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OPERATING INSTRUCTIONS

FLOWSIC150 CARFLOW
Exhaust Gas Flow Meter

Description
Installation
Operation

Content

About this Document ..........................................................................................................5

1 Safety Instructions...............................................................................................................6
1.1

Intended Use ............................................................................................................................6

1.2

Authorised Personnel .............................................................................................................6

1.3

Safety Instructions and Protection Measures ................................................................6
1.3.1

General Information ............................................................................................................................ 6

1.3.2

Danger from electrical Equipment ................................................................................................. 7

1.3.3

Preventive Measures for safe Operation .................................................................................... 7

1.3.4

Detecting and Preventing Malfunctions ....................................................................................... 7

2 Product Description.............................................................................................................9
2.1

System Features ................................................................................................................... 11

2.2

System Design ...................................................................................................................... 12

2.3

Measuring Principle Flow Measurement....................................................................... 13
2.3.1

Determining the Gas Velocity ........................................................................................................ 14

2.3.2

Calculating the Volumetric Flow ................................................................................................... 14

2.3.3

Determining the Velocity of Sound.............................................................................................. 14

2.3.4

Compensating Path Failure............................................................................................................. 15

2.4

Elements for Display, Operation and Communication............................................... 16

2.5

Self-diagnosis......................................................................................................................... 18

2.6

Technical Data ...................................................................................................................... 19

2.7

Dimensions, Part Numbers................................................................................................. 20

3 Installation........................................................................................................................... 21

4 Commissioning and Parameterization........................................................................ 27
4.1

Basics ....................................................................................................................................... 29
4.1.1

General Notes .................................................................................................................................... 29

4.1.2

Prerequisites ....................................................................................................................................... 29

4.1.3

Preparations ........................................................................................................................................ 30

4.1.4

Basic Settings ..................................................................................................................................... 30

FLOWSIC150 · Operating Instructions · 8010815 V 1.2 · © SICK MAIHAK GmbH Germany

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.........................3................................................................................................................................................................3 Checking the Measuring Pipe on Depositions ...............2 Spare Parts....................................................2....................................................................... Data Management............................................. 34 4.................................................... 55 5... 36 4........................................................................2 Warning Messages ................... 40 4...................................... 59 6........................................................................................ 31 4..... 65 7......................................................................................................................................................3............................................................................................... Data Save......2......................................... 66 8 Appendix....................................1 Fault Diagnosis ..........4 Data Collection.............................................................................................. 33 MEPA-Carflow Program ....................3............................................................................. 31 4.....................................................3 Start Standard Measuring Mode .......................................2........................................................................................51 5.....................................................................................................................................................................1 Standard Components........ 33 4...........................1 Program Interface......................67 4 FLOWSIC150 · Operating Instructions · 8010815 V 1..2 Menu Descriptions......................................................1 General .............3 Parameterization ............................................... 53 5......................63 7.. 42 5 Maintenance .....................2......................................................2.............2 4...2.......... 61 7 Parts Overview..............................................................2 Calibration .................................................................................................................2 Velocity of sound ....................................................................3 Data Recorder .......................................................................................3.. 54 5.......................................................... 34 4..............57 6.........................................................2 Routine Checks .... 60 6................... 55 6 Troubleshooting ........2 · © SICK MAIHAK GmbH Germany ....................................................................................1 Setting Basic Parameters and Analog Output ....................................................... 54 5..........................1 Gas temperature Measurement..................Content 4.............................3 Malfunction Messages.............................................................................

commissioning. Important Indicates a risk of damage to the device or system components and potential functional impairments. as well as instructions for planning. installation. These symbols are provided at the points in this documentation where the relevant information is required. The safety instructions and warnings must be followed at all times. ATTENTION Warning DANGER Identifies potential danger for personnel. These warnings are intended to protect you from (fatal) injuries. These Operating Instructions contain general information on the method of measurement used. These operating instructions only cover standard applications that match the technical data listed. assembly. maintenance and troubleshooting. Note Always read these operating instructions carefully before commencing work. Your SICK MAIHAK representative will gladly provide you with additional information and support for special applications. important safety information is specially highlighted in these operating instructions.2 · © SICK MAIHAK GmbH Germany 5 . Symbols used in this document For quick access and reasons of clarity. the design and function of the entire system and its components.About this Document About this Document The present Operating Instructions describe the FLOWSIC150 measuring system designed for contactless measurements of flow velocity and air temperature in tunnels. A comparison of the characteristics of the available system variants is provided to help you decide on the configuration that is best suited to your needs in the planning phase. particularly due to electrical equipment or as a result of incorrect handling of the device or system components. We strongly advise that you contact a SICK MAIHAK specialist for consultation with regard to special applications. Always read warnings carefully and follow them at all times! FLOWSIC150 CARFLOW · Operating Instructions · 8010815 V 1. along with additional tips. Note Provides information on the features of the device or system.

The instructions for preventing danger and damage contained in these documents must be observed at all times. transport and storage. device documents.2 Authorised Personnel Persons responsible for safety issues must ensure that: • All work on the measuring system is carried out by qualified personnel and checked by the experts responsible. accident prevention regulations. • All work must be carried out in accordance with the local. connection. and rating plates) • All of the measures required to maintain the device. the order documents. • Suitable safety equipment and personal protection measures must be available in accordance with the potential hazard and must be used by the personnel. it is important that: • The system is operated in accordance with the technical data and specifications regarding assembly. 1. or other directly equivalent standards. • These persons must be familiar with the hazards posed during operation and must have received special training on how to operate the measuring system. 6 FLOWSIC150 CARFLOW · Operating Instructions · 8010815 V 1.1 Intended Use The FLOWSIC150 measuring system was designed for contactless measurement of flow velocity and air temperature in tunnels.3 Safety Instructions and Protection Measures 1. ambient. system-specific conditions and with due consideration paid to the operating dangers and specifications.2 · © SICK MAIHAK GmbH Germany . education. It is crucial that these persons be able to identify and avoid potential hazards in good time. specifications. 1.3. are provided. It must only be used in the manner intended by the manufacturer.1 General Information Handling or using the device incorrectly can result in personal injury or material damage. • The operating instructions for the measuring system and plant documentation must be available on site. These persons must be qualified by virtue of their expertise (training. Technical experts are those persons defined in DIN VDE 0105. and operating conditions (see the documentation supplied. e. maintenance and inspection. In particular. and properties of the system. experience) or understanding of the relevant standards.g.Safety Instructions 1 Safety Instructions 1. Therefore take the following information into account absolutely to avoid damage: • The legal stipulations and associated technical regulations relevant for the present installation have to be adhered when preparing and carrying out work on the measuring system. IEC 364.

When working on power connections or on live components. the operator must ensure that any failure or malfunction does not lead to damaging or dangerous operating In order to prevent device failure. the specified maintenance actions must be carried out by qualified and experienced service staff in regular intervals. if the system is used for open or closed-loop control purposes).4 Detecting and Preventing Malfunctions Any deviations from normal operation must be regarded as a serious indication of a functional impairment.3. • Switching off equipment does not indirectly cause further malfunctions.3 Preventive Measures for safe Operation If the FLOWSIC150 is used in conjunction with process measurement and control equipment. the operator must ensure that • The maintenance personnel responsible can reach the site immediately. 1. circuit breakers and safety switches • Development of smell or smoke To prevent malfunctions. make sure that the power supply is switched off.3. 1. If necessary. These include: • Significant drift of measured values • Increased power consumption • Increased temperature of system components • Acting fuses.2 Danger from electrical Equipment The FLOWSIC150 measuring system is an item of electrical equipment designed for use in industrial power installations.Safety Instructions 1. FLOWSIC150 CARFLOW · Operating Instructions · 8010815 V 1. which can cause personal injury or damage to the system either directly or indirectly. and at any time. • The defective equipment can be switched off immediately if necessary.2 · © SICK MAIHAK GmbH Germany 7 .3. • The maintenance personnel is sufficiently qualified to respond to malfunctions on the FLOWSIC150 and any resulting malfunctions (for example. replace shock protection measures before reconnecting the power supply.

2 · © SICK MAIHAK GmbH Germany .Safety Instructions 8 FLOWSIC150 CARFLOW · Operating Instructions · 8010815 V 1.

Part Numbers .FLOWSIC150 CARFLOW Exhaust Gas Flow Meter Product Description System Features System Design Measuring Principle Flow Measurement Elements for Display. Operation and Communication Self-diagnosis Technical Data Dimensions.

