additional information and assistance for special applications are available from your SICK
representative. However, it is generally recommended to take advantage of qualified
consulting services provided by SICK experts for your specific application.
This operating manual is a part of the FLOWSIC600 device documentation. Which also
includes the following (optional, for trained staff only):
● FLOWSIC600 service manual,
● FLOWSIC600 extraction tool operating instructions,
● FLOWSIC600 MODBUS specification document,
● FLOWSIC600 HARTbus specification document.
● FLOWSIC600 Technical Bulletin ENCODER Output
All documentation is available on www.flowsic600.com or from your local representative.
Scope of Document
This document applies to meters with S/N 10xxxxxx, with firmware version
3.4.00 or higher and extended memory for the storage of e.g. hourly and daily
mean values.
The software describtion in this document applies to MEPAFLOW600 CBM
V1.1.13.
The following terms will be used for measurands:
Measurand
Basic abbrevations and
units for FLOWSIC600
Abbrevations used at
LCD-Display of SPU
MEPAFLOW600 CBM
software
Volume at flowing conditions Vf m³ acf Vf m³ cf Vf m³ acf
Volume at base conditions Vb Nm³ scf Vb m³ cf Vb Nm³ scf
Error volume at flowing conditions Ef m³ acf Ef m³ cf Ef m³ acf
Error volume at base conditions Eb Nm³ scf Eb m³ cf Eb Nm³ scf
Total volume at flowing conditions Vo m³ acf Vo m³ cf Vo m³ acf
Volume flow at flowing conditions Qf m³/h acf/h Qf m³/h cf/h Qf m³/h acfh
Volume flow at base conditions Qb Nm³/h scf/h Qb m³/h cf/h Qb Nm³/h scfh
8 FLOWSIC600 · Operating Instructions · 8010458 V2.0 · © SICK MAIHAK GmbH
Important Information
1.2
1.2.1 Intended Use of the Equipment
Safety Instructions
The FLOWSIC600 measuring system is used for measuring the actual volumetric flow rate
of gases transported in pipelines. It can be used for measuring the actual corrected
volume and the velocity of sound in gases.
The measuring system shall only be used as specified by the manufacturer and as set forth
below. Always observe the following information:
● Make sure the use of the equipment complies with the technical data, information
about the permitted use, assembly and installation specifications and ambient as well
as operating conditions. Relevant information is provided in the order documentation,
type plate, certification documents and this manual.
● Any actions for the purpose of maintaining the value of the equipment, e.g. service and
inspection, transport and storage etc., shall be performed as specified.
● Do not expose the equipment to mechanical stress, such as pigging.
● The flooding of the FLOWSIC600 with any liquid (e.g. for pressure or leakage tests) is an
improper use. The consequences of such activities can not be foreseen or estimated.
The result can be a failure of the ultrasonic transducers and consequently a failure of
the entire flow meter.
If a flooding is necessary nevertheless, please contact the manufacturer beforehand and
additionaly strictly respect the following instructions:
WARNING:
b
A FLOWSIC600 equipped with transducers of type “S1” may under no
circumstances be flooded with liquids.
b
The pressure during flooding may not exceed a pressure higher than 1,2
times the nominal pressure (when transducers are assembled).
1.3 Authorized Staff
Persons responsible for safety issues shall ensure the following:
● Any work on the measuring system shall only be carried out by qualified persons and
must be approved by responsible skilled persons.
Due to their professional training, knowledge and vocational experience, as well as their
knowledge of the relevant standards, regulations, health and safety regulations and
equipment conditions, qualified persons shall be assigned by the person responsible
for personal and plant safety to carry out such work. Qualified persons must be able to
identify possible dangers and to take preventive action in due time.
Skilled persons are defined in DIN VDE 0105 and IEC 364, or comparable standards.
● Skilled persons shall have precise knowledge of process-specific dangers, e.g. due to
the effects of hot, toxic and pressurised gases, gas-liquid mixtures and other process
media, and of the design and working principle of the measuring system and shall have
received and be able to document appropriate training.
● In hazardous areas, wiring and installation shall only be carried out by staff trained
according to EN 60079-14 and according to national regulations.
FLOWSIC600 · Operating Instructions · 8010458 V 2.0 · © SICK MAIHAK GmbH 9
Important Information
1.4
General Safety Instructions and Protective Measures
Using the equipment for any purpose other than intended, or improper operation may
result in injuries and damage to the equipment. Read this section and the notes and
warnings in the individual sections of this manual carefully and observe the instructions
given therein when carrying out any work on the FLOWSIC600 measuring system.
