OI_FLOWSIC600_en_8010458

O P E R A T I N G I N S T R U C T I O N S

Applifoto74 x 45 mm

(150 dpi: 437 x 266 pixel)

x = 136 mm y = 58 mm

Title

Ultrasonic Gas Flow Meterfor Custody Transfer and Process Applications

MEPAFLOW600 CBM and Firmware V3.4.xx

FLOWSIC600Ultrasonic Gas Flow Meter

Document Information

ProductProduct name: FLOWSIC600

Document IDTitle: Operating Instructions FLOWSIC600Order No.: 8010458Version: 2.0Release: 2010-01

PublisherSICK MAIHAK GmbHNimburger Str. 11 · D-79276 Reute · GermanyTel.: +49 7641 469-0Fax: +49 7641 469-11 49E-mail: [email protected]

TrademarksIBM 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 trade-marks and are only used for identification purposes.

Guarantee InformationSpecified product characteristics and technical data do not serve as guarantee declarations.

© SICK MAIHAK GmbH. All rights reserved.

Glossary

Abbreviations used in this manualact. actual (under operating/flowing conditions)AGC Automatic Gain ControlASCII American Standard Code for Information

InterchangeANSI American National Standards InstituteASME American Society of Mechanical EngineersAWG American Wire GageCBM Condition Based MaintenanceCSA Canadian Standards AssociationDC Direct CurrentDIN Deutsches Institut für Normung (German

Standards Institute)DN Nominal Diameter (internal)DSP Digital Signal ProcessorEC European CommunityEN Euro Norm (European Standard)EVC Electronic Volume CorrectorEx Potentially explosive atmosphere (hazardous

area)HART® Communication interfaceIEC International Electrotechnical CommissionLCD Liquid Crystal DisplayLED Light Emitting DiodeMEPAFLOW Menu-assisted Parameterisation and Diagno-

sis for FLOWSIC600MDR Manufacturer Datal RecordNAMUR Normenarbeitsgemeinschaft für Mess- und

Regeltechnik in der chemischen Industrie (now "Interessengemeinschaft Prozessleit-technik der chemischen und phar-mazeutischen Industrie"; ~ Association for Instrumentation andControl Standards in the Chemical Industry)

norm. normalized/corrected (under standard condi-tions)

OI Operating Instructions (this document)OIML Organisation Internationale de Metrologie

LegalePC Personal ComputerPTB Physikalisch Technische Bundesanstalt

(~ Federal Metrology Office in Germany)RTU Remote Terminal UnitSPU Signal Processing UnitVDE Verband der Elektrotechnik Elektronik Infor-

mationstechnik (~ Association of German Electrical Engineers)

2 FLOWSIC600 · Operating Instructions · 8010458 V 2.0 · © SICK MAIHAK GmbH

Warning Symbols

Warning Levels / Signal Words

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

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

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

NOTICEHazard which could result in property damage.

Information Symbols

Hazard (general)

Hazard in potentially explosive atmospheres

Hazard by voltage

Information about the use in potentially explosive atmospheres

Important technical information for this product

Important information on electric or electronic func-tions

Supplementary information

Link to information at another place

FLOWSIC600 · Operating Instructions · 8010458 V 2.0 · © SICK MAIHAK GmbH 3

ContentsContents

1 Important Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1.1 About this Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81.2 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91.2.1 Intended Use of the Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91.3 Authorized Staff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91.4 General Safety Instructions and Protective Measures . . . . . . . . . . . . . . . . . . . . . . . . . . . 101.5 Dangers due to hot, corrosive and explosive gases and high pressure . . . . . . . . . . . . 101.6 Dangers due to heavy loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111.7 Environmental information and instructions for disposal . . . . . . . . . . . . . . . . . . . . . . . . 11

2 Product Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2.1 System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142.1.1 Meter body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142.1.2 Ultrasonic transducers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152.1.3 Signal processing unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152.2 Operating Modes, Meter States and Signal Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162.2.1 Operation Mode and Configuration Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162.2.2 Meter States . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172.2.3 Pulse output and status information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182.3 MEPAFLOW600 CBM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202.3.1 Software Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202.3.2 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

3.1 General Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243.1.1 Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243.1.2 Transport and storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263.2.1 Measuring location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263.2.2 Installation configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273.3 Mechanical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293.3.1 Choosing flanges, seals and other parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293.3.2 Mounting the FLOWSIC600 in the piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303.3.3 SPU alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313.4 Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323.4.1 General information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323.4.2 Cable specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343.4.3 Checking the cable loops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353.4.4 Terminal enclosure on the SPU. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363.4.5 Operating the FLOWSIC600 in safe areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383.4.6 Operation in hazardous areas (Directive 94/9/EC (ATEX)) . . . . . . . . . . . . . . . . . . . . 39


Contents

4 Commissioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

4.1 General Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 444.2 Connecting the FLOWSIC600 to a PC or Laptop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454.2.1 Connecting the FLOWSIC600 via RS485 / RS232 cable . . . . . . . . . . . . . . . . . . . . . . 454.2.2 Connecting the FLOWSIC600 via RS485/USB converter . . . . . . . . . . . . . . . . . . . . . . 464.3 Connecting to the FLOWSIC600 with MEPAFLOW600 CBM . . . . . . . . . . . . . . . . . . . . . . 474.3.1 Starting MEPAFLOW600 CBM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 474.3.2 Choosing an User Access Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 484.3.3 Creating a new meter entry in the meter database . . . . . . . . . . . . . . . . . . . . . . . . . . . 484.3.4 Online Connection: Direct Serial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 494.3.5 Online Connection: Ethernet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 504.4 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 524.4.1 Checking identification, operation / design data and firmware version . . . . . . . . . 524.5 Field Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 534.5.1 Disconnecting from the Meter and Closing the Session . . . . . . . . . . . . . . . . . . . . . . . 544.6 Function Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 554.6.1 Function test on FLOWSIC600 with LCD front panel . . . . . . . . . . . . . . . . . . . . . . . . . . 554.6.2 Function test on FLOWSIC600 with LED front panel . . . . . . . . . . . . . . . . . . . . . . . . . . 554.6.3 Function test with MEPAFLOW600 CBM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 564.7 Activation of Path Compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 594.8 Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

5 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

5.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 625.2 Routine Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 635.2.1 Comparing theoretical and measured Speed of Sound (SOS) . . . . . . . . . . . . . . . . . . 635.2.2 Checking the Meter Health . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 645.2.3 Time Synchronization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 655.2.4 Battery Lifetime / Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 665.3 Maintenance Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 675.4 Optional Data Download . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 685.4.1 Logbook Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

6 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

6.1 General Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 726.2 Indication of Meter States, System Alarms and Warnings . . . . . . . . . . . . . . . . . . . . . . . . 726.2.1 Checking the “Meter Status“ Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 736.2.2 Checking the User Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 756.2.3 Battery Lifetime / Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 766.3 Generation of a Diagnosis Session . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 776.4 Meter Connection Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78


Contents

7 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

7.1 Conformities and Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 807.1.1 CE certificate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 807.1.2 Standard compatibility and type approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 807.1.3 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 827.2 Logbooks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 867.2.1 Overview of event entries in logbooks and MEPAFLOW600 CBM . . . . . . . . . . . . . . 867.3 Connection Diagrams for Operating the FLOWSIC 600 in Hazardous Areas in

Accordance with North American Guidelines (CSA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 907.4 Wiring Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 927.4.1 Intrinsically safe installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 927.4.2 Non-intrinsically safe installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 937.5 Sealing Plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94


Important Information

FLOWSIC600

1 Important Information

About this DocumentSafety Instructions

Authorized staffGeneral Safety Instructions and Protective Measures

Dangers Due to Hot, Corrosive and Explosive Gases and High PressureDangers Due to Heavy Loads

Environmental Information and Instructions for Disposal



1 . 1 About this DocumentThis manual describes the FLOWSIC600 measuring system, which is used to determine thevolumetric flow rate, volume and the speed of sound in gases transported in pipelines. Itprovides general information on the measuring method employed, design and function ofthe entire system and its components, and on planning, assembly, installation, calibrationcommissioning, maintenance and troubleshooting. Also included is a detailed descriptionof the various system capabilities, options and settings which will assist in optimizing themeter 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 SICKrepresentative. However, it is generally recommended to take advantage of qualifiedconsulting services provided by SICK experts for your specific application.This operating manual is a part of the FLOWSIC600 device documentation. Which alsoincludes 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 OutputAll documentation is available on www.flowsic600.com or from your local representative.

The following terms will be used for measurands:

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.

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 acfVolume at base conditions Vb Nm³ scf Vb m³ cf Vb Nm³ scfError volume at flowing conditions Ef m³ acf Ef m³ cf Ef m³ acfError volume at base conditions Eb Nm³ scf Eb m³ cf Eb Nm³ scfTotal volume at flowing conditions Vo m³ acf Vo m³ cf Vo m³ acfVolume flow at flowing conditions Qf m³/h acf/h Qf m³/h cf/h Qf m³/h acfhVolume flow at base conditions Qb Nm³/h scf/h Qb m³/h cf/h Qb Nm³/h scfh



1 . 2 Safety Instructions

1.2.1 Intended Use of the EquipmentThe FLOWSIC600 measuring system is used for measuring the actual volumetric flow rateof gases transported in pipelines. It can be used for measuring the actual correctedvolume and the velocity of sound in gases. The measuring system shall only be used as specified by the manufacturer and as set forthbelow. 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 andadditionaly strictly respect the following instructions:

1 . 3 Authorized StaffPersons 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.

WARNING: A FLOWSIC600 equipped with transducers of type “S1” may under no circumstances be flooded with liquids.The pressure during flooding may not exceed a pressure higher than 1,2 times the nominal pressure (when transducers are assembled).



1 . 4 General Safety Instructions and Protective MeasuresUsing the equipment for any purpose other than intended, or improper operation mayresult in injuries and damage to the equipment. Read this section and the notes andwarnings in the individual sections of this manual carefully and observe the instructionsgiven 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 pressureThe FLOWSIC600 measuring system is directly integrated into gas-carrying pipelines. The operating company is responsible for safe operation and for complying with additionalnational 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.



1 . 6 Dangers due to heavy loadsThe FLOWSIC600 measuring system must be safely attached to the carrying structurewhen being transported and installed.

1 . 7 Environmental information and instructions for disposalThe FLOWSIC600 components are easily disassembled and do not contain toxic,radioactive or any other enviromentally hazardous materials. The instrument consistsprimarily of steel, stainless steel, plastic and aluminium, and consequently there are fewrestrictions for disposal. Only the printed-circuit boards must be disposed of as electronicscrap.

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.


Product Description

FLOWSIC600

2 Product Description

System ComponentsOperating States and Signal Output

MEPAFLOW600 CBM


Product Description

2 . 1 System ComponentsThe FLOWSIC600 measuring system consists of the following hardware components:● Meter body● Ultrasonic transducers● Signal processing unit SPUThe MEPAFLOW600 CBM software is the user interface used to facilitate operation,configuration and diagnosis (see → pg. 20, 2.3).

Figure 1 FLOWSIC600

2.1.1 Meter bodyThe meter body consists of a mid section for mounting the ultrasonic transducers, withflanges 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 geometricparameters. For meters larger than 24“ the body is made of a single-piece casting orforged or the flanges are welded onto the machined mid section.The internal diameter, design of the sealing surface, and standard dimensions of theflanges are in accordance with the specifications in the key code. The meter body materialis chosen to suit customer requirements. Standard meter bodies are available in carbonsteel, Low Temperature Carbon Steel and stainless steel. The meter bodies can be delivered in several nominal sizes (see → pg. 82, 7.1.3).

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)


Product Description

2.1.2 Ultrasonic transducersThe FLOWSIC600 ultrasonic transducers are optimized to suit the applicationrequirements. The high quality of the transducer design provides the basis for accurateand highly stable propagation time measurements with nanosecond precision. Thesetransducers are of an intrinsically safe design (category “ia“).

2.1.3 Signal processing unitThe SPU contains all the electrical and electronic components for controlling the ultrasonictransducers. It generates transmission signals and analyzes the received signals tocalculate the measuring values. The SPU also contains several interfaces forcommunication with a PC or standardized process control system. The volume counters, errors, warnings, and system events are stored in a non volatile datamemory (FRAM) together with a time stamp (Logbooks → pg. 86, 7.2.) On system restart, thecounter readings that were last saved are restored as the start values for the volumecounters. The FRAM backup provides an unlimited number of writing cycles and protectsthe saved data for at least 10 years.The SPU is equipped with a front panel containing a two-line LCD to display currentmeasured values, diagnostics and logbook information (→ Figure 2). The values to bedisplayed can be selected using a magnetic pen without removal of the front cover . TheMEPAFLOW600 CBM software provides a more user-friendly way to display the information.

