Professional Documents
Culture Documents
OPERATING INSTRUCTIONS
Applifoto
74 x 45 mm
(150 dpi: 437 x 266 pixel)
FLOWSIC600
Ultrasonic Gas Flow Meter x = 136 mm y = 58 mm
Hazard (general)
Hazard by voltage
WARNING
Risk or hazardous situation which could result in severe personal
injury or death.
CAUTION
Hazard or unsafe practice which could result in personal injury or
property damage.
NOTICE
Hazard which could result in property damage.
Information Symbols
Supplementary information
1 Important Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.1 About this Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.2.1 Intended Use of the Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.3 Authorized Staff. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.4 General Safety Instructions and Protective Measures . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.5 Dangers due to hot, corrosive and explosive gases and high pressure . . . . . . . . . . . . 10
1.6 Dangers due to heavy loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.7 Environmental information and instructions for disposal . . . . . . . . . . . . . . . . . . . . . . . . 11
2 Product Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.1 System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.1.1 Meter body. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.1.2 Ultrasonic transducers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.1.3 Signal processing unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.2 Operating Modes, Meter States and Signal Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.2.1 Operation Mode and Configuration Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.2.2 Meter States . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.2.3 Pulse output and status information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.3 MEPAFLOW600 CBM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.3.1 Software Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.3.2 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.1 General Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.1.1 Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.1.2 Transport and storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.2.1 Measuring location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.2.2 Installation configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.3 Mechanical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.3.1 Choosing flanges, seals and other parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.3.2 Mounting the FLOWSIC600 in the piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.3.3 SPU alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.4 Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.4.1 General information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.4.2 Cable specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.4.3 Checking the cable loops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.4.4 Terminal enclosure on the SPU. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.4.5 Operating the FLOWSIC600 in safe areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3.4.6 Operation in hazardous areas (Directive 94/9/EC (ATEX)) . . . . . . . . . . . . . . . . . . . . 39
4 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4.1 General Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
4.2 Connecting the FLOWSIC600 to a PC or Laptop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4.2.1 Connecting the FLOWSIC600 via RS485 / RS232 cable . . . . . . . . . . . . . . . . . . . . . . 45
4.2.2 Connecting the FLOWSIC600 via RS485/USB converter . . . . . . . . . . . . . . . . . . . . . . 46
4.3 Connecting to the FLOWSIC600 with MEPAFLOW600 CBM . . . . . . . . . . . . . . . . . . . . . . 47
4.3.1 Starting MEPAFLOW600 CBM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
4.3.2 Choosing an User Access Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
4.3.3 Creating a new meter entry in the meter database . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
4.3.4 Online Connection: Direct Serial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
4.3.5 Online Connection: Ethernet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
4.4 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
4.4.1 Checking identification, operation / design data and firmware version . . . . . . . . . 52
4.5 Field Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
4.5.1 Disconnecting from the Meter and Closing the Session . . . . . . . . . . . . . . . . . . . . . . . 54
4.6 Function Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
4.6.1 Function test on FLOWSIC600 with LCD front panel . . . . . . . . . . . . . . . . . . . . . . . . . . 55
4.6.2 Function test on FLOWSIC600 with LED front panel . . . . . . . . . . . . . . . . . . . . . . . . . . 55
4.6.3 Function test with MEPAFLOW600 CBM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
4.7 Activation of Path Compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
4.8 Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
5 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
5.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
5.2 Routine Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
5.2.1 Comparing theoretical and measured Speed of Sound (SOS) . . . . . . . . . . . . . . . . . . 63
5.2.2 Checking the Meter Health . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
5.2.3 Time Synchronization. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
5.2.4 Battery Lifetime / Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
5.3 Maintenance Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
5.4 Optional Data Download . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
5.4.1 Logbook Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
6 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
6.1 General Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
6.2 Indication of Meter States, System Alarms and Warnings . . . . . . . . . . . . . . . . . . . . . . . . 72
6.2.1 Checking the “Meter Status“ Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
6.2.2 Checking the User Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
6.2.3 Battery Lifetime / Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
6.3 Generation of a Diagnosis Session . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
6.4 Meter Connection Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
7 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
7.1 Conformities and Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
7.1.1 CE certificate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
7.1.2 Standard compatibility and type approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
7.1.3 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
7.2 Logbooks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
7.2.1 Overview of event entries in logbooks and MEPAFLOW600 CBM . . . . . . . . . . . . . . 86
7.3 Connection Diagrams for Operating the FLOWSIC 600 in Hazardous Areas in
Accordance with North American Guidelines (CSA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
7.4 Wiring Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
7.4.1 Intrinsically safe installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
7.4.2 Non-intrinsically safe installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
7.5 Sealing Plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
FLOWSIC600
1 Important Information
1. 5 Dangers due to hot, corrosive and explosive gases and high pressure
The FLOWSIC600 measuring system is directly integrated into gas-carrying pipelines.