Generally:
● Always comply with the statutory provisions and the associated technical rules and
regulations relevant to the equipment when preparing for and carrying out any work on
the measuring system. Pay particular attention to potentially hazardous aspects of the
equipment, such as pressurized piping and explosion protection zones. Always observe
the relevant regulations.
● Always consider local and equipment-specific conditions and process-specific dangers
when carrying out any work on the equipment.
● Operating and service instructions and equipment documentation shall always be
available on site. Always observe the safety instructions and notes on the prevention of
injuries and damage given in these manuals.
● Make sure appropriate protective accessories are available in sufficient supply. Always
use such protective accessories. Check that appropriate safety devices are fitted and
working correctly.
1.5 Dangers due to hot, corrosive and explosive gases and high pressure
The FLOWSIC600 measuring system is directly integrated into gas-carrying pipelines.
The operating company is responsible for safe operation and for complying with additional
national and company-specific regulations.
WARNING:
In plants with toxic and explosive gases, high pressure or high temperatures,
the FLOWSIC600 measuring system shall only be installed or removed after
the associated piping has been isolated and depresurrized (i.e. vented to
atomsphere).
The same applies to repair and service work which involves opening any
pressurized component or the explosion-proof signal processing unit (SPU).
NOTICE:
Design, manufacture and inspection of the FLOWSIC600 measuring system
are performed in compliance with the safety requirements set forth in the
European Pressure Equipment Directive 97/23/EC. All relevant information for
the particular application (as specified in the technical information
questionnaire filled out by the customer) has been taken into account before
commencing order processing.
10 FLOWSIC600 · Operating Instructions · 8010458 V2.0 · © SICK MAIHAK GmbH
Important Information
1.6
Dangers due to heavy loads
The FLOWSIC600 measuring system must be safely attached to the carrying structure
when being transported and installed.
WARNING:
● Only use lifting gear and equipment (e.g. lifting straps) which is suitable for
the weight to be lifted. Max. load information can be found on the type plate
of the lifting gear.
● The eye bolts attached to the meter body are suitable for the transport of
the measuring device. However, additional loads (e.g. blind covers, filling
for pressure tests or associated piping) must not be lifted and transported
together with the measuring system without the use of additional support
from the lifting gear.
● Never attach lifting gear to the signal processing unit or its mounting
bracket and avoid contact between these parts and the lifting gear.
1.7 Environmental information and instructions for disposal
The FLOWSIC600 components are easily disassembled and do not contain toxic,
radioactive or any other enviromentally hazardous materials. The instrument consists
primarily of steel, stainless steel, plastic and aluminium, and consequently there are few
restrictions for disposal. Only the printed-circuit boards must be disposed of as electronic
scrap.
FLOWSIC600 · Operating Instructions · 8010458 V 2.0 · © SICK MAIHAK GmbH 11
Important Information
12 FLOWSIC600 · Operating Instructions · 8010458 V2.0 · © SICK MAIHAK GmbH
Product Description
FLOWSIC600
2 Product Description
System Components
Operating States and Signal Output
MEPAFLOW600 CBM
FLOWSIC600 · Operating Instructions · 8010458 V 2.0 · © SICK MAIHAK GmbH 13
Product Description
Meter body
Cover cap
Pressure tap
Flange
SPU
Hoisting eye
Position of the ultrasonic transducers
(cover cap taken off)
Marking for direction of
flow (forward)
2.1
System Components
The FLOWSIC600 measuring system consists of the following hardware components:
● Meter body
● Ultrasonic transducers
● Signal processing unit SPU
The MEPAFLOW600 CBM software is the user interface used to facilitate operation,
configuration and diagnosis (see
Figure 1 FLOWSIC600
→
pg.20, 2.3).
2.1.1
Meter body
The meter body consists of a mid section for mounting the ultrasonic transducers, with
flanges on either end. For meter sizes up to 24“, the body is made of a single-piece casting,
which is machined on precision equipment to ensure high reproducibility of the geometric
parameters. For meters larger than 24“ the body is made of a single-piece casting or
forged or the flanges are welded onto the machined mid section.
The internal diameter, design of the sealing surface, and standard dimensions of the
flanges are in accordance with the specifications in the key code. The meter body material
is chosen to suit customer requirements. Standard meter bodies are available in carbon
steel, Low Temperature Carbon Steel and stainless steel.