Figure 2 FLOWSIC600 front panel LCD

The power supply and interface terminals are located on the back of the SPU in a separateterminal section of the enclosure (→ pg. 36, 3.4.4).The electronics are mounted in the SPU enclosure certified to EN 60079-1 or IEC 60079-1with protection type “d“ (flameproof enclosure). The transducer circuits are of anintrinsically safe design (category “ia“).

Measured values

Control buttons for the magnetic pen

Control buttons for manual use


Product Description

2 . 2 Operating Modes, Meter States and Signal OutputThe FLOWSIC600 has two operating modes (→ 2.2.1):● Operation Mode

● Configuration Mode

In the Operation Mode the meter can have the following Meter states (→ 2.2.2):● Measurement valid● Check request● Measurement invalid

2.2.1 Operation Mode and Configuration ModeThe meter can be operated by the user in two modes: Operation or Configuration.

Operation ModeIn the Operation Mode, the meter runs in one of the aforementioned three Meter states,depending on the measuring conditions.

Configuration ModeThe Configuration Mode is used to modify parameters that directly influence themeasurement and to test the system and output signals. The Configuration Mode forcesthe meter into the status “Measurement invalid”. The digital output “Measurement valid” isdeactivated in Configuration Mode because invalid measured values may be produced.The system continues operation using the current sample rate and executes allcalculations as in the Operation Mode. Frequency output and analog output may representtest values and do thus not necessarily indicate measured values. Any parametermodifications are applied immediately to the running calculations, with the exception ofthe sample rate and baud rate of the MODBUS interface/device address.

Test CycleThe test cycle can be activated for a measuring path by setting the corresponding controlbit 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 tothe 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.

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.


Product Description

2.2.2 Meter States

2.2.2.1 Status: Measurement validThe “Measurement” status is the standard Meter state of the FLOWSIC600. Frequencyoutputs and current output are updated cyclically and indicate the actual volume andvolumetric 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 digitaloutput “Direction of flow” is updated in accordance with the direction of the volumetricflow. The digital output “Valid measurement” (active) represents the status of themeasurement. Positive (forward) and negative (reverse) volumetric flow rates areintegrated and saved in separate internal memory sections. The MODBUS interface allows the query of all parameters and signals at any time withoutinterfering with the function of the system. Each measurement initiated by the system controller includes one full transit timemeasurement with, and one against the direction of flow on each path. The result of eachmeasurement is written to a mean value memory to be used in further calculations. Thesize of this memory block and thus the device response delay can be modified through theparameter in register #3502 “AvgBlockSize”. If no result can be calculated due to poorsignal quality, this measurement is registered as an invalid attempt in the mean valuememory. The mean value is formed in a variable averaging process including all validmeasured 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 requestThis status becomes active if one measuring path has failed and the adaptive path failurecompensation has been activated. The multi-path FLOWSIC600 system is able tocompensate for this failure. Measurement is continued with reduced accuracy. If a pathfails while the path failure compensation is deactivated, the measuring system will activatethe “Measurement invalid” status.Moreover the check request status becomes active when the system alarms 2002 (“NoHART communication to temperature transmitter”), 2003 (“No HART communication topressure transmitter”), or 2004 (“Maximum pulse output frequency exceeded”) becomeactive (see table → pg. 86, 7.2.1).

2.2.2.3 Status: Measurement invalidIf the quality of received signals is deficient in more than one measuring path, the SPUmust mark the measured value invalid and activate the meter status “Measurementinvalid”. However, the SPU will cyclically try to re-establish valid measurements. As soon asthe signal quality and number of valid measurements meet the required criteria, the SPUwill automatically change back to the “Measurement valid” or “Check request” status.


Product Description

2.2.3 Pulse output and status information

* The meter can be configured to put out a fixed frequency at “Measurement invalid“. Thefrequency 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”.

NOTICE: TYPE APPROVALPulse output signals can be customized as shown in the following table.

Table 1 Pulse output

Output signal / LCD / port Signal behaviorMeasurement state Check request state Configuration Mode Measurement invalid*

Pulse output signals

Inverted with error signal **

Phase shift 90 ° ***

Positive flow rate

Negative flow rate

Separate outputs for each direction ***

Positive flow rate

Negative flow rate

Single pulse output ***


Product Description

****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 andother information. A flashing letter at the upper right corner of the LCD display indicates that a logbookcontains unacknowledged logbook entries. Depending on the type of entry this will be:● “I” for Information● “W” for Warning● “E” for ErrorAfter acknowledging all new entries, the flashing letter disappears. For details see → pg. 68,5.4.1.

Table 2 Status output

Output signal / LCD / portSignal behavior

Measurement state Check request state Configuration Mode Measurement invalid“Check request”Status signal

Status“active / inactive” ***Measurement valid

Status“active / inactive” ***Compensation of path failure

“undefined” “undefined”

“Direction of flow”Status signal

Status“active / inactive” ***Positive or negative direction of flow

Status“active / inactive” ***Positive or negative direction of flow


“Warning” Status“active / inactive” ***

Status“active / inactive” ***


LCD display

Display flashing Display flashingSerial port RS485 ● Measured value, diagnosis information and parameters

● Measuring data logging, diagnosis and configuration through the MEPAFLOW600 CBM software

● Connection with external process control equipment through implemented MODBUS protocol (data polling)

+V 123456 m³-V 1234 m³

1234 m³ FLOWSIC600Configuration

+V 123456 m³-V 1234 m³


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 CBMsoftware provides a more user friendly access to diagnostic, configuration andmeasurement 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.

InstallationA product CD containing the MEPAFLOW600 CBM software is included with theFLOWSIC600 when it is delivered. Insert the product CD into your CD-ROM drive to installthe software. Start the file ‘FLOWSIC600_R_CD.exe‘ to install the software.

Download from www.flowsic600.comMEPAFLOW600 CBM can be downloaded free of charge from the www.flowsic600.comwebsite. Select the Software tab and follow the download instructions.


Product Description

2.3.2 OverviewThe MEPAFLOW600 CBM software supplies a menu-based user interface with manyfeatures for the diagnosis of the FLOWSIC600 system. It allows the access of all systemparameters, 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 usedfor data analysis. It‘s meter database allows online and offline management ofparameters, reports, session files and logbooks.

Figure 3 MEPAFLOW600 CBM graphical user interface

Menu

Main system bar

with readings

Key navigation

Software features -

Status bar

Opens the “Meter Status” page

Opens the “User Warnings” page


Product Description


Installation

FLOWSIC600

3 Installation

General NotesInstallation

Mechanical InstallationElectrical Installation


Installation

3 . 1 General Notes

3.1.1 DeliveryThe FLOWSIC600 is delivered in a pre-assembled condition in a sturdy package. Whenunpacking the device, check for possible damage in transit. Pay particular attention to theinterior of the meter body, any visible transducer components and the sealing surfaces onthe flanges. Any damage must be documented and reported to the manufacturerimmediately.Also check the shipment to ensure all components are included. The standard metershipment is comprised of:

FLOWSIC600 measuring system (meter body with signal-processing unit and transducers)MEPAFLOW600 CBM control and configuration softwareOperating instructionsManufacturer Data Report (MDR)

Figure 4 FLOWSIC600 labels and marks

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).

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


Installation

3.1.2 Transport and storage

During FLOWSIC600 transport and storage operations, make sure that:The meter is firmly secured at all timesMeasures are taken to avoid mechanical damageHumidity 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 flangesand the interior of the meter body must be protected from corrosion, e.g. with Anticoritspray (not required for stainless steel meter bodies). The same measure shall be taken ifthe meter is to be stored in dry condition, but for more than a week.

Figure 5 Lifting requirements

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.

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.

max.45 °


Installation

3 . 2 InstallationGenerally, the installation arrangement is specified during the project planning phase,before installation of the system. Nominal size, material and type of flange shouldtherefore be in accordance with the design of the measurement facility. It is particularlyimportant that the meter inlet and outlet is of the same internal diameter as the adjacentpiping. Fastening bolts, nuts and flange seals used must be suited to the operational conditions,and comply with legal regulations and relevant standards.

3.2.1 Measuring locationGeneral 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 6 and → Figure 7.

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.


Installation

3.2.2 Installation configurationsThe choice of the installation configuration (see → Figure 6 and → Figure 7) depends on typeand extent of the flow disturbance at the installation position (according to TR G13).

Unidirectional use

Figure 6 FLOWSIC600 installation in the pipeline for unidirectional use

Type of disturbance (distance upstream < 20 DN) Possible installation configurationNone Configuration 1 or 2Elbow, reducerDouble elbow out of plane, T pieceGas pressure controller with/ without noise abatement trim Configuration 2DiffuserDiffuser 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.

≥ 3 DNmin. 2 DN min. 2 DN 1.5 .. 5 DN

Flow conditioner Temperature measuring point

Configuration 1

Configuration 2

≥ 10 DN 1.5 .. 5 DNFLOWSIC600 ≥ 3 DN

DN

≥ 5 DN


Installation

Bidirectional useTwo straight pipes shall be installed in the inlet and outlet sections if the meter is to beused bidirectionally. The temperature measuring point shall be disposed downstream theFLOWSIC600, seen in the direction of predominant use (position 1 or 2 in → Figure 7).

Figure 7 FLOWSIC600 installation in the pipeline for bidirectional use

≥ 10 DN FLOWSIC600 ≥ 10 DN

min. 5 DN min. 5 DN

min. 2 DN min. 2 DN min. 2 DN min. 2 DN1.5 .. 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

DNConfiguration 1

Configuration 2aApplicable for meters marked with an asterisk (*) in → »Meter sizes according to PTB approval« (pg. 84),

Configuration 2bApplicable for meters marked with an asterisk (*) in → »Meter sizes according to PTB approval« (pg. 84),

≥ 5 DN ≥ 5 DN

≥ 10 DN ≥ 10 DN


Installation

3 . 3 Mechanical InstallationWork on the pipelines to prepare for the installation of the gas flow meter is not included inthe scope of delivery. It is recommended to use the following tools, equipment and supplies for installation of theFLOWSIC600:● 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

3.3.1 Choosing flanges, seals and other partsUse pipeline flanges, bolts, nuts, and seals that withstand the maximum operationalpressure and temperature, as well as ambient and operational conditions (external andinternal corrosion) for the flange connections. For installation lengths and flangedimensions, see MDR).

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.

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.


Installation

3.3.2 Mounting the FLOWSIC600 in the pipingAn arrow on the meter body indicates the main direction of flow. It is recommended toinstall the FLOWSIC600 as indicated by this arrow if the meter is to be used forunidirectional flow applications. If the meter is to be used in the bidirectional mode, thearrow indicates the positive direction of flow.

Installation work to be carried out

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.Check for correct seating and alignment of the flange gasket after installing the flange bolts, but prior to tightening.Align the FLOWSIC600 such that the offsets between inlet pipe, meter body and outlet pipe are minimized.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.Mount the pressure sensing line between pressure tap and pressure transmitter.Fill the pipeline and check the installed FLOWSIC600 and piping connections for leaks.

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 → pg. 25, 3.1.2)

● 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.

It is recommended to perform a leak test in accordance with the relevant regulations and standards after completion of the mechanical installation.


Installation

3.3.3 SPU alignmentThe signal processing unit (SPU) can be turned so that the display can be easily read andthat cable routing is facilitated (see → Figure 8). A stop on the housing prevents the SPU frombeing turned by more than 330° to prevent damage to the cables that come from the meterbody.

Figure 8 Positioning the SPU.Signal processing unit

Loosen the hexagon Position the SPUTighten the hexagon socket head screw socket head screw

1. 2. 3.

Tool required for loosening andtightening the hexagonsocket head screw:3 mm Allen key

NOTICE:Do not forget to tighten the hexagon socket head screw after positioning the SPU.


Installation

3 . 4 Electrical Installation

3.4.1 General information

Pre-requisitesWiring work (routing and connecting the power supply and signal cables), which isnecessary when installing the FLOWSIC600, is not included in the scope of delivery. Themechanical installation described in Section → 3.3 must be completed first. Comply withthe minimum cable specification requirements set out in Section → 3.4.2.

Cable routingKeep cables in conduits or laid on cable trays to provide protection from mechanical damage.Observe the permitted bending radiuses (generally, min. six times the cable diameter for multi-conductor cables).Keep all connections outside of conduits as short as possible.