The operating company is responsible for safe operation and for complying with additional
national and company-specific regulations.
WARNING:
In plants with toxic and explosive gases, high pressure or high temperatures,
the FLOWSIC600 measuring system shall only be installed or removed after
the associated piping has been isolated and depresurrized (i.e. vented to
atomsphere).
The same applies to repair and service work which involves opening any
pressurized component or the explosion-proof signal processing unit (SPU).
NOTICE:
Design, manufacture and inspection of the FLOWSIC600 measuring system
are performed in compliance with the safety requirements set forth in the
European Pressure Equipment Directive 97/23/EC. All relevant information for
the particular application (as specified in the technical information
questionnaire filled out by the customer) has been taken into account before
commencing order processing.
FLOWSIC600
2 Product Description
System Components
Operating States and Signal Output
MEPAFLOW600 CBM
2. 1 System Components
The FLOWSIC600 measuring system consists of the following hardware components:
● Meter body
● Ultrasonic transducers
● Signal processing unit SPU
The MEPAFLOW600 CBM software is the user interface used to facilitate operation,
configuration and diagnosis (see → pg. 20, 2.3).
Figure 1 FLOWSIC600
SPU
Hoisting eye
Pressure tap
Flange
Cover cap
Measured values
The power supply and interface terminals are located on the back of the SPU in a separate
terminal section of the enclosure (→ pg. 36, 3.4.4).
The electronics are mounted in the SPU enclosure certified to EN 60079-1 or IEC 60079-1
with protection type “d“ (flameproof enclosure). The transducer circuits are of an
intrinsically safe design (category “ia“).
● Configuration Mode
In the Operation Mode the meter can have the following Meter states (→ 2.2.2):
● Measurement valid
● Check request
● Measurement invalid
Test Cycle
The test cycle can be activated for a measuring path by setting the corresponding control
bit in the System Control Register (#3002) (the setting can be carried out on the
“Parameters” page in MEPAFLOW600 CBM). In a test cycle, the transmitted signal is fed to
the receiver signal amplifier of the measuring path through an electric attenuation unit
(transducer simulator). This function can only be activated if the system is in the
“Configuration” mode. It is used to test a path-specific electronic module.
Test cycles are automatically cancelled when leaving the “Configuration” mode.
Phase Positive
shift flow rate
90 ° ***
Negative
flow rate
Separate Positive
outputs flow rate
for each
direction
***
Negative
flow rate
* The meter can be configured to put out a fixed frequency at “Measurement invalid“. The
frequency to be put out in this case can be configured in Reg.#3034 “ErrorFreq“ (0-6 kHz).
** Default setting on delivery.
*** Optional setting on customer request.
The default setting for “Check request”, “Configuration” and “Measurement invalid” is
“normally closed”.
****The “active” or “inactive” state can be assigned to the electric switch status
“normally open” or “normally closed” by configuration in the MEPAFLOW600 CBM software
(adjust settings for register #5101 on the “Parameters” page.)
The LCD display is capable of displaying measured values, parameters, messages and
other information.