The meter bodies can be delivered in several nominal sizes (see
14 FLOWSIC600 · Operating Instructions · 8010458 V2.0 · © SICK MAIHAK GmbH
→
pg.82, 7.1.3).
Product Description
Measured values
Control buttons for the magnetic pen
Control buttons for manual use
2.1.2
Ultrasonic transducers
The FLOWSIC600 ultrasonic transducers are optimized to suit the application
requirements. The high quality of the transducer design provides the basis for accurate
and highly stable propagation time measurements with nanosecond precision. These
transducers are of an intrinsically safe design (category “ia“).
2.1.3 Signal processing unit
The SPU contains all the electrical and electronic components for controlling the ultrasonic
transducers. It generates transmission signals and analyzes the received signals to
calculate the measuring values. The SPU also contains several interfaces for
communication with a PC or standardized process control system.
The volume counters, errors, warnings, and system events are stored in a non volatile data
memory (FRAM) together with a time stamp (Logbooks
counter readings that were last saved are restored as the start values for the volume
counters. The FRAM backup provides an unlimited number of writing cycles and protects
the saved data for at least 10 years.
The SPU is equipped with a front panel containing a two-line LCD to display current
measured values, diagnostics and logbook information (
displayed can be selected using a magnetic pen without removal of the front cover . The
MEPAFLOW600 CBM software provides a more user-friendly way to display the information.
Figure 2 FLOWSIC600 front panel LCD
→
pg.86, 7.2.) On system restart, the
→
Figure 2). The values to be
The power supply and interface terminals are located on the back of the SPU in a separate
terminal section of the enclosure (
→
pg.36, 3.4.4).
The electronics are mounted in the SPU enclosure certified to EN 60079-1 or IEC 60079-1
with protection type “d“ (flameproof enclosure). The transducer circuits are of an
intrinsically safe design (category “ia“).
FLOWSIC600 · Operating Instructions · 8010458 V 2.0 · © SICK MAIHAK GmbH 15
Product Description
2.2
Operating Modes, Meter States and Signal Output
The FLOWSIC600 has two operating modes (→2.2.1):
● Operation Mode
● Configuration Mode
In the Operation Mode the meter can have the following Meter states (
● Measurement valid
● Check request
● Measurement invalid
2.2.1 Operation Mode and Configuration Mode
The meter can be operated by the user in two modes: Operation or Configuration.
Operation Mode
In the Operation Mode, the meter runs in one of the aforementioned three Meter states,
depending on the measuring conditions.
Configuration Mode
The Configuration Mode is used to modify parameters that directly influence the
measurement and to test the system and output signals. The Configuration Mode forces
the meter into the status “Measurement invalid”. The digital output “Measurement valid” is
deactivated in Configuration Mode because invalid measured values may be produced.
The system continues operation using the current sample rate and executes all
calculations as in the Operation Mode. Frequency output and analog output may represent
test values and do thus not necessarily indicate measured values. Any parameter
modifications are applied immediately to the running calculations, with the exception of
the sample rate and baud rate of the MODBUS interface/device address.
→
2.2.2):
If the meter is in Configuration Mode and there have been no activities either
on the LCD display or via MEPAFLOW600 CBM for more than 15 minutes, the
meter automatically switches to Operation Mode.
Tes t Cycl e
The test cycle can be activated for a measuring path by setting the corresponding control
bit in the System Control Register (#3002) (the setting can be carried out on the
“Parameters” page in MEPAFLOW600 CBM). In a test cycle, the transmitted signal is fed to
the receiver signal amplifier of the measuring path through an electric attenuation unit
(transducer simulator). This function can only be activated if the system is in the
“Configuration” mode. It is used to test a path-specific electronic module.
Test cycles are automatically cancelled when leaving the “Configuration” mode.
16 FLOWSIC600 · Operating Instructions · 8010458 V2.0 · © SICK MAIHAK GmbH
Product Description
2.2.2
2.2.2.1 Status: Measurement valid
Meter States
The “Measurement” status is the standard Meter state of the FLOWSIC600. Frequency
outputs and current output are updated cyclically and indicate the actual volume and
volumetric flow rate. In addition, the analog signal can indicate the actual flowrate,
corrected volumetric flowrate, SOS (speed of sound) or VOG (velocity of gas) The digital
output “Direction of flow” is updated in accordance with the direction of the volumetric
flow. The digital output “Valid measurement” (active) represents the status of the
measurement. Positive (forward) and negative (reverse) volumetric flow rates are
integrated and saved in separate internal memory sections.