WARNING: DANGERAlways observe the general safety regulations and safety instructions given in Section 1 when carrying out any installation work.Installation work shall only be carried out by trained staff and in accordance with the relevant regulations issued by the operating company.Take all necessary precautions to avoid local or plant-specific dangers.


Installation

General connection of the FLOWSIC600

Figure 9 FLOWSIC600 connection diagram

Safe area

Hazardous area

Service PC / higher-level control system

RS485 / MODBUS

Gas volume at flowing conditions Pressure Temperature

Electronic Volume Corrector (EVC) / Flow Computer (FC)

FLOWSIC600

Compressibility factor Z

Heating value Hs

Gas Volume at base conditions

Energy content

12 ... 24 V DC

(Ex i isolating transformer only required for intrinsically safe installation)


Installation

3.4.2 Cable specifications

Power supply 12 … 28.8 V DC

Digital output / current output

Serial port (RS485)

WARNING:The cables must fulfill the requirements for use in hazardous areas (e.g set forth in EN 60079-14 or other relevant standards).

Specification Notes

Type of cable Two conductors Connect shielding (if present) to ground terminal

Min./ max. cross-sectional area

0.5 mm² / 1.5 mm² (16 to 20 AWG)

Maximum cable length Depending on loop resistance;Minimum input voltage on the FLOWSIC600 12 V

Peak current 150 mA

Cable diameter 6 ... 12 mm (1/4 to 1/2 inch) Fixing range of the cable glands

Specification Notes

Type of cable Twisted pair, shielded Connect shielding at other end to ground terminal


2 x 0.5 mm2 (2 x 20 AWG) Do not connect unused conductor pairs and prevent them from accidental short-circuit

Maximum cable length Loop resistance under load ≤ 250 Ω


Specification Notes

Type of cable Twisted pair, shielded,impedance approx. 120Ω

Connect shielding at other end to ground terminal


2 x 0.5 mm2 (2 x 20 AWG)

Maximum cable length 500 m at 0.5 mm² 1000 m at 0,75 mm² (1500 ft for 20 AWG)

Do not connect unused lead pairs and prevent them from accidental short-circuit.



Installation

3.4.3 Checking the cable loopsCheck the cable loops to verify that the cables are connected correctly. Proceed as follows:

Disconnect both ends of the cable of the loop to be tested. This is to prevent connected devices from interfering with the measurement.Test the entire cable loop between SPU and terminal device by measuring the loop resistance.If you want to test the insulation resistance as well, the cables must be disconnected from the electronic module before using the insulation resistance tester.

Reconnect all cables after the loop resistance test.

WARNING:The test voltage applied would seriously damage the electronic module!

WARNING:● In non-intrinsically safe installations, the Exe terminal boxes and connect/

disconnect cables must only be opened if the system is disconnected from the power supply.

● The front cap (with display panel) must only be opened if the system is disconnected from the power supply and only 10 minutes or more after the system has been switched off.

● Incorrect cabling may cause failure of the FLOWSIC600. This will invalidate warranty claims. The manufacturer assumes no liability for consequential damage.


Installation

3.4.4 Terminal enclosure on the SPU

Opening the rear housing coverLoosen the securing clip using a 3 mm Allen key.Turn the rear housing cover counter-clockwise and take it off.

A schematic wiring diagram is provided on the inside of the rear housing cover.

Figure 10 SPU housing

Figure 11 Terminal box on the rear of the SPU (see Section → 3.4.2 for North American wiring specification equivalents)

NOTICE: LubricantOnly use LOCTITE 8156 as lubricant for front and rear housing cover.

Open the cover

Cover

Securing clip

Cover for powersupply terminals

Cable entry for internal 10-core cable

10-pole terminal blockfor signal inputs and outputs

12

HSK-K type cable glands,M 20 x 1.5 plastic (EU)or ½ in NPT (North America)

Power supply2 x 1.5 mm2 (LiYCY or equivalent)

Digital output / current output4 x 2 x 0.5 mm2

(Li2YCY [TP] or equivalent)

MODBUS4 x 2 x 0.5 mm2 (Li2YCY [TP] or equivalent)

Bridge


Installation

Figure 12 Terminal assignment for use in safe areas

Terminal box

Power supply Field connections (10-pole terminal block)

PAPA

Terminals 2 and PE are bridged internally, i.e. there is no insulation between PE and negative potential (see → Figure 11).


Installation

3.4.5 Operating the FLOWSIC600 in safe areasAssign the terminals in the SPU terminal box (see → Figure 12) in accordance with thefollowing table.

No. Connection for Function Terminal Value Notes1 Power supply 1+, 2- 12 ... 24 (+20 %) V DC2 Digital output DO 0

(HF 2)Passive 31, 32 fmax = 6 kHz, pulse duration 0.05 s - 1 s

Range:Variable number of pulses per volume unit“closed”:0 V ≤ UCE L ≤ 2 V, 2 mA ≤ ICE L ≤ 20 mA (L=Low)“open”:16 V ≤ UCE H ≤ 30 V, 0 mA ≤ ICE H ≤ 0.2 mA (H=High)

With NAMUR contact for connection to switching amplifier (to DIN 19234)

3 Serial port MODBUS(RS485)

33, 34 9600 Baud, 8 data bits, no parity, 1 stop bit Baud rate to be set through software

4 Digital output DO 1(HF 1)

Passive 51, 52 fmax = 6 kHz, pulse duration 0.05 s - 1 sRange:Variable number of pulses per volume unit“closed”:0 V ≤ UCE L ≤ 2 V, 2 mA ≤ ICE L ≤ 20 mA (L=Low)“open”:16 V ≤ UCE H ≤ 30 V, 0 mA ≤ ICE H ≤ 0.2 mA (H=High)

With NAMUR contact for connection to switching amplifier (to DIN 19234)

5 Digital output DO 2 Passive 41, 42 “closed”:0 V ≤ UCE L ≤ 2 V, 2 mA ≤ ICE L ≤ 20 mA (L=Low)“open”:16 V ≤ UCE H ≤ 30 V, 0 mA ≤ ICE H ≤ 0.2 mA (H=High)“Check request” (default)

6 Digital output DO 3 Passive 81, 82 “closed”:0 V ≤ UCE L ≤ 2 V, 2 mA ≤ ICE L ≤ 20 mA (L=Low)“open”:16 V ≤ UCE H ≤ 30 V, 0 mA ≤ ICE H ≤ 0.2 mA (H=High)“Direction of flow” (default)(alternative “Warning”)

Alternative assignment with secondserial port (RS485)

9600 Baud, 8 data bits, no parity, 1 stop bit Baud rate to be set through software


Installation

3.4.6 Operation in hazardous areas (Directive 94/9/EC (ATEX)1)The power supply and field connections are designed with the increased type of protection(“e“). The transducer connections are of an intrinsically safe design (“ia“). All screw-type terminals as well as air gaps and creepage distances of the FLOWSIC600comply with EN 60079-7.

Connection characteristics

Connection optionsThe protection concept for the FLOWSIC600 permits the following connection options:● Non intrinsically safe power supply connection and field connections with increased

type of protection (“e“)● Intrinsically safe power supply connection and field connections (“i“)● Non intrinsically safe power supply connection with increased type of protection (“e“),

while the field connections are intrinsically safe (“i“)The user shall decide which option is to be used, taking into account local / nationalregulations and standards or EN 60079-14.A combination of intrinsically safe and non-intrinsically safe circuits is not permitted in theterminal box for the field connections.The rated voltage of non-intrinsically safe circuits is UM = 253 V.

1 For use in the US and Canada see Control drawings 781.00.02 page 1 to 3.

Power supply connection Field connectionsSeparate terminal box, separated from the field connections with partition wall in the housing and cover to EN 60079-11.

Separate terminal box, separated from the power supply connections with partition wall in the housing and cover to EN 60079-11.

Cable routing via Exe cable gland, M5 ground terminal integrated into housing section (cast-on part).

Cable routing via 2x Exe cable gland


Installation

Requirements regarding cabling in hazardous areas (ATEX)● The cables must fulfill the requirements set forth in EN 60079-14.● Cables that are subject to exceptional thermal, mechanical, or chemical loads must be

specially protected (e.g. laid in open-ended conduits).● Cables that are not installed fire proof must be fire retardant according to IEC 60332-1. ● Ferrules must be attached to the wire ends to ensure that they do not split up.● The applicable requirements regarding air gaps and creepage distances must be

observed in accordance with EN 60079-7. The available air gaps and creepage distances in the terminal box must not be reduced when connecting the cables.

● Unused cable glands must be replaced by the Exe plugs included in the delivery.● The equipotential bonding must be in accordance with EN 60079-14.● The meter body and SPU housing must be connected to the potential equalizer. In

intrinsically safe circuits, provide equipotential bonding along the wiring runs of the current outputs.

● The applicable national specifications shall also be observed.

Operation of ultrasonic sensors in Zone 0The ultrasonic transducers are suitable for the operation in Zone 0 at atmosphericconditions, i.e. ambient temperature -20 °C to 60 °C and ambient pressure 0.8 bar to 1.1bar(a). If ultrasonic transducers with titanium housing are to be used in Zone 0, it must beassured that the medium does not transport solid parts (like dust or other particles) whichcould cause an ignition hazard. After installation and after every deinstallation and following reinstallation of the ultrasonictransducers, the seal effect must be appropriately checked. During the operation the leaktightness must be periodically checked and the sealing must be renewed if necessary.After deinstallation and before every reinstallation the sealings must be renewed accordingto the original assembly. Sealings can be ordered from SICK (provide article number andserial number from type plate).

Terminal assignmentThe terminal assignment in the SPU terminal box (see → Figure 12) is the same as for theinstallation of the FLOWSIC600 in non-hazardous areas (see table in Section → 3.4.5).

NOTICE:The protective conductor must not be connected within the hazardous area. For measurement reasons, the equipotential bonding must, as far as possible, be identical to the pipeline potential or protective ground/earth. Additional grounding with the protective conductor via the terminals is not permitted!


Installation

Notes for safe operation in hazardous areas

● Type of explosion protection: II 1/2G Ex de ib [ia] IIC T4 or II 2G Ex de ib [ia] IIA T4● Ambient temperature:-20°C to +60°C

In the extended temperature range from -40 °C to +60 °C, metal cable glands shall be used.

● The cable glands included in the delivery are black. If terminals are assigned with intrinsically safe circuits, it is recommended to replace the black ones with the light-blue (RAL 5015) cable glands provided.

● The type of protection for the field connections and power supply connection is determined by the external circuits that are connected (for options see “Connection options“ above).

● Safety-relevant data for intrinsically safe circuits is provided in the EC Type Approval Certificate.

● Ensure that the cover on the power supply connection is properly sealed. In intrinsically safe installations, the terminal box can be opened and cables connected and disconnected while the system is live. In this case it is also allowed to connect or disconnect cables from each other when attention is paid to the safe separation of the curcuits.

● If the meter body is insulated, the insulation thickness must not exceed 100 mm. The SPU housing must not be insulated.

Figure 13 FLOWIC600 components and their type of protection

Approval of the ultrasonic transducers in zone 0 is only valid for operation under atmospheric conditions.

WARNING:Always observe the temperature specifications for use in hazardous areas.