A flashing letter at the upper right corner of the LCD display indicates that a logbook
contains unacknowledged logbook entries. Depending on the type of entry this will be:
● “I” for Information
● “W” for Warning
● “E” for Error
After acknowledging all new entries, the flashing letter disappears. For details see → pg. 68,
5.4.1.
2. 3 MEPAFLOW600 CBM
Most data provided by the FLOWSIC600 (like readings, logbook entries and parameters)
can be accessed via the LCD display of the meter. However, the MEPAFLOW600 CBM
software provides a more user friendly access to diagnostic, configuration and
measurement data of the flow meter.
Compatibility
MEPAFLOW600 CBM can be used for all firmware and hardware versions of the
FLOWSIC600. The availability of the software features depend on the firmware version of
the connected FLOWSIC600.
Installation
A product CD containing the MEPAFLOW600 CBM software is included with the
FLOWSIC600 when it is delivered. Insert the product CD into your CD-ROM drive to install
the software. Start the file ‘FLOWSIC600_R_CD.exe‘ to install the software.
Download from www.flowsic600.com
MEPAFLOW600 CBM can be downloaded free of charge from the www.flowsic600.com
website. Select the Software tab and follow the download instructions.
2.3.2 Overview
The MEPAFLOW600 CBM software supplies a menu-based user interface with many
features for the diagnosis of the FLOWSIC600 system. It allows the access of all system
parameters, displays diagnostic information in charts and graphs, generates reports (i.e.
Maintenance reports) and data files (records, logs) which can be exported and can be used
for data analysis. It‘s meter database allows online and offline management of
parameters, reports, session files and logbooks.
Menu
Key navigation
Software features -
Status bar
FLOWSIC600
3 Installation
General Notes
Installation
Mechanical Installation
Electrical Installation
3. 1 General Notes
3.1.1 Delivery
The FLOWSIC600 is delivered in a pre-assembled condition in a sturdy package. When
unpacking the device, check for possible damage in transit. Pay particular attention to the
interior of the meter body, any visible transducer components and the sealing surfaces on
the flanges. Any damage must be documented and reported to the manufacturer
immediately.
Also check the shipment to ensure all components are included. The standard meter
shipment is comprised of:
b FLOWSIC600 measuring system (meter body with signal-processing unit and
transducers)
b MEPAFLOW600 CBM control and configuration software
b Operating instructions
b Manufacturer Data Report (MDR)
NOTICE:
To guarantee safe and reliable operation of the measuring equipment, make
sure the actual site conditions match the information provided on the labels on
the meter body and SPU (see Fig. 5.1).
Flange dimensions
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 °
3. 2 Installation
Generally, the installation arrangement is specified during the project planning phase,
before installation of the system. Nominal size, material and type of flange should
therefore be in accordance with the design of the measurement facility. It is particularly
important that the meter inlet and outlet is of the same internal diameter as the adjacent
piping.
Fastening bolts, nuts and flange seals used must be suited to the operational conditions,
and comply with legal regulations and relevant standards.
Any deviation from the planned design of the FLOWSIC600 and installation
arrangement shall be agreed upon with the supplier and documented prior to
installing the meter.
When configuration 2 (with flow conditioner) is used, the velocity of gas must
not exceed 40 m/s (131 ft/s) in the pipe.
Unidirectional use
Configuration 1
DN
≥ 5 DN ≥ 3 DN
min. 2 DN min. 2 DN 1.5 .. 5 DN
Configuration 2
Bidirectional use
Two straight pipes shall be installed in the inlet and outlet sections if the meter is to be
used bidirectionally. The temperature measuring point shall be disposed downstream the
FLOWSIC600, seen in the direction of predominant use (position 1 or 2 in → Figure 7).