The MODBUS interface allows the query of all parameters and signals at any time without
interfering with the function of the system.
Each measurement initiated by the system controller includes one full transit time
measurement with, and one against the direction of flow on each path. The result of each
measurement is written to a mean value memory to be used in further calculations. The
size of this memory block and thus the device response delay can be modified through the
parameter in register #3502 “AvgBlockSize”. If no result can be calculated due to poor
signal quality, this measurement is registered as an invalid attempt in the mean value
memory. The mean value is formed in a variable averaging process including all valid
measured values in the memory.
If the number of invalid measurements on a path exceeds a predefined limit (register
#3514 “Limit%Error”), the measuring system activates the “Check request” status.
2.2.2.2 Status: Check request
This status becomes active if one measuring path has failed and the adaptive path failure
compensation has been activated. The multi-path FLOWSIC600 system is able to
compensate for this failure. Measurement is continued with reduced accuracy. If a path
fails while the path failure compensation is deactivated, the measuring system will activate
the “Measurement invalid” status.
Moreover the check request status becomes active when the system alarms 2002 (“No
HART communication to temperature transmitter”), 2003 (“No HART communication to
pressure transmitter”), or 2004 (“Maximum pulse output frequency exceeded”) become
active (see table
→
pg.86, 7.2.1).
2.2.2.3 Status: Measurement invalid
If the quality of received signals is deficient in more than one measuring path, the SPU
must mark the measured value invalid and activate the meter status “Measurement
invalid”. However, the SPU will cyclically try to re-establish valid measurements. As soon as
the signal quality and number of valid measurements meet the required criteria, the SPU
will automatically change back to the “Measurement valid” or “Check request” status.
FLOWSIC600 · Operating Instructions · 8010458 V 2.0 · © SICK MAIHAK GmbH 17
2.2.3 Pulse output and status information
NOTICE: TYPE APPROVAL
Pulse output signals can be customized as shown in the following table.
Table 1 Pulse output
Output signal / LCD / port
Pulse
output
Inverted with error
signal **
Measurement state Check request state Configuration Mode Measurement invalid*
signals
Product Description
Signal behavior
Phase
shift
Positive
flow rate
90 ° ***
Negative
flow rate
Separate
outputs
Positive
flow rate
for each
direction
***
Negative
flow rate
Single pulse output
***
* The meter can be configured to put out a fixed frequency at “Measurement invalid“. The
frequency to be put out in this case can be configured in Reg.#3034 “ErrorFreq“ (0-6 kHz).
** Default setting on delivery.
*** Optional setting on customer request.
The default setting for “Check request”, “Configuration” and “Measurement invalid” is
“normally closed”.
18 FLOWSIC600 · Operating Instructions · 8010458 V2.0 · © SICK MAIHAK GmbH
Product Description
+V 123456 m³
-V 1234 m³
1234 m³
FLOWSIC600
Configuration
+V 123456 m³
-V 1234 m³
Tab le 2 Status output
Output signal / LCD / port
“Check request”
Status signal
“Direction of flow”
Status signal
“Warning” Status
LCD display
Serial port RS485
Measurement state Check request state Configuration Mode Measurement invalid
Status
“active / inactive” ***
Measurement valid
Status
“active / inactive” ***
Positive or negative
direction of flow
“active / inactive” ***
● Measured value, diagnosis information and parameters
● Measuring data logging, diagnosis and configuration through the MEPAFLOW600
● Connection with external process control equipment through implemented
Status
“active / inactive” ***
Compensation of path
failure
Status
“active / inactive” ***
Positive or negative
direction of flow
Status
“active / inactive” ***
Display flashing Display flashing
CBM software
MODBUS protocol (data polling)
Signal behavior
“undefined” “undefined”
“undefined” “undefined”
“undefined” “undefined”
****The “active” or “inactive” state can be assigned to the electric switch status
“normally open” or “normally closed” by configuration in the MEPAFLOW600 CBM software
(adjust settings for register #5101 on the “Parameters” page.)
The LCD display is capable of displaying measured values, parameters, messages and
other information.
A flashing letter at the upper right corner of the LCD display indicates that a logbook
contains unacknowledged logbook entries. Depending on the type of entry this will be:
● “I” for Information
● “W” for Warning
● “E” for Error
After acknowledging all new entries, the flashing letter disappears. For details see
→
pg.68,
5.4.1.