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quick-release connector 2 ½") • Compact design. 2.2 · © SICK MAIHAK GmbH Germany 11 .g. mobile system • Integrated heating unit prevents gas condensation if ambient conditions change • Diagnostic functions for system check • No moving parts.1 System Features The FLOWSIC150 CARFLOW measuring system is designed for contactless measurements of gas velocity. 3 or 4 measuring paths and digital measured-value processing → high accuracy also at low gas velocities • Measurement of undiluted raw exhaust gas allows simultaneous gas analysis of lowest concentrations of pollutants • Practically no loss of pressure. Display and operation elements Main switch Control cabinet Connections Inlet pipe with flow straightener and protective insulation Connection for gas inlet Lockable roller Fig. minimum wear-and-tear FLOWSIC150 CARFLOW · Operating Instructions · 8010815 V 1. temperature and gas composition • Determination and output of standardized volume flow values by simultaneous measuring of exhaust gas temperature and pressure at the installation location • High rate of response → direct and "real time“ assignment of emissions • 1.1: FLOWSIC150 CARFLOW Features and advantages • Direct measurement of the gas velocity independent on pressure. pressure and temperature in exhaust gas pipes of motor and roll test stands in automotive industry. no influence on engine characteristics • Simple installation to the exhaust gas pipe by means of selectable connection elements (e.Product Description 2 Product Description 2. These measured variables are used to determine and output the volumetric flow rate normalized on pressure and temperature.

The measuring signals are read into the evaluation electronics synchronously with each flow measurement.g. If the temperature inside the cabinet falls below a minimum.Product Description 2. The test cell contains the ultrasonic transducers for the gas velocity mesurement (details see Section 2. The gas inlet module contains a flow straightener to reduce the influence of flow disturbances on the measurement accuracy while ensuring the pressure drop to be minimal. 3 Heater (Exhaust gas pipe) Ultrasonic transducer Fig. The gas is then heated to avoid condensate formation. The pressure tapping connection is connected via a hose to the pressure sensor in the evaluation electronics. The self-control function of the PTC-resistor ensures that a defined surface temperature is not exceeded (default setting: 105 °C).2: FLOWSIC150 CARFLOW system design. 3 paths version 2 ½“ The following temperature and pressure measurement delivers the values to calculate normalized volumetric flow rates. A PT100 temperature sensor delivering the control signal for the heater regulator is installed next to the test cell.3) as a basis for the volumetric flow calculation. A second heater regulator allows to connect an additional hose heating (not scope of supply). The temperature signal is collected by an thermocouple amplifier with cold junction compensation and then digitalised.. 400 °C PTC = Positive Temperature Coefficient 12 The gas temperature is measured by a jacket-type thermocouple element (Ni-CrNi)..2 · © SICK MAIHAK GmbH Germany .. the heater is turned on by a thermostat (default minimum temperature 15 °C). FLOWSIC150 CARFLOW · Operating Instructions · 8010815 V 1. This requires an external Pt100 temperature sensor for the control. To avoid condensate formations at the control electronics after measurements at very low ambient temperatures (e. Display and operation elements Heater regulator (Watlow) Heater for control cabinet Analog output 4.20 mA Control and evaluation electronics Control cabinet p Connection for gas outlet T Heater regulator (Watlow) v external Heater Power supply Normalized volume flow Flow straightener Connection for gas inlet Pt100 Exhaust gas (Exhaust gas pipe) Path 2 Test cell Path 1. The measuring range is 660 mbar to 1100 mbar (absolute). 2. Diameter 1 mm Calibrated measuring range 0 . A PTC-resistor is used as the heating element. climate test) and following warming. a heater is installed in the control cabinet..2 System Design The FLOWSIC 150 CARFLOW is installed in the exhaust gas pipe of the engine test stand using selectable connection elements.

Note The measuring precision specified in section 2. an alternating current is applied to the piezoceramic element so that it vibrates mechanically (piezoelectric effect). It is equipped with at least a couple of identical ultrasonic transducers. They are then converted into an electrical signal by the inverse piezoelectric effect and used for further signal analysis. FLOWSIC150 CARFLOW · Operating Instructions · 8010815 V 1.3 Measuring Principle Flow Measurement The FLOWSIC150 operates by measuring the propagation delay of an ultrasonic pulse. With no gas flowing. To transmit signals. The transducer pairs are integrated in the test cell and arranged opposite one another at a defined angle to the flow axis. The ultrasonic pulses cross the measuring pipe from transducer to transducer. while the pulse flowing against the flow is slower. 3 paths version 2 ½“ The FLOWSIC150 can be delivered with 1. A 3 paths version is designed with crossing paths.2 · © SICK MAIHAK GmbH Germany 13 . 4 path versions have all measuring paths in the same level.Product Description 2. The vibrations are propagated as acoustic waves in the gas and strike the diaphragm on the opposite transducer after a propagation time that depends on the sound and gas velocity. Each transducer is a piezoceramic element that is coupled with a diaphragm. This means that the transit time is shorter in the direction of flow (tAB) and longer against the direction of flow (tBA). The signals are then processed to calculate the transit times of the acoustic signals through the flowing medium. In this case a second flow straightener can be required. 2. the pulse in the direction of the gas flow is faster. When a gas is flowing through the test cell. The number of measurements per second depends on the path number (1 path: 80. The calibration under differing conditions and under use of other connections is possible on request. Ultrasonic transducer A Test cell Ultrasonic transducer B Measuring pipe Path 1 Path 2 Path 3 Fig. 2. The ultrasonic transducers operate alternately as a transmitter and receiver. The waves are transferred to the piezoceramic element in the form of mechanical vibrations.6 applies to a device with integrated flow straightener that is calibrated by the manufacturer with undisturbed inlet section with a homogeneous flow profile and under use of the SICK MAIHAK standard couplings. thereby forming a direct measuring path (see Fig. The measured values can then be calculated from the transit time thus determined.3: Measuring principle. 3 paths: 3x30. the pulses are propagated with the same velocity (velocity of sound) in both directions. These vibrations are then transferred through the diaphragm to the gas. 4 paths: 4x30 measurements).3). 3 or 4 measuring path(s).

i.S.3. 2. This theoretical velocity of sound and the measured velocity of sound should be identical. c= L 1 1 • + 2 tAB tBA ( ) (6) A theoretical velocity of sound can be derived from the gas composition. differences in the flow profile can be better taken into account. pressure and temperature information.S.3. although with a slightly lower accuracy.S.e. 14 FLOWSIC150 CARFLOW · Operating Instructions · 8010815 V 1. = vA • A = vA • D² • π 4 (5) The volumetric flow in normalized state QN. N: Number of measuring paths vA: Mean flow velocity in the cross-section 1 vA = wi: Weighting factor of a measuring path N N Σw i • vPfad i (4) i=1 If the measurement fails in one measuring path.S. Determining the Velocity of Sound The actual velocity of sound c in the gas is calculated from the sum of the two measured transit times tAB and tBA of a path. the gas velocity can be determined more precisely.1 Determining the Gas Velocity To the transit time of the sound in flow direction applies: L: Measuring path length c: Velocity of sound vPath: Path velocity α: tAB = L (1) c + vPath • cos α Sound transit time against the direction of flow tBA: Angle between the longitudinal axis of the test cell and the path tBA = L (2) c . T: Pressure and temperature in operating state 2. The mean flow velocity in the cross-section vA is then calculated by averaging of the weighted individual paths. T0: Pressure and temperature in normalized state p.2 Calculating the Volumetric Flow The volumetric flow in operating state is calculated from the determined flow velocity and the cross-sectional area in the measuring pipe: A: Cross-sectional area in the measuring pipe QO.: Volumetric flow in operating state p0.Product Description 2. The velocity of sound thus provides an excellent possibility of system diagnosis.3 QO. is calculated from the volumetric flow in operating state and the currently measured values for pressure and temperature in the measuring pipe: QN.S. the flow velocity in the cross-section can still be calculated without any changes in the measuring arrangement. This is possible because a replacement value is calculated for the faulty measuring path.2 · © SICK MAIHAK GmbH Germany .3.vPath • cos α The path velocity (vPath) is calculated from the difference between the two transit times: vPath = L 2 • cos α • ( t1 AB 1 tBA ) (3) If several measuring paths are arranged across the flow profile. = p • p0 T0 T • QO.

4 Compensating Path Failure Path failure is compensated using the ratio of the measuring path flow velocities to each other. FLOWSIC150 CARFLOW · Operating Instructions · 8010815 V 1. N bi: Status bit for path i bi = O: Path inactive bi = 1: Path active Σ vA = bi • w i • i=1 vPfad i PPfad i (8) N Σb i• wi i=1 The system signals the compensation of a path error with the "Check requested" signal. Adaptive compensation of one or more path failures Failures of more paths are compensated accordingly The self-diagnosis function implemented in the meter (see Section 2. this path is excluded from the calculation of the mean area velocity vA (equation 8). These mainly depend on the complexity of the flow profiles and the flow rate. An additional measurement uncertainty of less than ± 0. When this occurs. This improves the result of the compensation because the path ratios are more stable with higher flow rates. In addition to the adaptive calculation of the path ratios. vPath (7) PPath = vA These ratios are used for an adaptive mean value calculation for each individual path. default path ratios are used for compensation.3.8 m/s) and high flow rates.Product Description 2. Static compensation of one or more path failures If no statistically stable path ratio values are present when a path fails. This suppresses statistical fluctuations caused by turbulence without slowing down the process of adapting to new flow profile situations.5) can reliably filter out implausible results.5 % should be expected for 4 path systems when operating in this mode. the individual path ratios PPath are calculated continuously. Operating principle During normal operation. If the ratio between accepted and rejected measurements for a measuring path exceeds the permitted threshold. the following formula is used to calculate the average area velocity from the applicable measured values for the remaining paths and the stored adapted path ratios. the system differentiates between low (1 . The path ratios are not adjusted below 1 m/s.2 · © SICK MAIHAK GmbH Germany 15 .