≥ 10 DN FLOWSIC600 ≥ 10 DN
5 ..8 DN 5 .. 8 DN
Configuration 1
DN
≥ 5 DN ≥ 5 DN
min. 2 DN min. 2 DN min. 2 DN min. 2 DN
1.5 .. 5 DN 1.5 ..5 DN
Configuration 2a
Applicable for meters
marked with an asterisk
(*) in → »Meter sizes
according to PTB
approval« (pg. 84),
Flow conditioner
≥ 10 DN ≥ 10 DN
min. 2 DN min. 7 DN min. 7 DN min. 2 DN
Configuration 2b min. 5 DN min. 5 DN
Applicable for meters
marked with an asterisk
(*) in
→ »Meter sizes
according to PTB
approval« (pg. 84),
Temperature measuring point
Flow conditioner
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.
b Position the FLOWSIC600 at the desired place of the pipeline using the lifting gear. Only
use the lifting eyes provided to lift and transport the device. If lifting straps are used,
wrap them around the meter body.
b Check for correct seating and alignment of the flange gasket after installing the flange
bolts, but prior to tightening.
b Align the FLOWSIC600 such that the offsets between inlet pipe, meter body and outlet
pipe are minimized.
b Insert the remaining fastening bolts and tighten the nuts cross-wise. The tightening
torque applied must not be lower than specified in the project planning.
b Mount the pressure sensing line between pressure tap and pressure transmitter.
b Fill the pipeline and check the installed FLOWSIC600 and piping connections for leaks.
NOTICE:
Do not forget to tighten the hexagon socket head screw after positioning the
SPU.
3. 4 Electrical Installation
RS485 / MODBUS
Service PC / higher-
level control system (Ex i isolating transformer only
12 ... 24 V DC required for intrinsically safe
installation)
Safe area
Hazardous area
FLOWSIC600
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.
NOTICE: Lubricant
Only use LOCTITE 8156 as lubricant for front and rear housing cover.
A schematic wiring diagram is provided on the inside of the rear housing cover.
Cover
Securing clip
Figure 11 Terminal box on the rear of the SPU (see Section → 3.4.2 for North American wiring specification equivalents)
Terminal box
PA PA
Connection options
The 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 / national
regulations and standards or EN 60079-14.
A combination of intrinsically safe and non-intrinsically safe circuits is not permitted in the
terminal 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.
WARNING:
Always observe the temperature specifications for use in hazardous areas.
Aux. power 1+
Power supply 2-
PA
31 Signal processing unit
Terminal box “e”, “i”
Digital output
32 (SPU)
33
RS485
34
51 Pressure-resistant
Digital output
52 space “d”
Field connections
41
Digital output
42
81
Digital output
82
PA
Meter body
FLOWSIC600
4 Commissioning
General Notes
Connecting the FLOWSIC600 to a PC or Laptop
Connecting to the FLOWSIC600 with MEPAFLOW600 CBM
Identification
Field Setup
Function Test
Activation of Path Compensation
Sealing
4. 1 General Notes
Before commissioning, all activities described in the chapter → »Installation« must be
completed. It is recommended to use a laptop/PC with installed MEPAFLOW600 CBM
software 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 sound
test, and other system specific inspections/tests which belong to the manufacturing and
quality assurance process. The ’wet’ calibration is performed at a flow calibration test
stand (calibration test facility).
All parameters, determined by the aforementioned tests, as well as design specific data
are preset and stored in the FLOWSIC600 in a non-volatile memory before delivery. The
design-specific data which is known before manufacturing the device will not be changed
during commissioning. This is of special importance if the FLOWSIC600 is officially sealed
after an authorized flow calibration. Generally, the parameters are protected by a
password. Additionally a Parameter write lock in the SPU prevents custody relevant
parameter changes.
NOTICE: Type Approval
If 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.
In all other cases the output parameters of the FLOWSIC600 can be adapted on site by
trained staff.
Commissioning the FLOWSIC600 involves the following steps, no matter whether the
device 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).