FLOWSIC600 · Operating Instructions · 8010458 V 2.0 · © SICK MAIHAK GmbH 19
Product Description
2.3
MEPAFLOW600 CBM
Most data provided by the FLOWSIC600 (like readings, logbook entries and parameters)
can be accessed via the LCD display of the meter. However, the MEPAFLOW600 CBM
software provides a more user friendly access to diagnostic, configuration and
measurement data of the flow meter.
2.3.1 Software Installation
System requirements
● Microsoft Windows 2000/XP/Vista (later MEPAFLOW600 CBM versions will support
Windows 7 or higher)
● Min. 1 GHz CPU
● Min. 512 MB RAM
● USB- or serial interface
● Screen resolution min. 1024 x 768 pixel (optimal display resolution 1280 x 1024 pixel)
Compatibility
MEPAFLOW600 CBM can be used for all firmware and hardware versions of the
FLOWSIC600. The availability of the software features depend on the firmware version of
the connected FLOWSIC600.
Installation
A product CD containing the MEPAFLOW600 CBM software is included with the
FLOWSIC600 when it is delivered. Insert the product CD into your CD-ROM drive to install
the software. Start the file ‘FLOWSIC600_R_CD.exe‘ to install the software.
Download from www.flowsic600.com
MEPAFLOW600 CBM can be downloaded free of charge from the www.flowsic600.com
website. Select the Software tab and follow the download instructions.
20 FLOWSIC600 · Operating Instructions · 8010458 V2.0 · © SICK MAIHAK GmbH
Product Description
Menu
Main system bar
with readings
Key navigation
Software features -
Status bar
Opens the “Meter
Status” page
Opens the “User
Warnings” page
2.3.2
Overview
The MEPAFLOW600 CBM software supplies a menu-based user interface with many
features for the diagnosis of the FLOWSIC600 system. It allows the access of all system
parameters, displays diagnostic information in charts and graphs, generates reports (i.e.
Maintenance reports) and data files (records, logs) which can be exported and can be used
for data analysis. It‘s meter database allows online and offline management of
parameters, reports, session files and logbooks.
Figure 3 MEPAFLOW600 CBM graphical user interface
FLOWSIC600 · Operating Instructions · 8010458 V 2.0 · © SICK MAIHAK GmbH 21
Product Description
22 FLOWSIC600 · Operating Instructions · 8010458 V2.0 · © SICK MAIHAK GmbH
Installation
FLOWSIC600
3 Installation
General Notes
Installation
Mechanical Installation
Electrical Installation
FLOWSIC600 · Operating Instructions · 8010458 V 2.0 · © SICK MAIHAK GmbH 23
Installation
Type plate on the meter body
Flange dimensions
Main type plate on
the SPU
Main type plate, see
Drawing no. 902153 and
no. 902147 on product
CD
3.1
3.1.1 Delivery
General Notes
The FLOWSIC600 is delivered in a pre-assembled condition in a sturdy package. When
unpacking the device, check for possible damage in transit. Pay particular attention to the
interior of the meter body, any visible transducer components and the sealing surfaces on
the flanges. Any damage must be documented and reported to the manufacturer
immediately.
Also check the shipment to ensure all components are included. The standard meter
shipment is comprised of:
b
FLOWSIC600 measuring system (meter body with signal-processing unit and
transducers)
b
MEPAFLOW600 CBM control and configuration software
b
Operating instructions
b
Manufacturer Data Report (MDR)
NOTICE:
To guarantee safe and reliable operation of the measuring equipment, make
sure the actual site conditions match the information provided on the labels on
the meter body and SPU (see Fig. 5.1).
Figure 4 FLOWSIC600 labels and marks
24 FLOWSIC600 · Operating Instructions · 8010458 V2.0 · © SICK MAIHAK GmbH
Installation
max.
45 °
3.1.2
Transport and storage
WARNING:
Only use lifting gear and load handling equipment (e.g. lifting straps) which are
suitable for the weight to be lifted. Max. load information can be found on the
type plate of the lifting gear. It is strongly recommended to use only the eye
bolts when lifting the meter by itself. To lift the FLOWSIC600 please pay
attention to Fig. 5.2.