1+2-

31323334515241428182

Aux. power

PA

Digital output

RS485

Digital output

Digital output

Digital output

Power supply

Field connections

Term

inal

box

“e”,

“i” Signal processing unit(SPU)

Pressure-resistant space “d”

Meter body

Ultrasonic transducers “ia”

PA


Installation

Safety-relevant data of inputs and outputs

Output circuit Intrinsically safe Ex ia/ib IIA/IIb/ IIC Non-intrinsically safeVM = 253 V

Active current outputTerminals 31/32

VO = 22.1V VB = 18 VIB = 35 mAIO PO Ex ia/ib IIA Ex ia/ib IIB Ex ia/ib IIC

[mA] [mW] CO [nF] LO [mH] CO [nF] LO [mH] CO [nF] LO [mH]Hardware variant 1-5 155 857 4.1 7 163 1Hardware variant 6 87 481 2 7 0.5 4 77 1

Characteristic curve: linearor for connection to certified intrinsically safe circuits with the following maximum values:

UI = 30 VII = 100 mAPI = 750 mW

Internal capacity: CI = 4 nFInternal inductance: negligible

Digital outputTerminals 51/52Terminals 41/42Terminals 81/82

For connection to certified intrinsically safe circuits with the following maximum values:UI = 30 VII = 100 mAPI = 750 mW


UB = 30 VIB = 100 mA

RS485Terminals 33/34 Terminals 81/82

Characteristic curve: linearUo = 5.88 VIo = 313 mAPo = 460 mWCo = 1000 μF for IIA resp. 43 μF for IICLo = 1.5mH for IIA resp. 0.2 mH for IIC

or for connection to intrinsically safe circuits with the following maximum values:UI = 10 VII = 275 mAPI = 1420 mW


UB = 5VIB = 175 mA

Ultrasonic transducer connections(for connecting SICK ultrasonic transducers only)

Ex ia/ib IIA Ex ia/ib IIB Ex ia/ib IICCharacteristic curve: linearMax. transmission voltage: Uo = ±60.8 VShort-circuit current: Io = ±92 mA

Po = 1399 mWInternal capacity: negligibleInternal inductance: Li = 20.6 mH

Uo = ±51.2 VIo = ±77 mAPo = 556 mWnegligibleLi = 15.5 mH

Uo = ±38.9 VIo = ±59 mAPo = 556 mWnegligibleLi = 6.7 mH


Commissioning

FLOWSIC600

4 Commissioning

General NotesConnecting the FLOWSIC600 to a PC or Laptop

Connecting to the FLOWSIC600 with MEPAFLOW600 CBMIdentification

Field SetupFunction Test

Activation of Path CompensationSealing


Commissioning

4 . 1 General NotesBefore commissioning, all activities described in the chapter → »Installation« must becompleted. It is recommended to use a laptop/PC with installed MEPAFLOW600 CBMsoftware for the commissioning (→ pg. 47, 4.3). The FLOWSIC600 is ’wet’ or ’dry’ calibrated when delivered to the end user. The ’dry’calibration contains the 3-D measurement of the meter body, zeroflow and speed of soundtest, and other system specific inspections/tests which belong to the manufacturing andquality assurance process. The ’wet’ calibration is performed at a flow calibration teststand (calibration test facility).All parameters, determined by the aforementioned tests, as well as design specific dataare preset and stored in the FLOWSIC600 in a non-volatile memory before delivery. Thedesign-specific data which is known before manufacturing the device will not be changedduring commissioning. This is of special importance if the FLOWSIC600 is officially sealedafter an authorized flow calibration. Generally, the parameters are protected by apassword. Additionally a Parameter write lock in the SPU prevents custody relevantparameter changes.

In all other cases the output parameters of the FLOWSIC600 can be adapted on site bytrained staff.Commissioning the FLOWSIC600 involves the following steps, no matter whether thedevice is installed at a test facility or at the final measuring location: ● Connecting the FLOWSIC600 to a PC or Laptop (→ pg. 45, 4.2)● Connecting to the FLOWSIC600 with MEPAFLOW600 CBM (→ pg. 47, 4.3)● Identifikation (→ pg. 52, 4.4)● Field setup (→ pg. 53, 4.5)● Function test (→ pg. 55, 4.6)● Activation of path compensation (→ pg. 59, 4.7)● Sealing (→ pg. 60, 4.8).

NOTICE: Type ApprovalIf the FLOWSIC600 is to be used for custody transfer applications, each change of parameters and of the Parameter write lock has to be agreed to by the applicable national authorities.


Commissioning

4 . 2 Connecting the FLOWSIC600 to a PC or Laptop

4.2.1 Connecting the FLOWSIC600 via RS485 / RS232 cable

The FLOWSIC600 serial interface conforms with the RS485 standard. An RS485 /RS232cable and a 1:1 interface cable (pin 2 – pin 2 and pin 3 – pin 3) are required for datatransfer to PC or laptop (see → Figure 14). Because MEPAFLOW600 CBM, the operation anddiagnosis software for the FLOWSIC600, does not support RTS/CTS data transfer, theadapter must be able to distinguish between transmission and reception modeautomatically. We, therefore, recommend the use of a serial interface set available fromSICK.

Figure 14 Wiring example of “MEPA interface set RS485 / RS232” intrinsically safe for DIN rail mounting

Interface sets for the connection of the FLOWSIC600 with a PC via serial- or USB-interface can be ordered from SICK. See → pg. 46, Table 3.

*Possible terminals for the RS485 connection are:● 33 (+) and 34 (-)● 81 (+) and 82 (-)

Terminals*

1:1

Connection cable

COMport

(9-pole)Fieldbus Isolating Repeater

Type 9185 (Company “Stahl”)

Ex-Zone Safe-Zone


Commissioning

4.2.2 Connecting the FLOWSIC600 via RS485/USB converterIf the PC/laptop does not offer a RS232 serial interface, a USB interface can be used. Anappropriate USB converter is necessary to transform the signal for the RS485 deviceinterface. The USB converter available through SICK contains a CD-ROM with a softwaredriver which must be installed before an online connection between the FLOWSIC600 andthe MEPAFLOW600 CBM software can be established.

Figure 15 Wiring example of “MEPA interface set RS485/USB” (Converter, Cable, Terminal plug, CD-ROM with software driver), non-intrinsically safe

*Possible terminals for the RS485 connection are:● 33 (+) and 34 (-)● 81 (+) and 82 (-)

A / RxDB / TxD

USBUSB

USB

Terminals*

Connection cable

Safe-Zone

Table 3 Interface sets for the connection of the FLOWSIC600 to a PC

Description Part Number“MEPA interface set RS485 / RS232” intrinsically safe for DIN rail mounting 2033410

“MEPA interface set RS485/USB” (Converter, cable, terminal plug, CD-ROM with

software driver), non-intrinsically safe

6030669


Commissioning

4 . 3 Connecting to the FLOWSIC600 with MEPAFLOW600 CBM

4.3.1 Starting MEPAFLOW600 CBMThe MEPAFLOW600 CBM software is provided on the product CD shipped with the meter. Itcan also be downloaded from www.flowsic600.com. See → pg. 20, 2.3.1 for more details onthe installation.

After successful installation, start the MEPAFLOW600 CBM by selecting the “MEPAFLOW600 CBM” entry in the program group created during installation, or by double-clicking on the desktop icon.

Figure 16 MEPAFLOW600 CBM program group and desktop icon

Program Group Desktop Icon


Commissioning

4.3.2 Choosing an User Access Level After starting MEPAFLOW600 CBM, the “Connect / Disconnect” page appears with the Password dialog window. (→ Figure 17)Choose a User access level, activate the corresponding radio button, enter the password and click the “OK” button.

Figure 17 MEPAFLOW600 CBM “Connect / Disconnect” page with Password dialog window

The Password dialog disappears and the “Connect / Disconnect” page with a list of all meters in the meter database appears.

4.3.3 Creating a new meter entry in the meter database

Create a new meter entry in the meter database by clicking the “New” button. Then follow the instructions on screen.

User access level PasswordOperator No password requiredAuthorized operator “sickoptic”Service See Service Manual

New meter entries can be created, whether the corresponding meter is connected to the PC or not. If the meter is connected, MEPAFLOW600 CBM loads all available parameters from the meter. If the meter is not connected, an initial master data set is created from the information the user enters.


Commissioning

4.3.4 Online Connection: Direct SerialChoose a meter and click the “Direct serial” to establish a serial connection to a meter which is connected to the PC. Specify the appropriate connection settings in the Connection settings window (→ Figure 18) and click the “Connect” button to establish an online connection to the meter. If the connection fails, see → pg. 78, 6.4 for troubleshooting.

Figure 18 Connection settings

After the connection has been established, MEPAFLOW600 CBM displays the start page (can be specified in the Program settings) and the current readings from the meter.

The parameters shown in → Figure 18 are default values - except for the serial COM port which has to be individually configured.


Commissioning

4.3.5 Online Connection: EthernetThe FLOWSIC600 can be connected to a network via Ethernet with an according adapter.This adapter translates the meter MODBUS communication (ASCII or RTU) to MODBUS TCP.MEPAFLOW600 CBM supports the MODBUS TCP protocol.

Click the “Ethernet” button to establish a connection via Ethernet. Specify the IP address of the MODBUS TCP adapter and the bus address of the meter in the dialog “MODBUS TCP - MODBUS RTU/ASCII gateway settings” (→ Figure 19) .Click “OK” to establish an online connection to the meter.

Requirements● The Ethernet connection requires firmware V3.3.05 or higher installed on

the FLOWSIC600, which provides the necessary Generic MODBUS protocol on the RS485 interface.

● The FLOWSIC600 must be connected to a MODBUS ASCII/ MODBUS RTU to MODBUS TCP adapter, which is connected to a network via Ethernet and receives a - preferably permanent - IP address.

● The PC with MEPAFLOW600 CBM V1.0.46 or higher installed must be connected to the network and have uninhibited access to this IP address.

Preparations for Online Connections via EthernetMake sure one of the serial ports (terminals 33/34 or 81/82) of the FLOWSIC600 is configured to use Generic MODBUS RTU or Generic MODBUS ASCII (NOT a SICK MODBUS protocol). Connect a MODBUS RTU/MODBUS ASCII to MODBUS TCP adapter to the serial port according to the manual of the adapter.Connect the adapter cable to your network.Make sure the network assigns a permanent IP address to the adapter. Configure the adapter to the network settings (IP address / protocol / baudrate / gateway etc.) that you want to use (refer to adapter manual).Make sure the PC with MEPAFLOW600 CBM has access to the adapters IP address. Make sure you know the MODBUS bus address of the meter.

In case of problems with the network setup, refer to your network administrator.


Commissioning

Figure 19 “MODBUS TCP - MODBUS RTU/ASCII gateway settings” dialog for online connections via Ethernet

Tested MODBUS TCP to MODBUS ASCII/RTU AdapterThe connection between FLOWSIC600 and MEPAFLOW600 CBM has been tested with the “MODBUS TCP to MODBUS ASCII/RTU Converter“, Model MES1b by B&B Electronics. This adapter is shipped with a software, which searches the network for connectable devices and supplies the user with the according IP addresses.


Commissioning

4 . 4 Identification

4.4.1 Checking identification, operation / design data and firmware versionBefore commissioning, cross-check the data representing the flow meter with the data inthe test protocols which are contained in the Manufacturer Data Report (MDR). This can bedone on the LCD display (see “Technical Instructions“) or - much easier - withMEPAFLOW600 CBM software:

Open the ’’Meter information’’ page and compare the data in the ’’Identification’’ section (→ Figure 20) with the data in the check reports of the MDR or, when the meter has been calibrated, with the calibration and parameter report.

Figure 20 ’“Meter Information” page

FirmwareThe FLOWSIC600 firmware is stored on a non-volatile memory (FLASH PROM). Theprogram code for the signal processor and system micro-controller are identified by aversion number (register#5002) and a check sum (register #5005) and can be verified asmentioned above.

“Identification“ section

NOTICE: Type ApprovalIf the FLOWSIC600 is used for fiscal metering, the approved firmware versions and the associated check sums are documented in the national pattern approval certificates.


Commissioning

4 . 5 Field SetupThe MEPAFLOW600 CBM software “Field setup” wizard guides through the parameterconfiguration during the commissioning of the FLOWSIC600. The wizard consists of 8pages. For checking and configuration refer to the “Instrument Data Sheet” of theFLOWSIC600, which is included in the Manufacturer Data Record (MDR) (example see→ Figure 21).

To start the Field setup, choose “Tools / Field Setup” from the menu.Follow the instructions on screen step by step.

Figure 21 Example of an “Instrument Data Sheet” as contained in the MDR

The parameter changes performed in the Field setup wizard require the User Access Level “Authorized operator” (see → pg. 48, 4.3.2).

0

1 54

2 55 12 .. 28,8 V DC < 1W

3 56

4 57

5 58

6

7

8 59

9 60 Ambient temperature °C

10 Inner connection diameter mm 61

11 Overall length (A) mm 62

12 Overall hight (B) mm 63

13 Weight kg 64

14 Flow rate a.c m³/h 65

15 66 Connection type

16 67 Switching state

17 68 Meter factor 1/m³

18 69

19 70

20 71

21 72


23 Design temperature °C 74 Switching state

24 75

25 76


27 78 Switching state

28 79

29 80

30 81

31 82

32 83

33 84

34 85

Transcucer material (wetted) Titanium

TRANSDUCER

Pressure tapping 1/4" NPTF DO3 Clamp 81/82(RS485) SICK_MODBUS_ASCII

Enclosure rating IP 67 NAMUR (8,2V / 0,8...6,6mA)

Painting Grey white (RAL9002)/grey (RAL7012) sta normally open

Design pressure

Material test certificate 3.1 EN10204 DO2 Clamp 41/42 (Status) Maintenance required

Exchangeabil. under press. No NAMUR (8,2V / 0,8...6,6mA)

-20 ... 150 normally open

Material Carbon Steel (1.1120/WCC) DO1 Clamp 51/52 (Pulse) Volume a.c.