Figure 14 Wiring example of “MEPA interface set RS485 / RS232” intrinsically safe for DIN rail mounting
Ex-Zone Safe-Zone
Terminals* COM
Fieldbus Isolating port
Repeater (9-pole)
1:1
Type 9185
(Company “Stahl”) Connection cable
Figure 15 Wiring example of “MEPA interface set RS485/USB” (Converter, Cable, Terminal plug, CD-ROM with
software driver), non-intrinsically safe
Safe-Zone
Terminals*
A / RxD USB
USB
B / TxD
USB
Connection cable
Figure 17 MEPAFLOW600 CBM “Connect / Disconnect” page with Password dialog window
b The Password dialog disappears and the “Connect / Disconnect” page with a list of all
meters in the meter database appears.
The parameters shown in → Figure 18 are default values - except for the serial
COM port which has to be individually configured.
b 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.
In case of problems with the network setup, refer to your network administrator.
Figure 19 “MODBUS TCP - MODBUS RTU/ASCII gateway settings” dialog for online connections via Ethernet
4. 4 Identification
b 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.
“Identification“
section
Firmware
The FLOWSIC600 firmware is stored on a non-volatile memory (FLASH PROM). The
program code for the signal processor and system micro-controller are identified by a
version number (register#5002) and a check sum (register #5005) and can be verified as
mentioned above.
The parameter changes performed in the Field setup wizard require the User
Access Level “Authorized operator” (see → pg. 48, 4.3.2).
b To start the Field setup, choose “Tools / Field Setup” from the menu.
b Follow the instructions on screen step by step.
To disconnect from the meter and to close the session, proceed as follows:
b Go to the “Connect / Disconnect“ page by chosing “File / Connect/Disconnect“ from
the menu.
b Click the “Disconnect“ button. The “Session description“ window opens.
b Describe the activies you carried out during the session (e.g. “Field Setup“).
b Click the “OK“ button.
You are advised to check the plausibility of the measured and diagnosis
values, even if the device is functioning properly (see chapter → »Maintenance«).
Main system
bar
If the zero phase values do not meet the aforementioned criteria, the zero phase needs to
be adjusted according to the instruction in the “Technical Information“.
Additional the validity of the settings should be verified:
b 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
b 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).
b Switch between display of absolute and difference SOS by clicking the right mouse
button on the SOS graph and using the context-menu.
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.
b 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)
Figure 25 “Meter status” page with active “Path compensation valid” status bit
“Path compensation
valid”
4. 8 Sealing
After having completed the commissioning, seal the signal processing unit (if required) in
accordance with the sealing plan (see Section → pg. 94, 7.5).
FLOWSIC600
5 Maintenance
General
Routine Checks
Maintenance Report
Optional Data Download
5. 1 General
The FLOWSIC600 does not contain mechanically moving parts. The meter body and
ultrasonic transducers are the only components that come into contact with the gaseous
media. Titanium and high-quality stainless steel ensure that these components are
resistant to corrosion, provided that the meter is installed and operated in accordance with
the relevant specifications. This means that the FLOWSIC600 is a low-maintenance
system. User Warning Limits can be configured to provide early warnings for possible
issues with contamination or blockages. Maintenance is limited mainly to routine checks to
determine the plausibility of the measured values and diagnostic results produced by the
system.
It is recommended to create and file maintenance reports on a regular basis (→ 5.3). This
serves to create a basis of comparable data over time and helps when a fault has to be
diagnosed.
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.
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)
Battery
Charge 100%
Because the FLOWSIC600 has no regular maintenance cycle, after 8.5 years, a message
will be generated automatically, which forces the operator to change the battery. See
→ pg. 76, 6.2.3 for troubleshooting.
5.4.1.1 Downloading and saving logbook entries to the MEPAFLOW600 CBM database
To download and save logbook entries to the MEPAFLOW600 CBM database, proceed as
follows:
b Use MEPAFLOW600 CBM to connect to your meter (→ pg. 47, 4.3).
b Choose “Meter / Meter Logbook” from the menu to open the Logbook page.
b 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 can
view them offline without connection to the meter or share them with others (export the
device or the session).