During FLOWSIC600 transport and storage operations, make sure that:
b
The meter is firmly secured at all times
b
Measures are taken to avoid mechanical damage
b
Humidity and ambient temperature are within specified limits (see Section 2.2.4).
If the device is to be stored outside for more than one day, sealing surfaces of the flanges
and the interior of the meter body must be protected from corrosion, e.g. with Anticorit
spray (not required for stainless steel meter bodies). The same measure shall be taken if
the meter is to be stored in dry condition, but for more than a week.
NOTICE:
Due to natural temperature fluctuation in the course of a day, or if the meter is
transported to a place with different temperature and humidity conditions,
moisture may condense on any material. Carbon steel surfaces may corrode if
left unprotected.
Figure 5 Lifting requirements
FLOWSIC600 · Operating Instructions · 8010458 V 2.0 · © SICK MAIHAK GmbH 25
Installation
3.2
Installation
Generally, the installation arrangement is specified during the project planning phase,
before installation of the system. Nominal size, material and type of flange should
therefore be in accordance with the design of the measurement facility. It is particularly
important that the meter inlet and outlet is of the same internal diameter as the adjacent
piping.
Fastening bolts, nuts and flange seals used must be suited to the operational conditions,
and comply with legal regulations and relevant standards.
Any deviation from the planned design of the FLOWSIC600 and installation
arrangement shall be agreed upon with the supplier and documented prior to
installing the meter.
3.2.1 Measuring location
General requirements:
● The FLOWSIC600 can be installed in customary straight inlet and outlet pipes. The
adjacent pipes must have the same nominal size as the meter body. The max. variation
of the internal diameter of the inlet pipe from that of the meter body is 1%. Any welding
beads and burs on the flanges of the inlet pipe shall be removed.
● The meter body may be installed in a horizontal or vertical position. In case of horizontal
installation, the meter body shall be aligned so that the planes formed by the
measuring paths are in a horizontal position. This minimizes dirt in the pipeline from
entering the transducer ports. Vertical installation is only possible if the measuring
system is used for dry, non-condensing gases. The gas flow must be free from any
foreign material, dust and liquids. Otherwise, filters and traps shall be used.
● Do not mount equipment or fittings which may adversely affect the gas flow directly
upstream the FLOWSIC600.
● Seals at the flange connections between meter body and pipeline must not protrude
into the pipeline. Any protrusion into the flowing gas stream may change the flow profile
and thus the measuring accuracy may be adversely affected.
● Pressure transmitter shall be connected to the pressure tap provided (see Fig. 2.3). The
pressure tap can be a 1/8, 1/4 or 1/2 inch NPT (female) port, depending on meter size
and customer demand.
● For the leak-proof connection on the pressure line, a suitable thread sealing agent (e.g.
PTFE tape) must be used when the pressure connection adapter is screwed in. After
Installation and Commissioning the leak-tightness must be checked. Leakages must
not be tolerated. Temperature probes shall be arranged as shown in
→
Figure 7.
→
Figure 6 and
26 FLOWSIC600 · Operating Instructions · 8010458 V2.0 · © SICK MAIHAK GmbH
Installation
≥ 3 DN
min. 2 DN min. 2 DN 1.5 .. 5 DN
Flow conditioner Temperature measuring point
Configuration 1
Configuration 2
≥ 10 DN 1.5 .. 5 DN
FLOWSIC600 ≥ 3 DN
DN
≥ 5 DN
3.2.2
Installation configurations
The choice of the installation configuration (see →Figure6 and →Figure 7) depends on type
and extent of the flow disturbance at the installation position (according to TR G13).
Type of disturbance (distance upstream < 20 DN) Possible installation configuration
None Configuration 1 or 2
Elbow, reducer
Double elbow out of plane, T piece
Gas pressure controller with/ without noise abatement trim Configuration 2
Diffuser
Diffuser with swirling flow
When configuration 2 (with flow conditioner) is used, the velocity of gas must
not exceed 40 m/s (131 ft/s) in the pipe.