Flange face RFSD-Raised Face-Stock Finished MOD Clamp 33/34 (RS 485) SICK_MODBUS_ASCII

Flange standard ANSI B16.5

Flange/pressure rating Class 600

Typical meas. uncertainty +/- 0,2% of MV 0,1 ,, 1 Qmax NAMUR (8,2V / 0,8...6,6mA)

Repeatability < 0,1% 10100

50 ... 4000 DO0/AO0 Clamp 31/32 (Pulse) Volume a.c., no pulses when data invalid

Path design 4 Path parallel (4P)

600 Unit system Metric

330 SIGNAL PROCESSING UNIT - CONFIGURATION

Schedule 80 Display LCD SICK

750 LCD language English

Order no. SPU housing material Aluminium (-20°C)

METER BODY 0 ... 40

TAG no. (32 chars)

TAG-No. (max.8 char)

Article Ex approval. CSA Group D T4, 1/2 NPT

Nominal size 10 Inch/DN250 Cable entry 3 x 1/2 NPT

Meter type Flow meter Enclosure rating IP 67

OVERVIEW SIGNAL PROCESSING UNITPower supply / power consumption

Instrument Data Sheet for Ultrasonic Gas Flow MeterTYPE CODE FL600-4P3D10CL0600SC0080RF0N-S2-1DC1N1Y


Commissioning

4.5.1 Disconnecting from the Meter and Closing the SessionWhen you disconnect from the meter, a session is stored in the MEPAFLOW600 CBM meterdatabase. It contains the following data:● a complete parameter set from the meter at disconnection● all parameter changes made during Field setup (entries can be viewed in the Meter

Explorer)● all logbook data downloaded on page 7 of the Field setup● the Maintenance Report created on page 8 of the Field setupYou can later access this data with the “Meter Explorer”, even when you are not directlyconnected to the meter.

To disconnect from the meter and to close the session, proceed as follows:Go to the “Connect / Disconnect“ page by chosing “File / Connect/Disconnect“ from the menu.Click the “Disconnect“ button. The “Session description“ window opens.Describe the activies you carried out during the session (e.g. “Field Setup“).Click the “OK“ button.


Commissioning

4 . 6 Function TestThe major system parameters are configured at the factory. The default settings shouldallow error free operation of the FLOWSIC600. Nevertheless, correct meter operationshould be verified on site when the meter is installed and is subject to actual operatingconditions.

4.6.1 Function test on FLOWSIC600 with LCD front panelThe FLOWSIC600 is functioning correctly, if the standard display shows two pages ofmeasurands and current readings and the pages alternate every 5 seconds. If a current error or warning is active, the display will be interrupted by an error messageevery 2 seconds. As soon as the cause of the error/warning has been rectified, theFLOWSIC600 automatically returns to the standard display. If the logbooks contain unacknowledged Errors, Warnings or Information, thecorresponding letter is displayed in the upper right hand corner and flashes. The letterstops flashing, once the message has been acknowledged in the logbook.It disappearswhen the entries have been cleared from the logbook. Detailed information on errors is available in the logbook (see → pg. 68, 5.4.1 and → pg. 86,7.2 of this Manual). See chapter → »Troubleshooting« .

4.6.2 Function test on FLOWSIC600 with LED front panelThe FLOWSIC600 is functioning correctly when the green status LEDs for each measuringpath installed start flashing periodically approximately 30 seconds after the power supplyis switched on. If the yellow LED flashes, the FLOWSIC600 works in the operation state ’’Check request’’with an insignificantly reduced accuracy (e.g. if one path fails). If the yellow LED lights up permanently, the measurement is invalid. In this case, you mustdiagnose the error (see Chapter 8 of this Manual).

You are advised to check the plausibility of the measured and diagnosis values, even if the device is functioning properly (see chapter → »Maintenance«).


Commissioning

4.6.3 Function test with MEPAFLOW600 CBM

Performance CheckOnce the facility is flowing at the initial flow rate, go to the “Meter values“ page to check the performance of the meter. The performance value should be at least 75% on all paths. If the velocity of gas is greater than 30 m/s (100 ft/s), the performance values may be significantly lower. Check the Main system bar for system alarms (symbol “System” should be green) and warnings (symbol “User” should be green) (→ Figure 22). If there is a yellow or a red symbol, proceed as described on → pg. 72, 6.1.

Zero Phase CheckUse the “Path Diagnosis” wizard (→ Figure 24) to check the “Zero Phase” parameters of both transducers on each path (path 1, 2, 3, 4).

Properly adjusted zero phases of the individual paths are the basis for accurate transittime measurement of the ultrasonic signals. The “Zero Phase” parameter of a path isproperly adjusted, when the green cursor in the signal window is symmetrically within thetwo dotted red limit lines and the red asterisk is positioned exactly on the second positivezero crossing of the received ultrasonic signal.

Figure 22 “Path Diagnosis” wizard in MEPAFLOW600 CBM

Main system bar


Commissioning

If the zero phase values do not meet the aforementioned criteria, the zero phase needs tobe adjusted according to the instruction in the “Technical Information“. Additional the validity of the settings should be verified:

Open the “Meter status” window and go to the tab “Advanced or Path Status” (→ pg. 59, Figure 25). If a lamp for “Time plausibility” is on, it indicates an incorrect zero phase.

Figure 23 Signal window displaying ultrasonic signal in the “Path Diagnosis” page


Commissioning

Go to the “Meter values” page to check that the measured SOS values are almost the same at all paths of the FLOWSIC600, and that they differ by less then 0.1% (→ Figure 24).Switch between display of absolute and difference SOS by clicking the right mouse button on the SOS graph and using the context-menu.

Check that the measured SOS deviates no more than 0.3% from a theoretical SOS, which is calculated from gas composition, pressure and temperature (→ pg. 63, 5.2.1).

Figure 24 SOS per path on the “Meter values” page (left: absolute SOS , right: difference to average)

In the case of very low gas velocities (< 1 m/s or 3 ft/s), there may be more significant differences between the paths due to thermal stratification. In this case, the SOS on the upper paths (1 and 2) will be higher than the lower paths.


Commissioning

4 . 7 Activation of Path CompensationIf the status bit “Path compensation valid” is “active”, then the FLOWSIC600 is able tocompensate a path failure. The meter automatically sets this bit to “active” after operating for about 20 minutes witherror free measurement at all paths at a gas velocity between 1 to 8m/s (3 to 25ft/s) andalso about 20 minutes at a gas velocity higher than 8m/s (25ft/s).The status bit “Path compensation valid“ is displayed on the “Meter status” page (seebelow).

Figure 25 “Meter status” page with active “Path compensation valid” status bit

Opens the “Meter Status” screen

“Path compensation valid”


Commissioning

4 . 8 SealingAfter having completed the commissioning, seal the signal processing unit (if required) inaccordance with the sealing plan (see Section → pg. 94, 7.5).


Maintenance

FLOWSIC600

5 Maintenance

GeneralRoutine Checks

Maintenance ReportOptional Data Download


Maintenance

5 . 1 GeneralThe FLOWSIC600 does not contain mechanically moving parts. The meter body andultrasonic transducers are the only components that come into contact with the gaseousmedia. Titanium and high-quality stainless steel ensure that these components areresistant to corrosion, provided that the meter is installed and operated in accordance withthe relevant specifications. This means that the FLOWSIC600 is a low-maintenancesystem. User Warning Limits can be configured to provide early warnings for possibleissues with contamination or blockages. Maintenance is limited mainly to routine checks todetermine the plausibility of the measured values and diagnostic results produced by thesystem.It is recommended to create and file maintenance reports on a regular basis (→ 5.3). Thisserves to create a basis of comparable data over time and helps when a fault has to bediagnosed.

Routine checks :→ »Comparing theoretical and measured Speed of Sound (SOS)« (pg. 63)→ »Checking the Meter Health« (pg. 64)→ »Time Synchronization« (pg. 65)→ »Battery Lifetime / Capacity« (pg. 66)

Documentation:→ »Maintenance Report« (pg. 67)

The operating conditions (gas composition, pressure, temperature, flow velocity) under which the maintenance reports to be compared are generated should be similar. If the operating conditions are not comparable, they should be documented separately and taken into account when the data is analyzed.


Maintenance

5 . 2 Routine ChecksThe information displayed on the front panel LCD display of the FLOWSIC600 meter can bechecked to ensure that the system is functioning properly. The MEPAFLOW600 CBMsoftware provides a more user friendly way for doing routine checks.

5.2.1 Comparing theoretical and measured Speed of Sound (SOS)One of the most important criteria for the correct operation of an ultrasonic gas meter isthe consistency between the theoretical SOS, calculated for the actual gas composition,temperature and pressure, and the SOS measured by the ultrasonic gas meter. The Speed of Sound Calculator (SOS Calculator) available in MEPAFLOW600 CBMcalculates a theoretical SOS for a specific gas composition at a specified temperature andpressure (→ Figure 26). The calculation of thermodynamic properties is based on the “GERG-2004 Wide-Range Equation of State for Natural Gases and other Mixtures”. The algorithmsthat are implemented in the SOS calculator where developed by the Ruhr-UniversityBochum (Germany).

Figure 26 Speed of Sound Calculator with loaded gas composition file

Use MEPAFLOW600 CBM to connect to your meter (→ pg. 47, 4.3).Start the SOS calculator from the Maintenance report or choose “Tools / SOS Calculator” from the menu. Enter your gas composition and specify temperature and pressure for your application.For additional settings, activate the “Advanced” checkbox.Click the “Calculate” button.If you started the SOS calculator from the Maintenance Report, the calculated value is automatically copied to the corresponding field in the wizard and to the report.Compare the theoretical SOS with the SOS measured by the FLOWSIC600 (see Figure 27, main system bar).

The deviation between both should be less than 0.1%. If the deviation exceeds 0.3%, checkthe plausibility of temperature, pressure and gas composition. Else proceed according to→ pg. 63, 5.2.1.

Checkbox for advanced options


Maintenance

5.2.2 Checking the Meter HealthThe FLOWSIC600 monitors its own meter health with User Warnings and system alarms. Ifthe outputs are configured to indicate alarms and / or User Warnings, it is not necessary tomanually check the meter health. If you want to get a visual feedback about your meter‘s health, the “Main system bar“ inMEPAFLOW600 CBM provides a compact overview:

Use MEPAFLOW600 CBM to connect to your meter (→ pg. 47, 4.3).Check the main system bar for any yellow or red icon (→ Figure 27). A red or yellow icon indicates a potential problem with the meter.

If any of the icons in the main system bar are yellow or red, proceed with checking the“Meter Status” (→ pg. 73, 6.2.1) and the “User Warnings” (→ pg. 75, 6.2.2).

Figure 27 “Main system bar”

Main system bar

Measured SOS

Icons for system alarms, User Warnings and performance


Maintenance

5.2.3 Time SynchronizationAll entries in logbooks or datalogs saved in the meter‘s memory (FRAM) are written with atime stamp containing the meter time. The meter time can be synchronized with a masterclock (e.g. PC clock) via MODBUS or with MEPAFLOW600 CBM.

Synchronization via MODBUSThe date and the time of the FLOWSIC600 can be set separately by an external write. Eachoperation for date and time causes a separate entry in the Custody logbook [1].Alternatively the synchronization function can be used. To use this method, the dateregister (#5007) and the time register (#5008) have to be written sequentially within 2seconds. The date register (#5007) has to be written first. The write operation can beaccomplished by the MODBUS without setting the FLOWSIC600 into Configuration Mode.

Time synchronization via MEPAFLOW600 CBMMEPAFLOW600 CBM offers a synchronization function via a button in the “MeterInformation“ screen (→ Figure 28). The button is marked with a yellow sign calling attentionto the synchronization if the time difference between the meter clock and the PC clock isgreater than 30 seconds.

Figure 28 Synchronization button and meter clock synchronization window

A synchronization causes a logbook entry in the Custody logbook [1] only if the time change is greater than 3% of the time elapsed since the last synchronization.


Maintenance

5.2.4 Battery Lifetime / CapacityThe Real Time Clock (RTC) of the FLOWSIC600 is buffered by a battery with a guaranteedlife span of 10 years. The remaining battery capacity can be viewed on the LCD in the firstmenu level (see Technical Information).