At multi path systems. Malfunction This LED is activated when faults occur that prevent the system from measuring accurately. press the ↵ key.Product Description 2. fault-free system operation. FLOWSIC150 CARFLOW · Operating Instructions · 8010815 V 1. To choose the option currently displayed. the system returns to "Measurement" mode automatically. The analog output is updated periodically. Lamps green Normal.4 Elements for Display.the key for longer than >1 s). 2. If the cause for the fault ceases to exist. LED LCD Control keys Main switch Signalisation for status „Malfunction“ Signalisation for status „Operation“ Reglulator for external hose heating RS 232 interface Regulator for heating the measuring pipe Fig. The failure is compensated by the FLOWSIC150 with a slightly lower accuracy.4: Top side of the control cabinet Indication Type LC Display Display of 1st line Gas temperature at the measuring location (Ni-CrNi temperature sensor) Absolut pressure at the measuring Normalized volumetric flow Display of „AK Qn“ if AK mode is set LED 2nd line Status messages Operation Normal. red Faulty device operation or system is heated up Control keys Functions AK = Study group • Selecting a measuring variable • Switching in AK mode (special RS232 interface protocol for tomotive industry) • Activating maintenance mode 16 Remark You can display all of the options available by pressing the SET key (the display scrolls automatically if you press au.2 · © SICK MAIHAK GmbH Germany . fault-free system operation. this LED signalises that maintenance is needed because one of the measuring path has failed. Operation and Communication The elements for displaying measuring values and system status and as well as for the operation and communication are placed on the top side of the control cabinet. Maintenance Device is in maintenance mode.

20 mA External Heater 1 + − 3 4 6 7 Analog output 0/2/4. Heater regulator For details on modifying the settings refer to the separate document („WATLOW User’s Manual“) Note • Regulator for measuring pipe heater This regulator controls in connection with the Pt100 sensor the heating of the exhaust gas before it enters in the test cell to avoid condensation. • Regulator for external hose heating This regulator controls an external hose heating to be connected to the socket „External Heater“ (see Fig. The "Alarm high" threshold also affects the switching output. 3. 2. the regulator signals the status "Heater temperature < 80 °C" via the switching output. Therefore this threshold should be set to a value outside of the plausible gas temperature range (default setting 500 °C if not specified otherwise by the customer). The measures for the connection of the hose heating and the regulators settings are described in Chapt. Connections Analog output 0 ..2 · © SICK MAIHAK GmbH Germany 17 ..Product Description RS232 interface This interface can be used for connecting a PC/Notebook with installed MEPA CARFLOW program (Menu-operated Parameterisation CARFLOW) via standard serial interface cable for system configuration.20 mA for output of the normalized volumetric flow (BNC socket) Power 2 1 2 4 3 5 Socket for connection of an external hose heating Plug for connection mains voltage 115/230 V AC Fig.. If the temperature drops below the threshold „Alarm low“ (default setting 80 °C). The default set-point temperature is 130 °C. logging of measured data and system diagnosis. 2.5: FLOWSIC150 connections FLOWSIC150 CARFLOW · Operating Instructions · 8010815 V 1..5).

Additional signal and system diagnosis functions monitor the accuracy of the measured values. sources of noise near the measuring location. take into account plausible conditions for normal operation (in particular temperature stratification). < 93 dB Warning AGC Limit The absolute value of the reception gain is monitored. you can adjust the signalling threshold values to suit individual application requirements. If these parameters deviate from a preset range. the ratios of sound and path velocities. This enables immediate measures to be taken to prevent possible system malfunctions.Product Description 2. 18 FLOWSIC150 CARFLOW · Operating Instructions · 8010815 V 1. when the pressure doubles. valves that are not fully open. During commissioning or operation. Reasons for this include interference noise caused by fittings in the pipeline. that is. so that temperature stratification is disregarded at very low flow velocities. Signal-to-noise ratio < 13 dB Warning SNR This alarm is activated when the signal-to-noise ratio is too small. this can indicate a malfunction in the ultrasonic transducers. a warning signal is generated. and signal-to-noise ratios are continuously monitored. This enables you to create the most effective status warning system. Used to indicate whether or not the path is measuring the correct propagation time. Important High flow rates can also increase the difference in gain. The current flow velocity is used as a weighting factor. Reception gain < 6 dB Warning AGC Deviation The absolute difference between both path gain factors is evaluated and must remain below the threshold value. If one of the alarms is triggered by a path. Important The current receiving sensitivity largely depends on the current process pressure (inversely proportional in initial approximation. probe cables or parameter settings (signal models. by checking the plausibility of the ultrasonic signals received and the ultrasound signal propagation times calculated from them.5 Self-diagnosis In the measurement mode.2 · © SICK MAIHAK GmbH Germany . the required receiving sensitivity is halved). Note When setting the parameters. Note The "Warning" status signal does not affect the device function. electronics. Parameter Default threshold value Warning message Notes Velocity of sound < 5 m/s Warning SOS Deviation This message is produced when the current measured path velocity of sound deviates from the mean value of the mean velocities of sound calculated for all the paths by more than the specified threshold value. standard threshold values). or defective ultrasonic transducers. amplification settings.

. 2. from 0.3) ** Other dimensions on request FLOWSIC150 CARFLOW · Operating Instructions · 8010815 V 1. Ni-CrNi.. 1..1 Qmax to Qmax Measuring range actual volumetric flow Typical measuring uncertainty * Temperature measurement Pressure measurement (absolute) Displays 2-row LCD LED Installation Gas temperature Transducer temperature Inlet and outlet pipe thread ** Pressure drop by the integrated flow straightener 3 measuring paths < ± 0.5 mbar at 50 l/s approx. volumetric flow (normalized). measuring range 0 .45 mbar at 20 l/s approx. 260V AC. 1100 mbar For measured variables. 140 V AC..Product Description 2... 5. 0.6 Technical Data Measured value acquisition Measured variables Gas velocity. 5.. malfunction. 50/60Hz 695 W 2½“ 1095 W 4“ 600 W 2½“ 1000 W 4“ 1.5 % of the measured value. gas temperature..4 mbar at 150 l/s 0/2/4. load 760 Ohm.05 Qmax to Qmax 4 measuring paths < ± 0.2 · © SICK MAIHAK GmbH Germany 19 . update rate 10/s. maintenance max. from 0.. max.50 mbar at 70 l/s approx.. total stress maximum 100 cycles G 2½" G 4“ approx.. warnings and error messages For operation. mass W x H x D (in mm) Mass 90 .05 Qmax to Qmax Jacket-type thermocouple element.. 300 °C max. "K" type. absolute pressure Pipe size 2½" 1 measuring path 0 ..6 kW (230 V AC) for 2½“ und 4“ 0. 0. +50 °C IP 65 900 x 630 x 380 approx. volumetric flow (actual).8 kW (115 V AC) without external hose heating –20 ... 50/60Hz or 190 . 280 °C 1 measuring path 3 measuring paths 4 measuring paths 1 measuring path 3 measuring paths 4 measuring paths Output of measured values Analog output RS232 (Modbus/AK) Interfaces RS232 Power supply Operating voltage Power consumption < 10 min per 1 h.2 mbar at 100 l/s approx.5 % of the measured value. from 0. 150 l/s 3 measuring paths Pipe size 4" 4 measuring paths 0 .. 20 mA. scaling freely programmable 10/s (in burst mode) For configuration via PC using the MEPA CARFLOW program Heating capacity measuring system Maximum switchable heating capacity for external hose heating Ambient conditions Temperature range Class of protection Dimensions.40 mbar at 35 l/s approx. 400 °C Measuring range 660 .7 % of the measured value. 80 kg (with flow straightener) * tested at ambient air conditions (see note in Section 2. 300 l/s 1 measuring path < ± 2.

5Z XT 0H 3 measuring paths. L 600 380 A H D 630 B Type FLOWSIC150 FL150 1P1 2.0Z XT 0H 4 measuring paths. 2.2 · © SICK MAIHAK GmbH Germany . Part Numbers All dimensions are indicated in mm.6: FLOWSIC150 dimensions 20 FLOWSIC150 CARFLOW · Operating Instructions · 8010815 V 1. L A B D H 900 250 200 2 ½" 300 765 125 65 4" 260 7041982 7041984 1026307 Fig.7 Dimensions.5Z XT 0H 1 measuring path. connection thread 2 ½" FL150 4P1 4. connection thread 4" Part no. connection thread 2 ½" FL150 3P2 2.Product Description 2.

FLOWSIC150 CARFLOW Exhaust Gas Flow Meter Installation .