FLOWSIC600
6 Troubleshooting
General Troubleshooting
Indication of Meter States, System Alarms and Warnings
Generation of Diagnosis Session
Meter Connection Troubleshooting
If the routine tests during maintenance (→ pg. 63, 5.2) or the function tests after
commissioning (→ pg. 55, 4.6) indicate that there may be a measurement problem, this
chapter helps to determine the cause of the problem.
If the cause of the problem cannot be localized, it is recommended to use the
MEPAFLOW600 CBM software to record the current parameter set and diagnosis values in
a diagnosis session file (→ pg. 77, 6.3) and send this to a local SICK representative.
6. 1 General Troubleshooting
Problem Possible causes Actions
● No display b Check the input voltage at terminals 1
● No pulse and 2.
frequency Faulty power supply b Check cables and terminal connections.
● No active status Caution
signal Take the relevant safety precautions!
b Create a diagnosis session according to
Defective device → pg. 77, 6.3 and contact your local SICK
representative.
b 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 Actions
Yellow light “Logbook Logbook contains b Download, check and acknowledge all logbook entries according to
contains unack. entries” unacknowledged entries. → pg. 68, 5.4.1.1
Red light for any Logbook The logbook in question isb Download and check all logbook entries according to → pg. 68, 5.4.1.1.
“full” configured to “blocking“ b Clear the meter logbook according to → pg. 69, 5.4.1.3.
and is full of entries. b Consider reconfiguring the logbook to “rolling“ (Parameter Page).
b
If your meter is configured according to PTB requirements a full Custody
Logbook [1] will activate the meter status “Measurement invalid“.
b Download and check all logbook entries according to → pg. 68, 5.4.1.1.
b Clear the meter logbook according to → pg. 69, 5.4.1.3.
Yellow light for any The DataLog in question is b Download and check the DataLog according to the “Technical Information“.
DataLog “full” configured to “blocking“ b Clear the DataLog according to the “Technical Information“.
and is full of entries. b Consider reconfiguring the DataLog to “rolling“ (see “Technical Information“).
Yellow light “Battery After 8.5 years this b See → pg. 76, 6.2.3 for more details.
Lifespan (change battery)“ warning is activated to b Contact trained staff or your SICK representative.
force the user to change b Trained staff: Change the battery according to the procedure described in the
the battery. Service Manual
Figure 32 Main system bar with “System” button and opened “Meter Status” window
Opens the “Meter
Status” window
Main system
bar
Indication if logbook(s)
contains unacknowledged
entries “Logbooks“
Battery Lifespan section
“DataLogs“
section
Figure 33 Main system bar with button “User” and opened “User Warnings” window
Opens the “User
Warnings” window
Figure 34 Flashing message on the LCD display, prompts to change the battery
INFORMATION 1030
LifeSpan Battery
“Battery
Lifespan”
status bit
“Diagnosis
session” itme
b Specify a file name. (The file path is set according to the program settings. If necessary,
specify a different path.)
b Click the “Save” button.
b 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.
b Email the Diagnosis session file to your SICK representative for support.
Figure 37 “Meter not found” dialog for the specification of wider search options
FLOWSIC600
7 Appendix
7.1.1 CE certificate
The FLOWSIC600 has been developed, manufactured and tested in accordance with the
following EC directives:
● Pressure Equipment Directive 97/23/EC
● Directive 94/9/EC (ATEX100)
● EMC Directive 2004/108/EC
Conformity with above directives has been verified. The equipment has been designated
the CE label. The specific designation of the pressure equipment demanded according to
the Pressure Equipment Directive 97/23/EC under part 3.3 and 3.4 is to find in the MDR
of the FLOWSIC600.
1 In derogation of the AGA9, strength test will be performed as hydrostatic pressure test with 30 minutes
holding 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 any
configuration change, including the original and new parameter, and date and time the change
occurred.