Figure 29 Display of remaining battery capacity on the LCD display

Because the FLOWSIC600 has no regular maintenance cycle, after 8.5 years, a messagewill be generated automatically, which forces the operator to change the battery. See→ pg. 76, 6.2.3 for troubleshooting.

BatteryCharge 100%


Maintenance

5 . 3 Maintenance ReportIt is recommended to generate and file Maintenance reports on a regular basis. Thisserves to create a basis of comparable data over time and helps when a problem has to bediagnosed.

Figure 30 “Maintenance report” wizard

To create a maintenance report, follow the described procedure:Choose “Tools / Maintenance report” from the menu to open the Maintenance report wizard (→ Figure 30). Enter the information (Description, Technician) in the fields provided. Specify the collection duration, a timespan, over which live meter data is to be collected to document the meter‘s state (default: 1 minute).Enter the current pressure, temperature and SOS. Use the SOS Calculator to calculate the SOS for the gas composition (→ pg. 63, 5.2.1).The gas composition must be current and representative.Click the “Start” button to start live data collection. Diagnosis data, measured values and status information will be collected over the specified time span and will be saved in the meter databaseClick the “Create report” button. The Maintenance report will be generated and displayed. Print it and file the copy in the Manufacturer Data Report (MDR) shipped with the meter. Additionally the data is stored in the MEPAFLOW600 CBM meter database and accessible via the “Meter explorer” and the “Report manager”. The Maintenance report can also be exported to Excel using the direct link provided when the Maintenance report is displayed.

The operating conditions (gas composition, pressure, temperature, flow velocity) under which the Maintenance reports are created, should be similar. If the operating conditions are not similar, they should be documented separately and taken into account when the data is analyzed.

Click to open the “SOS Calculator”


Maintenance

5 . 4 Optional Data Download

5.4.1 Logbook Check

The “Meter logbook” page shows all logbook entries on the meter and in theMEPAFLOW600 CBM database. It provides details on each entry and information on thenumber of registered events and the remaining memory space.

Figure 31 “Meter logbook“ page in MEPAFLOW600 CBM

5.4.1.1 Downloading and saving logbook entries to the MEPAFLOW600 CBM databaseTo download and save logbook entries to the MEPAFLOW600 CBM database, proceed asfollows:

Use MEPAFLOW600 CBM to connect to your meter (→ pg. 47, 4.3).Choose “Meter / Meter Logbook” from the menu to open the Logbook page.In the dialog “Logbook selection”, select those logbooks that you want to download and click “OK”.

The logbook entries are now downloaded to your MEPAFLOW600 CBM database. You canview them offline without connection to the meter or share them with others (export thedevice or the session).

To prevent an overflow of the logbooks and possible data loss, logbook entries can be saved to a device database with the MEPAFLOW600 CMB software. The entries on the meter can then be deleted.


Maintenance

5.4.1.2 Acknowleding logbook entries on the meterTo acknowledge logbook entries on the meter, proceed as follows:

Download and save the logbook entries from the meter according to → 5.4.1.1.Select the logbook in which you want to acknowledge entries or select “All logbooks“ if you want to acknowledge entries in all logbooks at once. Mark those entries that you want to acknowledge. Click the “Acknowledge selection” button if you want to acknowledge only the selected entries or click the “Acknowledge all“ button if you want to acknowledge all entries in the selected logbook(s).

5.4.1.3 Clearing logbooks on the meterIf the logbooks are configured with the storage behaviour “rolling”, it is not necessary toclear the logbooks on the meter. When the logbook is full, new entries will overwrite theoldest entries.If a logbook is configured with the storage behaviour “blocking” (e.g. with custodyconfiguration), a full Custody logbook [1] will activate the meter status “Measurementinvalid”. In this case it is recommended to clear the logbooks.

To clear the logbooks on the meter, proceed as follows:Choose the User Access Level “Service” (→ pg. 48, 4.3.2)Download and save the logbook entries from the meter according to → 5.4.1.1.Select the logbook which you want to clear on the meter or select “All logbooks” to clear all at once.Switch the meter to Configuration Mode.Click the “Clear meter logbook” button and confirm the warning with “OK”.Switch the meter to Operation Mode.If the Parameter write lock was unlocked prior to clearing the meter logbook, follow all necessary procedures to bring the meter to back to its original state.

NOTICE:The following preconditions must be met to clear logbooks on the meter:● The Parameter write lock must be in the “UNLOCKED” position (see

“Technical Information“)● The user must be in the User Access Level “Service” (password see Service

Manual).● The meter must be in Configuration Mode.


Maintenance


Troubleshooting

FLOWSIC600

6 Troubleshooting

General TroubleshootingIndication of Meter States, System Alarms and Warnings

Generation of Diagnosis SessionMeter Connection Troubleshooting


Troubleshooting

If the routine tests during maintenance (→ pg. 63, 5.2) or the function tests aftercommissioning (→ pg. 55, 4.6) indicate that there may be a measurement problem, thischapter helps to determine the cause of the problem. If the cause of the problem cannot be localized, it is recommended to use theMEPAFLOW600 CBM software to record the current parameter set and diagnosis values ina diagnosis session file (→ pg. 77, 6.3) and send this to a local SICK representative.

6 . 1 General Troubleshooting

6 . 2 Indication of Meter States, System Alarms and WarningsThe FLOWSIC600 gives information about alarms and warnings in the following ways:● The LCD display indicates active system alarms or warnings. If a current error or

warning is active, the display will flash and a message will be displayed with a message number in the upper right corner (→ pg. 86, 7.2.1 for more details on LCD error messages).

● A status output can be configured to indicate if the meter status „Measurement invalid“, the meter status “Check request“ or the “Warning“ status become active.

● The pulse output can be configured to indicate if the meter is in Configuration Mode or if the meter status “Measurement invalid“ becomes active.

● The meter status registers can be read via MODBUS (see document “FLOWSIC600 Modbus Specification“).

● The MEPAFLOW600 CBM software can be used to check the meter health. System alarms and User Warnings are indicated in the Main system bar.

It is recommended to use MEPAFLOW600 CBM to get further information on the meter´shealth:

If the meter indicates “Measurement invalid“ or “Check request“ follow → pg. 73, 6.2.1. If the meter indicates “Warning“, follow → pg. 75, 6.2.2.To do a more detailed check of the meter health see “Technical Information“

Problem Possible causes Actions● No display● No pulse

frequency● No active status

signal

Faulty power supply

Check the input voltage at terminals 1 and 2.Check cables and terminal connections.

CautionTake the relevant safety precautions!

Defective deviceCreate a diagnosis session according to → pg. 77, 6.3 and contact your local SICK representative.


Troubleshooting

6.2.1 Checking the “Meter Status“ WindowThe “Meter status” window in MEPAFLOW600 CBM displays an overview about the metersstatus and operation.

Use MEPAFLOW600 CBM to connect to your meter (→ pg. 47, 4.3).Click on the “System” button in the main system bar to open the “Meter status” window (→ Figure 32). Check the general “Meter Status” section (marked in Figure 32) for yellow or red lights.

If there are no yellow or red lights in the general “Meter Status” section you can check the following other sections (also marked in Figure 32) for yellow or red lights.

Meter status light Causes ActionsGreen light “Measurement valid”

Measurement is valid, meter is operating correctly.

Red light “Measurement valid”

Measurement is invalid and / or the meter is in Configuration Mode.(The measured volume is counted in the error volume counter).1

1 See → pg. 17, 2.2.2 for more details on meter states.

If the meter is in Configuration Mode, choose “File / Operation Mode“ from the menu to switch it to Operation Mode. Otherwise proceed according to → pg. 77, 6.3.

Yellow light “Check request”

One or more paths have failed or another problem affects the measurement accuracy.1

Proceed according to → pg. 77, 6.3.

Yellow light “User Warning Limit exceeded“.

A User Warning Limit was exceeded.2

2 See “Technical Information“ for more details on User Warnings.

Check the User Warnings according to → pg. 75, 6.2.2.

Red light “Path failure” One or more paths have failed. Proceed according to → pg. 77, 6.3.

Meter status light Causes ActionsYellow light “Logbook contains unack. entries”

Logbook contains unacknowledged entries.

Download, check and acknowledge all logbook entries according to → pg. 68, 5.4.1.1

Red light for any Logbook “full”

The logbook in question is configured to “blocking“ and is full of entries.

Download and check all logbook entries according to → pg. 68, 5.4.1.1. Clear the meter logbook according to → pg. 69, 5.4.1.3.Consider reconfiguring the logbook to “rolling“ (Parameter Page).

If your meter is configured according to PTB requirements a full Custody Logbook [1] will activate the meter status “Measurement invalid“.

Download and check all logbook entries according to → pg. 68, 5.4.1.1. Clear the meter logbook according to → pg. 69, 5.4.1.3.

Yellow light for any DataLog “full”

The DataLog in question is configured to “blocking“ and is full of entries.

Download and check the DataLog according to the “Technical Information“. Clear the DataLog according to the “Technical Information“.Consider reconfiguring the DataLog to “rolling“ (see “Technical Information“).

Yellow light “Battery Lifespan (change battery)“

After 8.5 years this warning is activated to force the user to change the battery.

See → pg. 76, 6.2.3 for more details.Contact trained staff or your SICK representative.Trained staff: Change the battery according to the procedure described in the Service Manual


Troubleshooting

Figure 32 Main system bar with “System” button and opened “Meter Status” windowOpens the “Meter Status” window

General “Meter Status” section

Main system bar

Indication if logbook(s) contains unacknowledged entries “Logbooks“

section

“DataLogs“section

Battery Lifespan


Troubleshooting

6.2.2 Checking the User WarningsThe “User Warnings” window displays an overview about the User Warning status.

Use MEPAFLOW600 CBM to connect to your meter (→ pg. 47, 4.3).Click on the “User” button in the main system bar of the MEPAFLOW600 CBM screen to open the “User Warnings” window (→ Figure 33). Check the window for yellow lights and proceed according to the “Technical Information“..

Figure 33 Main system bar with button “User” and opened “User Warnings” window

Opens the “User Warnings” window


Troubleshooting

6.2.3 Battery Lifetime / CapacityBecause the FLOWSIC600 has no regular maintenance cycle, after 8.5 years, a messagewill be generated automatically, which forces the operator to change the battery (→ Figure 34and → Figure 35). The procedure to change the battery is decribed in the Service Manual.

Figure 34 Flashing message on the LCD display, prompts to change the battery

Figure 35 “Battery Lifespan” status bit in “Meter Status” window

INFORMATION 1030LifeSpan Battery

“Battery Lifespan” status bit


Troubleshooting

6 . 3 Generation of a Diagnosis SessionIf it becomes necessary to generate a Diagnosis session for remote support, follow theprocedure described below:

Start the MEPAFLOW600 CBM software and establish an online connection to the meter (see → pg. 47, 4.3 for all necessary preparations).Choose “Tools / Diagnosis session” from the menu or click the “Diagnosis session” item in the Key navigation (see → Figure 36)

Figure 36 “Diagnosis session” generation

Specify a file name. (The file path is set according to the program settings. If necessary, specify a different path.)Click the “Save” button.MEPAFLOW600 CBM will now download the logbooks from the meter and generate a Diagnosis session with all relevant data. The entire process usually takes about three minutes. If the logbooks contain a lot of entries, the process may take longer.Email the Diagnosis session file to your SICK representative for support.

“Diagnosis session” itme


Troubleshooting

6 . 4 Meter Connection TroubleshootingMeter not found at initial connection

Check all cabeling and hardware including the correct installation of the adapters (see → §4.2.1 and → §4.2.2).Use the options in the displayed window to make MEPAFLOW600 CBM search with wider options (see → Figure 37).

Figure 37 “Meter not found” dialog for the specification of wider search options

Connection lost during sessionCheck all cabling and hardware. Use the options in the displayed window to make MEPAFLOW600 CBM search with wider options (see → Figure 37), especially If parameters (e.g. the baudrate) may have changed.


Appendix

FLOWSIC600

7 Appendix

Conformities and Technical DataLogbooks

Sealing Plan


Appendix

7 . 1 Conformities and Technical Data

7.1.1 CE certificateThe FLOWSIC600 has been developed, manufactured and tested in accordance with thefollowing EC directives:● Pressure Equipment Directive 97/23/EC● Directive 94/9/EC (ATEX100)● EMC Directive 2004/108/ECConformity with above directives has been verified. The equipment has been designatedthe CE label. The specific designation of the pressure equipment demanded according tothe Pressure Equipment Directive 97/23/EC under part 3.3 and 3.4 is to find in the MDRof the FLOWSIC600.