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Installation

3

Installation
Warning
• All installation work must be carried out in line with the relevant safety regulations and instructions listed in Chapter 1.
GEFAHR

• The measuring system should be installed in the exhaust gas pipe only when the plant is
shut down!
• Take suitable measures to protect against local or installation-specific hazards!

Activities
‡ Install the Flowsic150 in the exhaust gas pipe by connecting the respective connection
elements to the gas inlet and outlet of the measuring pipe (standard: 2 ½" for 1 and 3
path version, 4“ for 4 path version).
‡ Check the assignment of the plug bridges to the terminals 15 to 26 in the control cabinet
under consideration of the existing supply voltage according to Fig. 3.2 and correct if necessary.
‡ To protect the integrated heating units, the terminals are equipped with exchangeable
fuses (see Fig. 3.2). This prevents a damage of heating units at incorrect power connection. In case of faults destroyed fuses have to be replaced against new ones.
fuse type:
current value:

fine-wire fuse 5x20 mm, SuperFlink, 250 V AC
see tab. 3.1

Terminal / Heater module

FL150 1-path, 3-path (2,5“)

FL150 4-path (4“)

15, 18 / pipe heating

FF 1,25 A

FF 3 A (3,15 A)

21, 24 / meter body heating

FF 2 A

FF 2 A

Tab. 3.1: current values

FLOWSIC150 CARFLOW · Operating Instructions · 8010815 V 1.2 · © SICK MAIHAK GmbH Germany

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Installation

exchangeable
fuses

Assignment of the plug bridges
Supply voltage 115 V AC
Supply voltage 230 V AC

(6 pcs. 1 to 4)

(2 pcs. 1 to 6, 2 pcs. 1 to 3)

Fig. 3.2: Assignment of the plug bridges for supply voltage in the FLOWSIC150 control cabinet

‡ Connect the power cable (scope of supply) with a power supply 115 / 230 V AC and the
socket „Power“ at the FLOWSIC150 (see Fig. 3.3).
‡ Connect the analog output (socket „Analog output“) via coaxial cable with BNC plug (see
Fig. 3.3).
Connections

Analog output
0 ... 20 mA

+

External
Heater

1

Power

2
3
4

6
7

1

2

4

3

5

Fig. 3.3: FLOWSIC150 connections
Terminal

1

2

3

4

„External Heater“ socket assignment

L

N

-

-

„Power“ plug assignment

L

-

N

PE

5

6

Pt100

7
PE

Connecting an external hose heater
‡ Connect a cable with a suitable plug to the „External Heater“ socket (for terminal assignment see Fig. 3.3 and connection table).

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FLOWSIC150 CARFLOW · Operating Instructions · 8010815 V 1.2 · © SICK MAIHAK GmbH Germany

Installation

Attention
The cable may only be made by an authorized expert!
ACHTUNG

‡ Connect the terminals 13 and 14 in the control cabinet using the enclosed jumper (see
Fig. 3.4).

Jumper

Fig. 3.4: Jumper for connection of an external hose heater

‡ Configure the heater regulator according to the attached instruction (WATLOW User's
Manual).
Note

If the jumper is set, but the external hose heater not connected, the display of this heater
regulator shows the message „Er 4“ when the FLOWSIC150 is switched on. This only means
that no thermocouple element is connected to the regulator. The normal system function is
ensured.

FLOWSIC150 CARFLOW · Operating Instructions · 8010815 V 1.2 · © SICK MAIHAK GmbH Germany

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2 · © SICK MAIHAK GmbH Germany .Installation 26 FLOWSIC150 CARFLOW · Operating Instructions · 8010815 V 1.

FLOWSIC150 CARFLOW Exhaust Gas Flow Meter Commissioning and Parameterization Basics Parameterization MEPA-CARFLOW Program .

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In certain cases (e. Password protection Access level "Operator".3). see Section 4. Other functions (such as data backup and graphical display functions) are also available (see Section 4. The MEPA CARFLOW program is supplied with the device for configuring the system parameters. if the device is not deployed in line with the specifications set out in the technical data) are accessible only after entering a password.1. disturbed flow profile in the inlet section) an additional calibration can be required after installation of the system (Section 4.1 Basics 4..g.2. The existing program menus allow an easy configuration of the required settings. Access level „Service“.2 Prerequisites • Laptop/PC with: – – – – – Processor: Pentium 2 or higher VGA graphics card Serial interface COM 1 or COM 2 Main memory (RAM): minimum 32 MB Operating system: Microsoft Windows 95 or higher • Interface cable (serial cable for connecting a laptop/PC to the FLOWSIC150 (connection at the RS232 interface).g. FLOWSIC150 CARFLOW · Operating Instructions · 8010815 V 1.1.2 · © SICK MAIHAK GmbH Germany 29 . 4.1. 4.4 All program components and device parameters required for standard commissioning and system use are accessible without password.2.Commissioning and Parameterization 4 Commissioning and Parameterization 4. for password contact SICK MAIHAK Device internal parameters which have to be changed if necessary for the adaption of the FLOWSIC150 to plant-specific conditions (e.1 General Notes Commissioning essentially entails entering the base parameters and configuring the analog output (Section.1). Pin assignment FLOWSIC 150 socket PC connector 9 pole Pin 2 (txd) Pin 2 (rxd) Pin 3 (rxd) Pin 3 (txd) Pin 5 (gnd) Pin 5 (gnd) • The FLOWSIC150 must be connected to the power supply.2). Changes only may be carried out by sufficiently qualified persons.

3.3 Preparations ‡ Install the MEPA CARFLOW operating and parameterization program: – Insert the CD – Choose the CD drive – Start "MEPA-CARFLOW_SETUP.3 Basic Settings Before you configure the parameters. carry out the steps listed in the table below (if applicable).exe” and follow the instructions ‡ Connect the interface cable with socket from the front panel on the control cabinet to the RS232 port on the laptop/PC.the active parameter set of the device is downloaded to the MEPA CARFLOW program Set the language "Options / Language” For using the MEPA CARFLOW Generate a new session file (recommended) "File / New session" To store all device settings and operating actions.1. see Section 4.g.exe”.1.2 · © SICK MAIHAK GmbH Germany .Commissioning and Parameterization 4.4 FLOWSIC150 CARFLOW · Operating Instructions · 8010815 V 1. 4. The menu "Connect to" occurs. COM 1) in the "Connect to” menu Connect to the FLOWSIC150 30 Click on "Connection” to confirm .4 Program details are described in Section 4. Step Menu Notes/ action Choose the port on the PC "Connect to” Choose the port (e. ‡ Change to the installation directory and start "MepaCarFlow.

We recommend to check the take-over of the values into the device by pressing the button "Read register". press the button "Write register".Commissioning and Parameterization 4. activate "Configuration" in the menu "Operation mode".2.1: "Device parameter" tab page (password level "Operator") After selecting the respective parameter (click on subdirectory in the "Parameters" window) enter the required value in "Parameter editor" windows. After selecting the ""Device parameter" tab page the following picture appears. 1013.3 0 hPa 20 SI standard 20 US standard FLOWSIC150 CARFLOW · Operating Instructions · 8010815 V 1. After entering of the parameters these must be transferred to the FLOWSIC150. 4. "Register value" box.3 To set the parameters described below. To do this.2 · © SICK MAIHAK GmbH Germany 31 . "Operating Mode" menu Adjustable parameters in the password level "Operator" Fig. 4. Pressure Norm.2 Parameterization Program details are described in Section 4.1 Directory "Meter Setup" Setting Basic Parameters and Analog Output Basic parameters Parameter Meaning LCD Display Norm. Temperature Set value Assignment Setting/change of the language at the LCD on the top side of the control cabinet 0 German 1 English Reference value for device-internal normalisation of the volumetric flow.

. 4. 3. To do it. 20 mA.AO RangeLow The parameter "AO Test" serves to check the correct function of the analog output. analog output settings Parameter Meaning AO Live Zero Value for Live Zero (LZ) Set value Assignment 0 0 mA 2 2 mA 4 4 mA AO RangeLow Lower measuring range limit (corresponds to Live Zero) x x l/s AO RangeHigh Upper measuring range limit (corresponds to 20 mA) x x l/s AO Maintenance Output value for operating mode "Configuration" 0 0 mA 1 LZ 2 Current measuring value (MV) 3 Span (test value) The current at the analog output is calculated as follows: Iout = LZ + (MV . the measuring range as well as the output value in the "Configuration" mode and in case of errors have to be adjusted in the "Device parameter" tab page for the exact assignment of the measuring value to the output value (see Fig.2: "Device parameter" tab page.AO RangeLow) • 20 mA .3) provides the measuring value for the volumetric flow (normalized with pressure and temperature) as an analog signal 0 . The zero point. Fig. see Fig.2 · © SICK MAIHAK GmbH Germany . enter a value between 0 and 20 mA in the "Register value" box and transfer it into the 32 FLOWSIC150 CARFLOW · Operating Instructions · 8010815 V 1.LZ AO RangeHigh ..2 and the following table).Commissioning and Parameterization Analog output The analog output (BNC socket. 4.