Unidirectional use
Figure 6 FLOWSIC600 installation in the pipeline for unidirectional use
FLOWSIC600 · Operating Instructions · 8010458 V 2.0 · © SICK MAIHAK GmbH 27
Bidirectional use
≥ 10 DN FLOWSIC600 ≥ 10 DN
min. 5 DN min. 5 DN
min. 2 DN min. 2 DN min. 2 DN min. 2 DN
1.5 .. 5 DN 1.5 ..5 DN
min. 2 DN min. 7 DN min. 7 DN min. 2 DN
Temperature measuring point
Flow conditioner
Flow conditioner
Temperature measuring point
5 ..8 DN 5 .. 8 DN
DN
Configuration 1
Configuration 2a
Applicable for meters
marked with an asterisk
(*) in
→
»Meter sizes
according to PTB
approval« (pg. 84),
Configuration 2b
Applicable for meters
marked with an asterisk
(*) in
→
»Meter sizes
according to PTB
a p p r o v a l « ( p g . 8 4 ) ,
≥ 5 DN ≥ 5 DN
≥ 10 DN ≥ 10 DN
Two straight pipes shall be installed in the inlet and outlet sections if the meter is to be
used bidirectionally. The temperature measuring point shall be disposed downstream the
FLOWSIC600, seen in the direction of predominant use (position 1 or 2 in
Figure 7 FLOWSIC600 installation in the pipeline for bidirectional use
→
Figure 7).
Installation
28 FLOWSIC600 · Operating Instructions · 8010458 V2.0 · © SICK MAIHAK GmbH
Installation
3.3
Mechanical Installation
Work on the pipelines to prepare for the installation of the gas flow meter is not included in
the scope of delivery.
It is recommended to use the following tools, equipment and supplies for installation of the
FLOWSIC600:
● Lifting gear or fork lift (with sufficient capacity to lift meter or meter-piping assembly)
● Wrenches for tightening flanges and other fittings
● Thread seal (e.g. PTFE tape) and flange gaskets
● Bolt lubricant
● Leak detection spray
WARNING: DANGER
● Always observe the general safety regulations and safety instructions given
in Section 1 when carrying out any installation work.
● The FLOWSIC600 must only be mounted on depressurised and vented
pipelines.
● Take all necessary precautions to avoid local or plant-specific dangers.
3.3.1 Choosing flanges, seals and other parts
Use pipeline flanges, bolts, nuts, and seals that withstand the maximum operational
pressure and temperature, as well as ambient and operational conditions (external and
internal corrosion) for the flange connections. For installation lengths and flange
dimensions, see MDR).
WARNING: DANGER
● Always strictly observe the safety instructions for the installation of
pressure equipment including the connection of several pressure
components set forth in the local or national relations and standards or
Pressure Equipment Directive 97/23/EC.
● Installation staff must be familiar with the directives and standards
applicable for pipeline construction.
FLOWSIC600 · Operating Instructions · 8010458 V 2.0 · © SICK MAIHAK GmbH 29
3.3.2 Mounting the FLOWSIC600 in the piping
An arrow on the meter body indicates the main direction of flow. It is recommended to
install the FLOWSIC600 as indicated by this arrow if the meter is to be used for
unidirectional flow applications. If the meter is to be used in the bidirectional mode, the
arrow indicates the positive direction of flow.
Installation work to be carried out
WARNING:
● The lifting eyes are designed for transporting the meter only. Do not lift the
FLOWSIC600 using these eyes when additional loads (such as blind covers,
filling for pressure tests or piping) are attached (also see
● Never attach lifting gear to the signal processing unit or its mounting
bracket and avoid contact between these parts and the lifting gear.
● The FLOWSIC600 must not turn over or start to swing while being
transported. Flange sealing surfaces, SPU housing and transducer cover
caps may be damaged when the lifting gear is not attached properly.
● Take suitable measures to prevent damage to the meter when carrying out
any other work (welding, painting) near the FLOWSIC600.
b
Position the FLOWSIC600 at the desired place of the pipeline using the lifting gear. Only
use the lifting eyes provided to lift and transport the device. If lifting straps are used,
wrap them around the meter body.
b
Check for correct seating and alignment of the flange gasket after installing the flange
bolts, but prior to tightening.
b
Align the FLOWSIC600 such that the offsets between inlet pipe, meter body and outlet
pipe are minimized.
b
Insert the remaining fastening bolts and tighten the nuts cross-wise. The tightening
torque applied must not be lower than specified in the project planning.
b
Mount the pressure sensing line between pressure tap and pressure transmitter.
b
Fill the pipeline and check the installed FLOWSIC600 and piping connections for leaks.
→
pg.25, 3.1.2)
Installation
It is recommended to perform a leak test in accordance with the relevant
regulations and standards after completion of the mechanical installation.
30 FLOWSIC600 · Operating Instructions · 8010458 V2.0 · © SICK MAIHAK GmbH
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