7.1.2 Standard compatibility and type approvalThe FLOWSIC600 conforms to the following norms, standards or recommendations:● EN 60079-0, EN 60079-1, EN 60079-7, EN 60079-11, EN 60079-26● OIML R 137-1, 2006, “Gas meters, Part 1: Requirements“● OIML D 11, 2004, “General requirements for electronic measuring instruments“● A.G.A Report No. 9, 1998, “Measurement of Gas by Multipath Ultrasonic Meters“1

● API 21.1 “Flow Measurement Using Electronic Metering Systems” (draft)2

Type approval for commercial or custody transfer has been granted by the relevantauthorities, e.g.:● Germany: PTB (Physikalisch-Technische Bundesanstalt), code number 7.421 / 03.05● Netherlands: NMI (Netherlands Meetinstituut), code number B35● Canada: Measurement Canada, Approval No. AG-0521● Switzerland: Metrologie und Akkreditierung Switzerland, Appr. No. CH-G4-04404-00● Europe: MID Approval, DE-08-MI002-PTB005

1 In derogation of the AGA9, strength test will be performed as hydrostatic pressure test with 30 minutesholding time according to the requirements of PED and ASME B31.5 “Process piping”.

2 The FLOWSIC600 meets or exceeds the new proposed audit logging requirements of API 21.1 (draft).Specifically the API 21.1 (draft) requires the ultrasonic meter to provide an internal record of anyconfiguration change, including the original and new parameter, and date and time the changeoccurred.


Appendix

Figure 38 Common key code (for short description of meter design, indicated on Type Plate and Instrument Data Sheet**)

** The Instrument Data Sheet is included in the Manufacturer Data Report (MDR).

Group 7 8 10 12 13 14 15

FL600- - -

METER BODYPath configuration

1-Path 1 P2-Path 2 P4-Path 4 P1+1-Path redundant 1 R2+2-Path redundant 2 R4+4-Path (Qatro) 4 R4+1-Path (2plex) 5 C2-Path crossed 2 X4-Path crossed 4 X

Overall length2D (at meters >24") 2 D3D (standard length) 3 D5D 5 DShortened Meter body S DOther size X D

Nominal size 2" / DN 50 0 2 3" / DN 80 0 3 4" / DN 100 0 4 6" / DN 150 0 6 8" / DN 200 0 810" / DN 250 1 012" / DN 300 1 216" / DN 400 1 6Other size X X

Connection flange typeANSI CLASS 150 C L 0 1 5 0ANSI CLASS 300 C L 0 3 0 0ANSI CLASS 600 C L 0 6 0 0ANSI CLASS ??? C L X X X XDIN/ISO PN16 P N 0 0 1 6DIN/ISO PN 64 P N 0 0 6 4DIN/ISO PN 100 P N 0 1 0 0DIN/ISO PN ??? P N X X X X

Inner diameterSchedule 40 (ANSI) S C 0 0 4 0Schedule 80 (ANSI) S C 0 0 8 0Schedule ??? (ANSI) S C X X X XSpecified in [mm] (DIN) X X X . X X

Flange type / sealing face Raised Face (ANSI B16.5) R FRing Type Joint (ANSI B16.5) R JGlatt Form C (DIN 2526) G CGlatt Form E (DIN 2526) G EForm B1 (EN 1092-1) B 1Form B2 (EN 1092-1) B 2Special design X X

MaterialCarbon Steel (1.1120 / ASTM A216 Gr. WCC ) 0Stainless steel (1.4408 / ASTM A351 Gr. CF8M) 1LT-CS (1.6220 / ASTM A352 Gr. LCC) 2Duplex (1.4470 / ASTM A995 Gr. 4A / UNS J92205) 3Superduplex (1.4469 / ASTM A995 Gr. 5A) 4Superaustenit (1.4557 / ASTM A351 Gr. CK-3MCuN) 5

Connection for Extraction ToolYes YNo N

9 ULTRASONIC TRANSDUCER (Will be selected by SICK on the basis of the technical data ) _ _

SIGNAL PROCESSING UNITEx-proof-design

CSA Group D T4 1CSA Group B, C, D T4 2ATEX IIA T4, M20x1.5 3ATEX IIC T4, M20x1.5 4ATEX IIA T4, 1/2 NPT 5ATEX IIC T4, 1/2 NPT 6

11 Power supply12 ... 24V DC D C

Data outputsHardware variant 1 (4 digital outputs) 1Hardware variant 2 (1 analog current output and 3 digital outputs) 2Hardware variant 3 (with integrated volume corrector, p- and T-transmitters internally power supplied) 3Hardware variant 4 (1 analog current output and 2 RS485) 4Hardware variant 5 (with integrated EVC, p- and T-transmitters externally power supplied, I/O board with DSP) 5Hardware variant 6 (with integrated EVC, p- and T-transmitters internally power supplied, I/O board with DSP) 6Hardwarevariante 7 (same as hardware variant 1, but with LowPressureAnalogBoard) 7Hardwarevariante 8 (same as hardware variant 2, but with LowPressureAnalogBoard) 8Hardwarevariante 9 (same as hardware variant 4, but with LowPressureAnalogBoard) 9Hardware variant A (same as hardware variant 5, but with LowPressureAnalogBoard) AHardware variant B (same as hardware variant 6, but with LowPressureAnalogBoard) B

HART-Protocol (By selection of hardware variant 2 and 8 only)Yes YNo N

Front panelLED SICK 0LCD SICK 1

Custody Transfer designYes YNo N

3

4

115 61 2 3 4

2

9

Key code1

15

14

13

12

5

6

8

10

7

Rev. 1.8


Appendix

7.1.3 Technical data

Table 5 Common meter sizes and flow rates

Type approvalThe information in this section may differ from the type approval which is valid for the FLOWSIC600 in your country. Please use your national type approval for the FLOWSIC600.

Nominal Size Actual flow rate

[m³/h]Actual flow rate

[ft³/h] Max. Velocity*

Min. Max. Min. Max. [m/sec] [ft/sec]DN 50 (NPS 2) 6 400 210 14,000 65 213DN 80 (NPS 3) 12 1,000 280 35,000 65 213DN 100 (NPS 4) 20 1,600 460 57,000 60 197DN 150 (NPS 6) 32 3,000 1,130 106,000 50 164DN 200 (NPS 8) 40 4,500 1,410 159,000 45 148DN 250 (NPS 10) 50 7,000 1,770 247,000 40 131DN 300 (NPS 12) 65 8,000 2,300 283,000 33 108DN 350 (NPS 14) 80 10,000 2,830 353,000 33 108DN 400 (NPS 16) 120 14,000 4,240 494,000 33 108DN 450 (NPS 18) 130 17,000 4,590 600,000 33 108DN 500 (NPS 20) 200 20,000 7,060 706,000 33 108DN 600 (NPS 24) 320 32,000 11,300 1,130,000 33 108DN 700 (NPS 28) 650 40,000 22,950 1,413,000 30 98DN 750 (NPS 30) 650 45,000 22,950 1,589,000 30 98DN 800 (NPS 32) 800 50,000 28,250 1,766,000 30 98DN 900 (NPS 36) 1,000 66,000 35,320 2,331,000 30 98DN 1000 (NPS 40) 1,200 80,000 42,380 2,825,000 30 98DN 1050 (NPS 42) 1,300 85,000 45,910 3,002,000 30 98DN 1100 (NPS 44) 1,400 90,000 49,440 3,178,000 28 92DN 1200 (NPS 48) 1,600 100,000 56,500 3,531,000 27 89

*When a configuration with flow conditioner is used, the velocity of gas must not exceed 40 m/s (131 ft/s) in the pipe.

TYPE APPROVAL


Appendix

Table 6 Technical Data

MaterialMeter body Carbon steel 1.1120/ ASME A216 WCC

Stainless steel 1.4408/ ASME A351 Gr. CF 8MLow temperature carbon steel 1.6220/ASME A352 L CCDuplex steel 1.4470/ASME A995 Gr.4A/UNS J92205

Common dataNumber of measuring paths 1, 2 or 4Min. gas velocity 0.3 m/s; 1 ft/sTurn down (vmin/vmax) Max. 1 : 130Measured mediumGases Natural gas, process gases, air, Ethylene, etc.Pressure range1 0 bar(g) ... 250 bar(g) (0 psi(g) ... 3600 psi(g)); up to 450 bar(g) (6500 psi(g)) on requestTemperature range -40 °C ... + 180 °C (-40 °F ... 356 °F); -194 °C ... 280 °C (-317 °F ... 536 °F) on request Measuring uncertaintyRepeatability < 0.1 % of readingTypical uncertainty 1 path

2 paths4 paths

± 2.0 %2± 1.0 %2± 0.5 %3 (dry calibrated); ± 0.2 %3 (after flow calibration + adjustment with constant factor); ± 0.1%3 (after flow calibration + adjustment with polynomial correction)

Power supplyOperating voltage 12 ... 28.8 V DC (minimum 15 V DC for active current output)Typ. power consumption < 1 W OutputsMeasured variables Flow rate and volume at flowing and base conditions, gas velocity, speed of sound Analog output 4 .. 20 mA; active / passive; electrically isolated; max load = 250 Ω Pulse and status outputs Passive, electrically isolated, open collector or acc. NAMUR, fmax = 6 kHz (scalable),

pulse width = 0,05 .. 1 s in accordance with NAMUR (EN50227)InterfacesMODBUS ASCII and RTU 2 x RS485 for configuration, measured value output and diagnosisHART® Configuration, measured value output and diagnosisEx approvalEurope (ATEX 94/9/EG) II 1/2G Ex de ib [ia] IIA T4 or II 1/2G Ex de ib [ia] IIC T4

Ultrasonic transducers intrinsically safe “ia“ 4USA / Canada (CSA) Class I, Division 1, Group D T4; Class I, Division 2, Group D T4

Class I, Division 1, Groups B,C, D T4; Class I, Division 2, Groups A, B, C, D T4Ultrasonic transducers intrinsically safe

Ambient conditionsTemperature range -40 °C ... +60 °C (-40 °F .. 140 °F)Storage temperature -40 °C ... +60 °C (-40 °F .. 140 °F)IP classification IP 67Relative humidity < 95 %

1 Depending on transducer type and meter size, a minimum operating pressure can be neccessary. Please consult the manufacturer2 Within Qt to Qmax and with straight inlet/outlet section of 20D/3D or with flow straightener 10D/3D. 3 Within Qt to Qmax and with straight inlet/outlet section of 10 D/3 D or 5 D/3 D with flow straightener4 Approval for operation of the ultrasonic transducers within zone 0 only valid under atmospheric

conditions (-20 °C ≤ Tmedium ≤ +60 °C; 0.8 bar(a) ≤ pmedium ≤ 1.1 bar(a))(-4 °F ≤ Tmedium ≤ 140°F; 11.6 psi(a) ≤ pmedium ≤ 16 psi(a))


Appendix

Criteria applicable to meter when used in accordance with German PTB specifications Table 7 Meter sizes according to PTB approval

Meter size G-class

Measuring range (Qmin [m³/h]) Max. flow rate

Qmax [m³/h]

Meter factor

[pulses/m³] 1:100 1:80 1:50 1:30 1:20

DN 80(3“)

G160 13 250 28800G250 13 20 400 18000

G400* 13 20 32 650 11100DN 100

(4“)G250 20 400 18000G400 20 32 650 11100

G650* 20 32 50 1000 7200DN 150

(6“)G400 32 650 11100G650 32 50 1000 7200

G1000 32 50 80 1600 4500G1600* 32 50 80 130 2500 2880

DN 200(8“)

G650 50 1000 7200G1000 50 80 1600 4500G1600 50 80 130 2500 2880

G2500* 40 80 130 200 4000 1800DN 250

(10“)G1000 50 80 1600 4500G1600 50 80 130 2500 2880G2500 50 80 130 200 4000 1800

G4000* 65 80 130 200 320 6500 1110DN 300

(12“)G1600 80 130 2500 2880G2500 80 130 200 4000 1800G4000 65 80 130 200 320 6500 1110

G4000 E 7800 920DN 350

(14“)G1600 80 2500 2880G2500 80 130 200 4000 1800G4000 80 130 200 320 6500 1110

G4000 E 80 7800 920DN 400

(16“)G2500 130 200 4000 1800G4000 130 200 320 6500 1110G6500 120 200 320 500 10000 720

G6500 E 120 12000 600DN 450

(18“)G2500 130 4000 1800G4000 130 200 320 6500 1110G6500 130 200 320 500 10000 720

G6500 E 120 12000 600


Appendix

● Any flow rates given above are also valid in the bidirectional mode.● G-classes marked with an asterisk (*) must only be used in configuration No. 2 (see

→ pg. 27, 3.2.2).● G-classes marked with an (E) have an extended max. flow rate (max. flow velocity vmax =

36 m/s) related to commonly established turbine meter G-classes● The transition flow Qt is based on the flow range the meter is designed for according to

the main plate. It is:

DN 500(20“)

G4000 200 320 6500 1110G6500 200 320 500 10000 720

G10000 200 320 500 800 16000 450G10000 E 200 20000 360

DN 600(24“)

G6500 320 500 10000 720G10000 320 500 800 16000 450G16000 320 500 800 1300 25000 288

G16000 E 320 32000 225DN 700

(28“)G6500 500 10000 720

G10000 500 16000 450G16000 500 25000 290G25000 400 500 40000 180

DN 800(32“)

G10000 500 16000 450G16000 500 25000 290G25000 500 40000 180

G25000 E 500 48000 150DN 900

(36“)G10000 800 16000 450G16000 800 25000 290G25000 800 40000 180G40000 650 800 65000 111

DN 1000(40“)

G16000 1300 25000 290G25000 1300 40000 180G40000 800 1300 65000 111

- for a flow range of 1:20 Qt=0.20 Qmax and- for a flow range of 1:30 Qt=0.15 Qmax and

- for a flow range of ≥ 1:50 Qt=0.10 Qmax.