Malfunctions are signaled at the analog output with 20mA (see section 6. No further calibration is usually required after the installation. FLOWSIC150 CARFLOW · Operating Instructions · 8010815 V 1. enter the values for cc0. Then check the value at the analog output with a multimeter. QN_corr = cc2 • QN_ncorr2 + cc1 • QN_ncorr + cc0 QN_corr QN_ncorr cc2 cc1 cc0 = = = = = normalized volumetric flow corrected normalized volumetric flow not corrected square calibration coefficient linear calibration coefficient absolute calibration coefficient To set the calibration coefficients select the respective directory. The characteristic generated with this procedure is stored in the device. signal transit time measurements and the determination of other system-specific parameters. however.2.g. Under certain circumstances (e. to re-calibrate the measuring system in the specific installation situation by a comparison measurement with a reference measuring system. an additional comparison measurement is carried out with standards. 4.2 Calibration The FLOWSIC150 is delivered in a pre-calibrated condition.2 · © SICK MAIHAK GmbH Germany 33 .2.3 Starting Standard Measuring Mode Standard measuring mode is started when you switch to "Measure mode" ("Operating mode / Measure mode" menu). Directory Assignment NFlowrate CC0 cc0 NFlowrate CC1 cc1 NFlowrate CC2 cc2 The manufacturer settings are cc 0 = 0. Set and output value must be the same if the device works correctly. at unfavorable installation conditions) it can be required. zero point test. This calibration includes a geometric survey of the meter body. cc1 and cc2 in the "Register value" boxes and apply your setting by clicking on "Write register". cc 2 = 0. 4.Commissioning and Parameterization FLOWSIC150 (click on button "Write register"). The calibration coefficiants determined in this way have to be entered in the 2nd order calibration function implemented in the FLOWSIC150. To achieve the highest possible precision. cc 1 = 1.3).

e. dialog area and status bar (see Fig. In the password level "Operator" provided for the normal system use some functions and displays are hidden. distinguished into signal and value recording FLA Terminal Opens a box for entering terminal commands Version MEPA-CARFLOW program version Help F1 Online help FLOWSIC150 CARFLOW · Operating Instructions · 8010815 V 1.4) Operating mode • Configuration • Measure mode Changes the FLOWSIC150 operational mode Monitors System status Indicates the current system status % Errors Displays the error rates in all paths SNR Displays the signal-to-noise ratio in all paths AGC levels Displays the gain in all paths Velocity of sound Displays the velocity of sound in all paths Relation of velocity of sound Relative variation of the sound velocity among the individual paths Options Help 34 Velocity of gas Displays the velocity of gas in all paths Trend set-up Opens a dialog box to change the trend representation on the "Log/ trend” tab (colours.2 · © SICK MAIHAK GmbH Germany . Depending on the selected password level. The control elements used. The displays and functions available in the password level "Operator" are more fully explained in the following sections more. All functions are only accessible in the password level "Service" (description see service manual). are designed to correspond with generally used Windows elements.∼SF”) Open session Opens an existing session file Save session Saves the current session file Save session as… Saves the current session under a new name Diagnosis session Starts a diagnosis session Session history Opens the "Session history” dialog box and displays scanned session contents Upload configuration Starts transmission of a configuration to the FLOWSIC150 Printer selection Opens the printer selection menu Exit Terminates the program after a confirmation dialog Connection Connection Opens the "Connect to” dialog box (see Section 4.3.3 MEPA-CARFLOW Program The MEPA-CARFLOW operating program was developed as an application software based on Microsoft Windows• . 4.1.1 Program Interface Menu bar Menu Item Description File New session Opens a new session file ("DEFAULT.3). i.X axis) Language Opens a dialog box to select the interface language Colour adjustment Opens a dialog box to select a global colour pattern Diagnosis setup Opens a dialog box to select the time slot for data recording in a diagnosis session. different displays and settings are available. tool bar (icons). 4. dialog boxes. time slot . buttons.Commissioning and Parameterization 4. The program interface is generally divided into five parts: menu bar. menu bars. tabs.

display and input of all parameters for meter setup. analog outputs (see Fig.4.Commissioning and Parameterization Tool bar The tool bar contains major functions which shall be activated quickly and simply.3) Device parameters Display of device identification parameters. calibration.2 · © SICK MAIHAK GmbH Germany 35 . Open a new session Open an existing session Save current session Create a diagnosis session Upload an external configuration file History information of current session and editing Connect to device or change to offline mode Switch device to configuration mode Switch device to measurement mode Open logged data Find record… Stop logging Start logging Play log Pause Go to first record Go to previous record (hold mouse button down to scroll) Go to next record (hold mouse button down to scroll) Go to last record Enable signal sound Tabs Tab Content Measuring values Display of currently measured values and status information (see Fig.1) Log/ trend Dialog for collecting measured values. menu to select measured values for logging FLOWSIC150 CARFLOW · Operating Instructions · 8010815 V 1.4.

minimum and maximum Fig. temperature. The display depends on the password level. If you place the cursor in the graphic fields for flow rate.2 · © SICK MAIHAK GmbH Germany . temperature or pressure(right part of the dialog area) you can read the mean value as well as maximum and minimum value of these measured values. values Normalized flow rate Actual flow rate Gas temperature Pressure in the measuring pipe Average velocity of sound Average gas velocity Status code (detailed information by clicking on the respective field) Display of malfunctions and warnings (description see Section 6.2 Menu Description "Measured values" tab This tab shows the measured values as well as information to the system status (see Fig. 4. 4. pressure. velocity of sound and gas velocity. 36 FLOWSIC150 CARFLOW · Operating Instructions · 8010815 V 1.Commissioning and Parameterization 4. Menu bar Tool bar Tabs current meas.3) Status bar temporal course of the measured values with display of average.3.3).3: "Measured values" tab (Password level "Operator") The "Measure values (FLA)" field shows the current values of normalized and actual flow rate.2 and 6.

4. 2.4).2. parameter Description Meter Setup LCD Display Setting of the language at the LCD Norm. The following table shows the parameters adjustable in the "Operator" password level. Temperature Calibration Analog Output NFlowrate CC0 absolute calibration coefficient NFlowrate CC1 linear calibration coefficient NFlowrate CC2 square calibration coefficient AO Maintenance Output value for operating mode "Configuration" AO RangeLow Lower measuring range limit (corresponds to Live Zero) AO RangeHigh Upper measuring range limit (corresponds to 20 mA) AO Test Test value to check the analog output AO Life Zero Value for Live Zero (0. These measuring data are read out from the FLOWSIC150 by the operating program and saved in a session file.3. These data can be exported from the session file into a structured ASCII file by selecting the item "Session history” from the "File” menu (see Section 4. Parameter modifications are saved in the current session and in the FLOWSIC150 logbook (session concept see Section 4.3. Fig.4 Session history). Group of parameters. 4 mA) "Log/ trend" tab This tab allows to log device-internal measuring data.1 This tab provides the possibility to change device parameters.4: "Log/ trend" tab FLOWSIC150 CARFLOW · Operating Instructions · 8010815 V 1.2 · © SICK MAIHAK GmbH Germany 37 . Pressure Reference values for pressure und temperature Norm. The FLOWSIC150 must be set to the configuration mode to be able to modify parameters.Commissioning and Parameterization Device parameters” tab see Section 4.

4. The data can be logged in different ways: Logging rate e. You can select the data to be logged by clicking on the "Add" or "Remove" button (see Fig.5). The data is now shown in the table or diagram (see Fig.6). Removing with "Remove" button (or double-click on the entry) Selection with "Add" button (or double-click on the entry) Fig. 4. Use the "Trend" / "Log table" button to switch between the two display modes.5: Configuring the variables to be displayed (selected entries form an example) Fig. 4.6: Display of the selected data 38 FLOWSIC150 CARFLOW · Operating Instructions · 8010815 V 1. Confirm your settings with "OK”. once in 2 s • Automatic mode The data are logged with low speed (provided by the measuring system).Commissioning and Parameterization The inquired data can be displayed in a table or trend diagram.2 · © SICK MAIHAK GmbH Germany . 4.g.

10 times per s.7: Burst mode The logging rate can be selected manually in the box "Storing intervals" by clicking on the "Start" button in the Tool bar instead of the button "Burst mode start!". see Fig.8: Possibilities for logging in the burst mode FLOWSIC150 CARFLOW · Operating Instructions · 8010815 V 1. 4. The maximum possible logging rate is set automatically if you click on the button "Burst mode start!" (approx. displayed in the status bar.8).5) and not excluded by the log are recorded. Sampling rate Fig.Commissioning and Parameterization • Burst mode The data are logged with fundamentally higher speed. No choice for logging All data listed in the box "Available registers" (see Fig. 4. 4.2 · © SICK MAIHAK GmbH Germany 39 . Selectable storing intervals Fig. 4.

Click on the "Stop logging” icon to stop data logging. Data logging To log the data content of a tab.9.3.3 Data recorder A data recorder was integrated into the MEPA-CARFLOW operating program. Note: Do not change to another tab while data are being logged. The data sets recorded with that are stored into the session file and can be analyzed afterwards into two variants. 4. 4. 4.2 · © SICK MAIHAK GmbH Germany . Replaying tab contents All logged data records of the current session will be saved in a session file. 4.9: Icons of the data recorder The recorder functions can be used for all tabs. Open logging Play logging Start logging Stop logging Fig. call up the tab and click on the "Start logging” icon (red circle). a dialog box will appear in which all logs of the session are listed (see Fig. 1.10). otherwise the data of the new tab will be recorded (the tab cannot be changed in the burst mode). They are formed by analogy with generally usual pictographs for these functions. If you click on the "Open log data" icon in the tool bar. 2. Account of the tab contents in the operating interface. 40 FLOWSIC150 CARFLOW · Operating Instructions · 8010815 V 1. The saving of the individual data records is indicated in the status bar of the program. Export into a structured ASCII file using the storing function of the menu "File / Session history" .Commissioning and Parameterization The selected data will be saved in the session file only after clicking on the "Start" button in the tool bar (see the following Section). The functions of this recorder are controlled by the buttons as shown in Fig.

previous. velocity of sound. the tool bar provides icons to start the first. FLOWSIC150 CARFLOW · Operating Instructions · 8010815 V 1.2 · © SICK MAIHAK GmbH Germany 41 .g.11: "Replay log” activity bar This activity bar allows you to navigate the data log. so that you can analyse major diagnosis data at the same time (e. In addition.1). all monitors in the "Monitors” menu can be activated while you play a log.Commissioning and Parameterization Fig. The control program will change to the corresponding tab and shows an activity bar to control the replay functions. In addition. These data can be exported into an ASCII export file by selecting the item "Session history” from the "File” menu (see page 45). Fig. AGC). so that you can simulate and analyse the device conditions afterwards. 4. next and last record (see Section 4.3. without a direct connection to the device.10: Log selection dialog box Select an entry with the mouse and open it to replay that log. 4. The logged measured values will be visualised in the displays of the tabs when you play the log.

4 Data Collection. terms Function Description Session The term "session” includes controlling. New session This command opens a session and creates a new session file. measuring records). All further activities are stored in this file. It will always be saved in the session history when you open a session. Session file All operations performed on a certain device with the help of MEPA-CARFLOW after a session is opened are saved in this file. If further operations become necessary later. The information is saved in a session file which can be opened and analysed later Session history This menu item is used to monitor the current session and activities contained therein.FSF. monitoring. The correspondence between the open session and connected device is monitored by the software. execute and exit a data logging session. Session files have the extension *. Note If the default session is not stored with a file name.Commissioning and Parameterization 4. data management and data save using the MEPA-CARFLOW program. the program will automatically start.2 · © SICK MAIHAK GmbH Germany . Data Management. If you call up this command. Device management A session opened for a certain device only contains information about this device. Data Save The following sections inform about data collection. the existing session file can be opened again. data collecting and configuration activities of a FLOWSIC150 with the help of the MEPA-CARFLOW program. "File" menu 42 FLOWSIC150 CARFLOW · Operating Instructions · 8010815 V 1. New session files can be generated for further devices. so that you operations and time can be related over the entire installation period of a device. The default session can be stored as a new regular session by the operator. instances of inconsistency will be signalled. Functions. Certain operations performed in a session can also be stored in ASCII files (e. Diagnosis session The diagnosis session aims to save all important information which should be collected during maintenance actions. Long-term data management Sessions can be saved and are thereby closed. All major operations in the program during a session are automatically logged by the software and are available for later offline reading and analysis. The old data are lost in this case.3. Save session as A default session file is generated always after starting the MEPA-CARFLOW program. All further operations will then be in the existing session file.g. she is overwritten completely at the next program start. Open session This command is used to open an existing session file. All operations which are now performed in the MEPA-CARFLOW program will be logged in this session file Save session This command saves the currently open session.

Commissioning and Parameterization Contents of a session file The following operations and information collected in a session are saved in a session file (see also Fig.1. parameter name. Fig. If you use this function with care.2 · © SICK MAIHAK GmbH Germany 43 . Session entry Type of information Corresponding activity Description Current device configuration Parameter set • Automatically when a Contains the current configuration of new session is created • Continuous update the FLOWSIC150 FLASH file Program code Automatically when a new session is created Program code segment of the flash memory EEPROM file Parameter code Automatically when a new session is created Data code segment of the EEPROM memory Parameter modifications Parameters Parameter modifications Entry of the modification of a parameter. as you want to create a new session. The program creates a new default session file and logs the activities listed in the table above during the session. 4. operations etc. old and new value Log/ trend Record Log/ trend Start logging • Collection of the values measured by the FLOWSIC150 • Selection of measured variables for data logging in the "Log/ trend” menu Switching between Event measurement and configuration mode Switching between measurement and configuration mode Logging the operational mode change Opening and closing a session Opening/ closing Each opening and closing of the session file will be logged together with a time stamp. Ask the question whether you wish to open the last session with "No" ("Nein"). of several FLOWSIC150 devices consistently and comprehensibly over the entire life of the devices. Creating a new session ‡ Run the MEPA-CARFLOW program and establish a data connection. Event Session scenario The session concept of the MEPA CARFLOW control program was developed to manage all measured values. Compare Section 4. these data provide information over years on the condition of the device at each point of time you have carried out actions on the device.14). parameters.12: "Open last session" dialog ‡ Select "New session” from the "File” menu or the tool bar.4 1. FLOWSIC150 CARFLOW · Operating Instructions · 8010815 V 1. A sample scenario is illustrated below. 4.

you can exit the program. ‡ Select the measuring variable registers for data logging (see Fig. ‡ Switch to the "Log/ trend” tab.Commissioning and Parameterization ‡ Closing a session.2 · © SICK MAIHAK GmbH Germany .). 4. The session file can be used and managed during the entire life of the device. etc.13: "Rename default session" dialog You have now created an ordinary session file for your session. ‡ Carry out further operations (e. select "Save session" in the "File" menu or "Save current session" in the tool bar. Fig.5). Continuing an existing session If further operations become necessary on the FLOWSIC150 at a later point of time. Fig. record data and stop data logging (see Fig. Carry out the following steps: ‡ Run the MEPA-CARFLOW program and connect to the FLOWSIC150.g. 4. Ask the question whether you want to save the current default session under a new name with "Yes" ("Ja") and enter a session file name.. measuring point no.9). ‡ Start data logging.14: "Log / Trend" tab The logged data are saved in the session file. trend logging). If you do not want to carry out further operations. ‡ Open the associated session file ("File / Open session" menu). they should be performed while the session file generated during commissioning is open. Session files automatically receive the extension *. You may save the EEPROM and FLASH code segment and the current logbook (if any) when saving the session. 4. 4. If you have finished the operating activities. 44 FLOWSIC150 CARFLOW · Operating Instructions · 8010815 V 1. Note See Section Session history and following The name of a session file should be associated with the FLOWSIC150 it relates to (e. 2. serial no. The program title bar now shows the session file name.g. even if it is modified or reinstalled somewhere else.FSF.

Proceed as follows: ‡ Run MEPA-CARFLOW.Commissioning and Parameterization 3. The parameters are automatically saved in the session file. The FLOWSIC150 is updated with the changed information when you connect to the device the next time.2 · © SICK MAIHAK GmbH Germany 45 . data logging events etc. non-conformance of parameters saved in the session file and the information stored in the FLOWSIC150 will be detected automatically. i. You can confirm the validity of the changed parameters saved in the session file and upload them to the measuring system (see also Fig. without a connection to the device (offline). ‡ Modify the parameters as desired. while the program is connected to the device (online) or later. If you want to use the offline option. This allows to set parameters before you connect to the device. Session history Type and scope of logged information are shown in the table on page 43 You can monitor and analyse the history of a session including all operations.15: Dialog "Sitzungsverlauf" Several entries in the session history can be exported and printed. If the changed session file is opened during the next connection. It is necessary to open the associated session file by selecting “Open session” from the “File” menu. 4. 4. you must select “Offline” from the interface dropdown list in the “Connect to” dialog box when you start MEPA-CARFLOW.e. FLOWSIC150 CARFLOW · Operating Instructions · 8010815 V 1. ‡ Select "Offline" from the interface dropdown list in the “Connect to” dialog box. Offline modification of parameters in the session file Session files can be opened online with the FLOWSIC150 connected and offline without a connection to the measuring system. Fig.18). ‡ Open the existing session file associated with the FLOWSIC150 by selecting “Open session” from the “File” menu.