Meter size G-class

Measuring range (Qmin [m³/h]) Max. flow rate

Qmax [m³/h]

Meter factor

[pulses/m³] 1:100 1:80 1:50 1:30 1:20


Appendix

7 . 2 Logbooks1 Classification of logbook entriesThe entries are distinguished into three classes and identified by the initial character in thefirst line.● “I”information● “W”warning● “E”error/ malfunction2 Type of occurrence● “+”point of time identifying the beginning of a status● “-”point of time identifying the end of a status

7.2.1 Overview of event entries in logbooks and MEPAFLOW600 CBM

Message No.

on LCD

Logbook message in MEPAFLOW600 CBM Logbook LCD-Text

Custody logbook [1]

3002 NO DSP communication 1 E+System 0001NO DSP-Communic.

E-System 0001NO DSP-Communic.

3003 Measurement invalid 1 E+DSP 0001Reading invalid

E-DSP 0001Reading invalid

3004 Firmware CRC invalid 1 E+Firmware 0001CRC invalid

E-Firmware 0001CRC invalid

3005 Parameter CRC invalid 1 E+Parameter 0001CRC invalid

E-Parameter 0001CRC invalid

3006 Parameter out of range 1 E+Parameter 0001#XXXX range error

E-Parameter 0001#XXXX range error

3007 Failure during storage of path compensation

parameter

1 E+PathComp. 0001Storage error

E-PathComp. 0001Storage error

3008 Meter clock time invalid 1 E+System 0001ClockTime inval.

E-System 0001ClockTime inval.


Appendix

3009 Custody logbook [1] overflow 1 E+Logbook 1 0001Overflow

E-Logbook 1 0001Overflow

3011 CRC volume counter (a.c) invalid 1 E+Count.ac 0001CRC invalid

E-Count.ac 0001CRC invalid

3012 CRC volume counter (n.c) invalid 1 E+Count.sc 0001CRC invalid

E-Count.sc 0001CRC invalid

3013 Transit time mode activated 1 E+System 0001TransitTimeMode

E-System 0001TransitTimeMode

3014 No signature key 1 E+System 0001No signature key

E-System 0001No signature key

2001 Path failure 1 W+PathError 0001Path 1 2 3 4

W-PathError 0001All paths OK

2002 No HART communication to temperature

transmitter

1 W+HART T 0001No communication

W-HART T 0001No communication

2003 No HART communication to pressure transmitter 1 W+HART P 0001No communication

W-HART P 0001No communication

2004 Maximum pulse output frequency exceeded

(6kHz)

1 W+PulseOut 00016000 Hz exceeded

W-PulseOut 00016000 Hz exceeded

2005 EVC parameter invalid 1 W+EVC 0001EVC para.invalid

W-EVC 0001EVC para.invalid

2006 EVC hardware error 1 W+EVC 0001EVC module error

W-EVC 0001EVC module error

1001 Flow meter power ON 1 I Power ON 0001dd/mm/yy mm:ss

1002 Meter clock adjusted 1 I Set Time 0001dd/mm/yy mm:ss

Message No.

on LCD



Appendix

1003 Configuration Mode active 1 I+Meas.Mode 0001Configurat. ON 1

I-Meas.Mode 0001Measurement ON 1

1004 Firmware changed 1 I Update FW 00013104 -> 3200

1007 Custody logbook [1] erased and initialized 1 I Logbook 1 0001Reset and Init

1014 Overflow volume counter (a.c.) 1 I Count.ac 0001Overflow

1015 Overflow volume counter (s.c.) 1 I Count.sc 0001Overflow

1016 Error volume counter cleared 1 I Reset E 000101/01/07 10:47

1017 All volume counters cleared 1 I Reset V 000101/01/07 10:47

1027 Initialization error → Default parameter loaded 1 I+InitError 0001DefaultParaLoad

I-InitError 0001DefaultParaLoad

1029 Air test mode activated 1 I+Airtest 0001Active

I-Airtest 0001Not active

Warning logbook [2]

1008 Warning logbook [2] erased and initialized 2 I Logbook 2 0001Reset and Init

1010 Warning logbook [2] overflow 2 I+Logbook 2 0001Overflow

I-Logbook 2 0001Overflow

1018 DataLog 1 cleared 2 I DataLog 1 0001Reset



1021 DataLog 1 overflow 2 I+DataLog 1 0001Overflow

I-DataLog 1 0001Overflow



Message No.

on LCD



Appendix



1024 DatenLog 1 CRC error 2 I+DataLog 1 0001CRC invalid

I-DataLog 1 0001CRC invalid

1025 DatenLog 2 CRC error 2 I+DataLog 2 0001CRC invalid


1026 DataLog 3 CRC error 2 I+DataLog 3 0001CRC invalid


1028 Customer limit exceeded 2 I+Userlimit 0001Limit XXXXXXXXXX

I-Userlimit 0001Limits OK

Parameter logbook [3]

1005 Parameter changed 3 I Parameter 0001Change Reg3001

1006 All parameters to default (Reset) 3 I Parameter 0001Reset all

1009 Parameter logbook [3] erased and initialized 3 I Logbook 3 0001Reset and Init

1011 Parameter logbook [3] overflow 3 I+Logbook 3 0001Overflow

I-Logbook 3 0001Overflow

Message No.

on LCD



Appendix

7 . 3 Connection Diagrams for Operating the FLOWSIC 600 in Hazardous Areas in Accordance with North American Guidelines (CSA)

Figure 39 Control drawing CSA 781.00.02 (page 1)


Appendix

Figure 40 Control drawing CSA 781.00.02 (page 2)


Appendix

7 . 4 Wiring Examples

7.4.1 Intrinsically safe installation

Figure 41 FLOWSIC600 intrinsically safe installation

internal

Non Hazard Area

.

<= 24V DC

<= 24V DC RL

RL

<= 24V DC

<= 24V DC RL

RL

24V DC +

24V Gnd

sh

ieldR

S 4

85Ex

[EEx ib] IICR

S 2

32

24VDC

STAHL9185 Rx

DT

xD

Service

Interface

Modbus

Volume pulse

Status

Status

ExplosionHazard Location

Intrinsic savety circuits

Non Intrinsic savety circuits

AO 0DO 0

FLOWSIC 600

RS 485

DO 1

DO 2

DO 3

Class1, Division1, Groups B, C and D

Class1, Division2, Groups A, B, C and D

Class1, Zone 1 Group IIB + Hydrogene

Class1, Zone 2, Group IIC

II 1

/2G

EE

x d

e i

b [

ia]

IIC

T4

o

rII

1/2

G E

Ex

de

ib

[ia

] II

A T

4

31+

32-

33+

34-

51+

52-

41+

42-

81+

82-

1 (+)

2 (-)

FL600

Li2YCYv(TP)

4x2x0,5 mm²

Screen

Screen

(TP) - Twisted pair

NYY-O

2 x 1,5 mm²

Li2YCYv(TP)

2x0,5 mm²

in EU in accordance with EN 60079-14

National regulation must be observed.

maximum length: 100 m

RS485Modbus - approx. impedance 120 Ohm

1/2"NPT (North America)

6 -12 mm cable diameter

Attention:

!WARNING!

Incorrect cabling can cause

the FLOWSIC 600 to fail!

For further details see

operation manual.

Cable glands

Intrinsic savety installation:

in accordance with

in North America

NEC and CEC, see

Control Drawing 781.00.02

Compliance CSA 1298901

EC-Typ-Examination Certificate

ForSavety/Entity - Parameters see

TÜV01 ATEX 1766 X resp. Certificate of

M20x1,5 (EU) or

or 4 .. 20 mA passivVolume pulse

Remark:

Flowcomputer

SICKrecommends to connect all signals

of FLOWSIC600 with cabels to the non

hazardous area.

Ex

24VDC

[EEx ia] IIC

1+

4-

2+

5-

8+

9-

11

12

10-

7+

MK13-22EX0-T/24VDC

Ex

24VDC

[EEx ia] IIC

1+

4-

2+

5-

8+

9-

11

12

10-

7+

MK13-22EX0-T/24VDC

[EEx ib]

LN Ex

9143

STAHL

10

11

STHAL power supply

9143/10-156-160-10s


Appendix

7.4.2 Non-intrinsically safe installation

Figure 42 FLOWSIC600 non-intrinsically safe installation

.

-X

..

.

LR

Imax = 100 mA

super fast

100 mA

fast

1A

internal

Fuse

Fuse

24 V DC

Non Hazard Area

Volume pulse

Hazard Location Explosion

or 4 .. 20 mA

Status

..FuseImax = 100 mA

RL

..FuseImax = 100 mA

RL

..

FuseImax = 100 mA

RL

Modbus

Status

<= 24V DC

<= 24V DC

<= 24V DC

<= 24V DC

super fast

100 mA

super fast

100 mA

LN

24 VDC

.

AO 0DO 0

FLOWSIC 600

RS 485

DO 1

DO 2

DO 3

Class1, Division1, Groups B, C and D

Class1, Division2, Groups A, B, C and D

Class1, Zone 1 Group IIB + Hydrogene

Class1, Zone 2, Group IIC

II 1

/2G

EE

x d

e i

b [

ia]

IIC

T4

o

rII

1/2

G E

Ex

de

ib

[ia

] II

A T

4

31+

32-

33+

34-

51+

52-

41+

42-

81+

82-

1 (+)

2 (-)

FL600

NYY-O

2 x 1,5 mm²

..

100 mA

super fast

Li2YCYv(TP)

2x0,5 mm²

Li2YCYv(TP)

4x2x0,5 mm²

(TP) - Twisted pair

Fuse

Screen

Attention:

6 -12 mm cable diameter

1/2"NPT (North America)

RS485Modbus- approx. impedance 120 Ohm

maximum length: 100 m

Cable glands

operation manual.

For further details see

the FLOWSIC 600 to fail!

Incorrect cabling can cause

WARNING!

!

in EU in accordance with EN 60079-14

National regulation must be observed.

Volume pulse

in North America

Non intrinsic installation:

see control drawing 781.00.02

in accordance with NEC and CEC,

M20x1,5 (EU) or

Flowcomputer/Systemcontroller

Fusesfor field terminals:

Veryfast acting type (FF-Type)

In case ofblow out lock for reason

before change.

Additional surge protection is

recommended in case of powerful or

recurrent strokes of lightning.

Remark:

SICKrecommends to connect all signals

of FLOWSIC600 with cabels to the non

hazardous area.


Appendix

7 . 5 Sealing Plan

Figure 43 Sealing plan, part 1


Appendix



Appendix


alternatively


Appendix

Figure 47 Examples: Main type plates at the signal processing unit

Figure 48 Example: Type plate at the meter body


Appendix


SICK MAIHAK GmbH | GermanyNimburger Str. 11 | 79276 Reute | www.sick.comPhone +49 7641 469-0 | Fax +49 7641 469-11 49 | [email protected]

8010

458/

2010

-01

(V2.

0) SICK worldwide

You will find our local subsidiary or agency at:www.sick.com

Your local sales and service partner

FLOWSIC600

OI_FLOWSIC600_en_8010458

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