COF. Configuration files have the extension *.2 · © SICK MAIHAK GmbH Germany .15) and click on the “Export entry” button.16). You can name the file as desired.16: “Measured values” export dialog • Exporting current parameters The current set of parameters will be exported to a configuration file if you select the “Current device configuration” entry (see dialog area in Fig. An export dialog box will appear in which you can configure export formats (see Fig. 46 FLOWSIC150 CARFLOW · Operating Instructions · 8010815 V 1. 4. • Printing current parameters The current set of parameters will be printed to a specified printer if you select the “Current device configuration” entry and click on the “Print entry” button. 4.Commissioning and Parameterization Exporting data records Data records will be exported to a structured ASCII file if you click on the “Export entry” button. 4. Fig.

just like a standard session (see page 45). 2.3. FLOWSIC150 CARFLOW · Operating Instructions · 8010815 V 1. • After changing to the “Measured values” tab.17: “Diagnosis session settings” dialog box ‡ Select “Diagnosis session” from the “File” menu to start the diagnosis session. If you start the session. Proceed as follows: ‡ Run the MEPA-CARFLOW program and connect to the FLOWSIC150. Replaying recorded tab contents in the MEPA-CARFLOW program The tab recordings of the diagnosis session can be replayed with the help of the data recorder integrated into the MEPA-CARFLOW program (see Section 4. The MEPA-CARFLOW program automatically collects the following information: • EEPROM and FLASH code segment • Current parameter configuration • After changing to the “Log/ trend” tab.2 · © SICK MAIHAK GmbH Germany 47 . ‡ Specify the scope of data collected in the diagnosis session by selecting “Diagnosis setup” from the “Options” menu. For this purpose. it automatically records all major measured variables. it automatically records further measured variables. the MEPACARFLOW program will automatically detect any measuring variables and parameters which characterise the condition of the measuring system and save them in a diagnosis session file.Commissioning and Parameterization Diagnosis session After completion of maintenance work on the FLOWSIC150 it is recommended to diagnose and to save the current condition of the measuring system. 4. Export to a structured ASCII file Export a completed diagnosis session through the item “Session history” in the “File” menu.3). you can run a diagnosis session in addition to the standard session. • Saving and termination of the diagnosis session file The information collected in a diagnosis session can be analysed afterwards in two different ways: 1. für Fig.

If differences are detected.18 will appear. 4.Commissioning and Parameterization Data consistency The MEPA-CARFLOWprogram checks whether or not the configuration saved in the session file is identical to that stored in the connected FLOWSIC150 when you open a session file. Fig.2 · © SICK MAIHAK GmbH Germany . It contains a list of all deviating parameters. 48 FLOWSIC150 CARFLOW · Operating Instructions · 8010815 V 1. the dialog box shown in Fig. 4.18: Consistency check: session configuration – device configuration You can now decide: • The parameters stored in the FLOWSIC150 are valid → “Device is valid” button • The parameters stored in the session file are valid → “Session is valid” button • The session file is not associated with the FLOWSIC150 → Cancel If you click on the “Apply to registers” button to apply the parameters of the valid system to the other system.

register no. ASCII files have the extension *. Device configuration file The device configuration file contains the current device configuration which can be exported from a session history. FLASH memory image If you export the FLASH segment from a session. The measured values are arranged in columns. interface.LNG. the MEPA-CARFLOW program will create a binary file with the extension *.2 · © SICK MAIHAK GmbH Germany 49 . the MEPA-CARFLOW program will create a binary file with the extension *.g. You can name the file as desired during export.Commissioning and Parameterization File type overview The following table shows the file types produced by the MEPA-CARFLOW program. Program initia. program layout.4.INI and are used during initialisation in the context of the next program start (e.TXT.TSK which contains a memory image of the FLASH firmware memory.). Changes should only be performed after consultation of the manufacturer.Basic settings of the MEPA-CARFLOW program made by the user during the lisation file execution of the program are saved in the binary file MEPA. File Remark Program language file The available program interface languages are managed in the language file MEPA. Identifier. EEPROM memory image If you export the EEPROM segment from a session. and value of all parameters are saved in the form of structured ASCII text.16). ASCII export file Measured values exported from the session history are saved as text in structured ASCII files. The data contained may be formatted as locally required during the export operation from the session history (see Fig. Important Changes of the language file directly affect the running of the MEPA-CARFLOW program and may result in faulty execution of the control program.EEP which contains a memory image of the EEPROM parameters. FLOWSIC150 CARFLOW · Operating Instructions · 8010815 V 1. directories etc. This file contains any text modules in the available languages in the ASCII format.

2 · © SICK MAIHAK GmbH Germany .Commissioning and Parameterization 50 FLOWSIC150 CARFLOW · Operating Instructions · 8010815 V 1.

FLOWSIC150 CARFLOW Exhaust Gas Flow Meter Maintenance General Routine Checks .

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As part of maintenance and repair agreements.g. Maintenance intervals The plant operator is responsible for defining the maintenance intervals. all maintenance activities can also be performed by the SICK MAIHAK Service department. We recommend to start with shorter maintenance intervals (e. Maintenance agreement If requested. Maintenance work is confined mainly to routine checks to determine the plausibility of measured values produced by the FLOWSIC150 as well as cleaning work.1 General The FLOWSIC150 is a low-maintenance measuring system. 4 weeks) and to extend this step by step on a measure adjusted to the respective conditions. repairs are carried out by specialists on site (as far as possible). The use of Titanium and highquality stainless steel for components that come into contact with the gaseous media ensure that these are resistant to corrosion.Maintenance 5 Maintenance 5. The activities required and their completion must be documented by the operator in a maintenance log. such as plant operation and ambient conditions. In addition. SICK MAIHAK assumes responsibility for all maintenance activities. These intervals will depend on the specific operation parameters. FLOWSIC150 CARFLOW · Operating Instructions · 8010815 V 1. or an authorized service partner. the FLOWSIC150 does not contain any mechanically moved parts. provided that the device is implemented in accordance with the relevant specifications.2 · © SICK MAIHAK GmbH Germany 53 .

to prevent thermal stratification. Note 54 If the device is still heated up. Warning Observe and adhere to the required protective measures! DANGER ‡ Switch off the internal heater. the gas temperature may also be determined by measuring the ultrasonic transit time in the gas.2. Activities: ‡ Disconnect the FLOWSIC150 from the exhaust gas line. 5. A comparison of the acoustically determined temperature and the value measured by the jacket-type thermocouple element forms a simple method of checking the plausibility of the gas temperature measurement. e.2 · © SICK MAIHAK GmbH Germany . it is recommended to effect an even temperature distribution across the pipe cross-section.g.2 Routine Checks The proper function of the FLOWSIC150 can be stated directly at the display elements on the top side of control cabinet of the (see Fig. If you want to check the function of the gas temperature measurement while the device is heated up. The reference measurements must be conducted in air.1: Display for the function check of the gas temperature measurement The gas temperature measurement is performed correctly if the difference between both temperature values does not exceed 10 °C. 30 s).4). ‡ Wait until the measuring pipe is cooled down on ambient temperature. using a hairdryer. there may be significant differences between acoustically measured temperature and temperature measured by the thermocouple element due to thermal stratification.1 Gas Temperature Measurement Because the velocity of sound depends on the temperature. FLOWSIC150 CARFLOW · Operating Instructions · 8010815 V 1. Acoustically determined temperature Temperature measured by the thermocouple element Fig. ‡ Press the “Set” button at the front panel until the information shown below is displayed (display is maintained for approx.Maintenance 5. 5. 2.

Parameter Standard value Error Comment Difference between theoretical and measured sound velocity ≤ ± 0. 5. Warning Observe and adhere to the required protective measures! DANGER ‡ Switch off the internal heater.Maintenance 5. Differences between the sound velocities of the individual paths at multipath systems ≤ 0. Repeated path failures are a symptom for this. If there is no or only low flow. ‡ Wait until the measuring pipe is cooled down on ambient temperature. In addition to diagnosing the error (as described in Section 6).3 Checking Measuring Pipe on Depositions At exhaust gas measurings behind diesel engines. particularly in a hot measuring cell. in particular. strong soot depositions can cover the inside of the measuring cell and the ultrasonic transducers. To avoid measurement problems therefore we recommend to check the FLOWSIC150 on soot depositions considering the respective use duration and intensity of the check cycles. you can also create a diagnosis and status log and send this to SICK MAIHAK for analysis. Deviations from the standard values specified in the table can indicate a malfunction. as well as at multipath systems by comparison of the sound velocities of the individual paths. and to clean measuring cell and ultrasound transducers if required.2 Velocity of sound The plausibility of the measured gas velocity and the volume flow which is calculated from it can be checked by comparison of the theoretical sound velocity and that which is measured by the FLOWSIC150.5 m/s ≥ ± 2 m/s The values only apply to flowing gas.5 m/s ≥ ± 2 m/s When calculating the theoretical velocity of sound. pressure and. temperature stratifications can occur which can cause differences of the sound velocities in the individual paths of > 10 m/s. Activities ‡ Disconnect the FLOWSIC150 from the exhaust gas line.2.2 · © SICK MAIHAK GmbH Germany 55 .2. the temperature are the same as at the measuring location when the log was recorded. you must take special care to ensure that the gas composition. ‡ Clean measuring pipe and ultrasound transducers with a soft brush carefully. Attention • Do not use hard brushes to not damage the transducer surfaces! • Do not damage the coat thermocouple when cleaning! ATTENTION FLOWSIC150 CARFLOW · Operating Instructions · 8010815 V 1.

Maintenance 56 FLOWSIC150 CARFLOW · Operating Instructions · 8010815 V 1.2 · © SICK MAIHAK GmbH Germany .

FLOWSIC150 CARFLOW Exhaust Gas Flow Meter Troubleshooting Fault Diagnosis Warning Messages Malfunction Messages .

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If you still cannot find the cause for the fault.5 indicate that the device is not functioning properly. the following table will help you to diagnose and remove the fault. whether the faults disappear at larger velocities. Different gas composition or No work required on the device process pressure Transducer(s) are dirty Clean the transducer(s) Additional noise sources Remove noise sources Gas velocity outside of the measurement range FLOWSIC150 CARFLOW · Operating Instructions · 8010815 V 1.damaged sitivity • Increased number of • Additional sources of noirejected measurese due to fittings. Display. you can use the MEPA CARFLOW program to carry out a more detailed fault diagnosis (see service manual). especially with very low flow (higher temperatures → higher velocities of sound). if necessary.2 or device messages described in Section 2.2 · © SICK MAIHAK GmbH Germany 59 .1 Fault Diagnosis If the routine checks described in Section 5. remove noise sources. parameter Possible reason Faulty power supply • No display • No active status signal Different velocities of sound in the individual paths (only for multipath devices) Contact the manufacturer Transducer or electronics fault Replace the transducer(s) (see service manual) Note Different velocities of sound can occur on the individual paths as a result of temperature stratification. noise ments in individual pasources near the device ths • Temperature stratifications Increased number of rejected measurements in all paths (only for multipath devices) Check cables and terminal connections Important Take the relevant safety precautions! Defective device • Lower signal-to-noise Increased reception sensitivity Remedy Replace the transducer(s) (see service manual) • Check the measurement plausibility and number of rejected measurements and. Induvidual transducer(s) ratio and reception sen. • Check.Troubleshooting 6 Troubleshooting 6.

for measuring pipe heater. 6.1 and service manual). or alarm temperature (regulator • Check the values and correct them. Warning! No USM-Communic. • Check the set measuring range. 10 s.Troubleshooting 6. or if the internal check detects a device status that can lead to a failure. Device in „Configuration mode“ and no signal burst (measuring values are not updated) Finish „Configuration mode“ and switch the device into „Measuring mode“ after approx.4 Note Warnings are displayed if measurements are not possible temporarily. • Changed settings for set and/ Warning! Reduced Accuracy! (only for multi-path devices) • Transmitted or received signal • Check the connection of the trans- too low • Transducer cable not really contacted or defective • Gas velocity outside of the measuring range • Failure of a measuring path ducer cables (see Fig. 6.4) Manual“). They are signaled by advertorials at the LCD. Warning messages do not influence the device function.2 · © SICK MAIHAK GmbH Germany . Connections of the transducer cables USM measuring transmitter Fig. see if necessary (see „WATLOW User’s Fig. Warning The gas-carrying parts are hot if the system is checked during or shortly after operation! Take suitable measures to protect against possible danger in this case! DANGER Additional signalisation on the top side of the control cabinet: • The red lamp shines • LED „Maintenance“ flashes Indication on the LCD Possible reason Remedy Warning! Heating up • Operating temperature still not • Start the measuring mode only if reached. 2.2 Warning Messages see Fig. 2. the operating temperature is reached.1: Connections of the transducer cables in the control cabinet 60 FLOWSIC150 CARFLOW · Operating Instructions · 8010815 V 1.

2.• Check the bonding of the interface monics and USM measuring dule (see Fig. Warning The gas-carrying parts are hot if the system is checked during or shortly after operation! Take suitable measures to protect against possible danger in this case! DANGER Indication on the LCD Possible reason Error! No Signal • Failure of all measuring pa. • Check the RS485 cable (see Fig. They are signaled by shining of the red lamp on the top side of the control cabinet and advertorials at the LCD. 6.1 and service manual). or device components (for example. 6.2) between evaluation electro.2) transmitter • Switch the device off and switch on after • Interface module not really short waiting period again contacted • Use the service manual • Device in service mode • Check the EPROM bonding (see Fig.3 Malfunction Messages see Fig.2 · © SICK MAIHAK GmbH Germany 61 . 6. ROM reading 6.2) • Incorrect parameter setting • Check the parameter setting Check the cabling (see Fig. Para • Wrong check sum at EP- Error! I/O-Module Fault/defect in the cabling to the I/O module (no pressure and temperature measurement) Evaluation electronics Remedy cables (see Fig. the transducers) have failed.2) Terminal for temperature measurement Interface module I/O module Pressure sensor Fig.• Check the application ths • Check the parameter setting • Ultrasonic damping too • Check the connection of the transducer strong • Wrong signal parameter EPROM RS485 cable Error! No USM-Communic. • Fault/defect in the cabling Error! Dev. 6. 6.2: Evaluation electronics and I/O module FLOWSIC150 CARFLOW · Operating Instructions · 8010815 V 1.4 Malfunctions are displayed if measurements are not possible.Troubleshooting 6.

2 · © SICK MAIHAK GmbH Germany .Troubleshooting 62 FLOWSIC150 CARFLOW · Operating Instructions · 8010815 V 1.

FLOWSIC150 CARFLOW Exhaust Gas Flow Meter Parts Overview Standard Components Spare Parts .

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Parts Overview 7 Parts Overview 7.1 Standard Components Name Part number FLOWSIC150 CARFLOW FL150 1P1 2. connection thread 2 ½" 7041984 FLOWSIC150 CARFLOW FL150 4P1 4.5Z XT 0H 3 measuring paths. connection thread 2 ½" 7041982 FLOWSIC150 CARFLOW FL150 3P2 2.2 · © SICK MAIHAK GmbH Germany 65 .5Z XT 0H 1 measuring path.0Z XT 0H 4 measuring paths. connection thread 4" 1026307 FLOWSIC150 CARFLOW · Operating Instructions · 8010815 V 1.

. Kamlok type D 5313693 Coupling G4".2 · © SICK MAIHAK GmbH Germany .Parts Overview 7.2 Spare Parts Elektronics Name Part number FL150-1 measuring transmitter with case 7041640 FL150-3 measuring transmitter with case 7041080 FL150-4 measuring transmitter with case 2033089 FLA150 master board 7042418 Prozessor board I960 7041300 FL150 Front panel with LCD 7041652 I/O module 7041651 EPROM M27C4002-12F1 for FLOWSIC150 7042420 Temperature controller type WATLOW 7041731 Thermocouple jacket-type 7041625 Switch cabinet heater 110 .. Kamlok type A 5313692 Inlet pipe D65 L291 (for 1/3 path version) 4041420 Insulating covering D165 L200 (for inlet pipe) 4041454 Flow straightener 2½“ (for 1/3 path version) 7041807 Flow straightener 2½“ Fix (for 1/3 path version) 4042353 Miscellaneous Name 66 Part number Steering roll d75 antistatic 7041621 Steering roll antistatic double lockable 7041622 FLOWSIC150 CARFLOW · Operating Instructions · 8010815 V 1. 250 V AC 6029772 Heater regulator for cabinet heater 7043277 Bridge Set 115 V / 230 V 7041094 Power cable with plug length 3 m 7041810 Ultrasonic transducers Name Part number Set ultrasonic transducer D12F135P16 2033090 Spare part set transducer exchange in S3/1P 2039311 Spare part set transducer exchange in S3/3P 2039322 Connection for exhaust pipe Name Part number Coupling 2½" female part 7041831 Coupling 2½" male part 7042413 Coupling G4".

FLOWSIC150 CARFLOW Exhaust Gas Flow Meter Appendix .

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1 -8. 16 A optional 115 V / 60 Hz (change bridges!) Heater external heater Temp. contr. contr. internal heater red Plug-in bridges for 1150 V ac (6 pcs.1: Wiring diagram power supply 69 .2 · © SICK MAIHAK GmbH Germany Power supply 230 V / 50 Hz Fuse protection max. external heater Bridge for Ub_N2 Temp. 1 -3) Evaluation electronics Analog output Thermocouple lower ring heater board System cable Probe Probe Converter box Control panel 8 Thermostat short circiut-prrof 1. 8.FLOWSIC150 CARFLOW · Operating Instructions · 8010815 V 1.4 A Appendix Appendix Fig. 1 -4) Meter body heater Bridges plugged for 230 V / 50 Hzr Piper heater green Heating connection Plug-in bridges for 230 V ac (2 pcs. 2 pcs.

Appendix 70 FLOWSIC150 CARFLOW · Operating Instructions · 8010815 V 1.2 · © SICK MAIHAK GmbH Germany .

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de . 11 | 79276 Reute | www.sick.com Phone +49 7641 469-0 | Fax +49 7641 469-11 49 | info.8010815/2010-03 (V 1.2) FLOWSIC150 CARFLOW SICK worldwide You will find our local subsidiary or agency at: www.sick.pa@sick.com Your local sales and service partner SICK MAIHAK GmbH | Germany Nimburger Str.