Figure 38 Common key code (for short description of meter design, indicated on Type Plate and Instrument
Data Sheet**)
Group 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
9 ULTRASONIC TRANSDUCER (Will be selected by SICK on the basis of the technical data ) _ _
Rev. 1.8
** The Instrument Data Sheet is included in the Manufacturer Data Report (MDR).
Type approval
The 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.
Table 5 Common meter sizes and flow rates
Actual flow rate Actual flow rate
Max. Velocity*
Nominal Size [m³/h] [ft³/h]
Min. Max. Min. Max. [m/sec] [ft/sec]
DN 50 (NPS 2) 6 400 210 14,000 65 213
DN 80 (NPS 3) 12 1,000 280 35,000 65 213
TYPE APPROVAL DN 100 (NPS 4) 20 1,600 460 57,000 60 197
DN 150 (NPS 6) 32 3,000 1,130 106,000 50 164
DN 200 (NPS 8) 40 4,500 1,410 159,000 45 148
DN 250 (NPS 10) 50 7,000 1,770 247,000 40 131
DN 300 (NPS 12) 65 8,000 2,300 283,000 33 108
DN 350 (NPS 14) 80 10,000 2,830 353,000 33 108
DN 400 (NPS 16) 120 14,000 4,240 494,000 33 108
DN 450 (NPS 18) 130 17,000 4,590 600,000 33 108
DN 500 (NPS 20) 200 20,000 7,060 706,000 33 108
DN 600 (NPS 24) 320 32,000 11,300 1,130,000 33 108
DN 700 (NPS 28) 650 40,000 22,950 1,413,000 30 98
DN 750 (NPS 30) 650 45,000 22,950 1,589,000 30 98
DN 800 (NPS 32) 800 50,000 28,250 1,766,000 30 98
DN 900 (NPS 36) 1,000 66,000 35,320 2,331,000 30 98
DN 1000 (NPS 40) 1,200 80,000 42,380 2,825,000 30 98
DN 1050 (NPS 42) 1,300 85,000 45,910 3,002,000 30 98
DN 1100 (NPS 44) 1,400 90,000 49,440 3,178,000 28 92
DN 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.
Criteria applicable to meter when used in accordance with German PTB specifications
Table 7 Meter sizes according to PTB approval
Max. flow Meter
Measuring range (Qmin [m³/h])
Meter rate factor
G-class
size Qmax [pulses/
1:100 1:80 1:50 1:30 1:20 [m³/h] m³]
DN 80 G160 13 250 28800
(3“)
G250 13 20 400 18000
G400* 13 20 32 650 11100
DN 100 G250 20 400 18000
(4“)
G400 20 32 650 11100
G650* 20 32 50 1000 7200
DN 150 G400 32 650 11100
(6“)
G650 32 50 1000 7200
G1000 32 50 80 1600 4500
G1600* 32 50 80 130 2500 2880
DN 200 G650 50 1000 7200
(8“)
G1000 50 80 1600 4500
G1600 50 80 130 2500 2880
G2500* 40 80 130 200 4000 1800
DN 250 G1000 50 80 1600 4500
(10“)
G1600 50 80 130 2500 2880
G2500 50 80 130 200 4000 1800
G4000* 65 80 130 200 320 6500 1110
DN 300 G1600 80 130 2500 2880
(12“)
G2500 80 130 200 4000 1800
G4000 65 80 130 200 320 6500 1110
G4000 E 7800 920
DN 350 G1600 80 2500 2880
(14“)
G2500 80 130 200 4000 1800
G4000 80 130 200 320 6500 1110
G4000 E 80 7800 920
DN 400 G2500 130 200 4000 1800
(16“)
G4000 130 200 320 6500 1110
G6500 120 200 320 500 10000 720
G6500 E 120 12000 600
DN 450 G2500 130 4000 1800
(18“)
G4000 130 200 320 6500 1110
G6500 130 200 320 500 10000 720
G6500 E 120 12000 600
● 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:
- 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.
7. 2 Logbooks
1 Classification of logbook entries
The entries are distinguished into three classes and identified by the initial character in the
first line.
● “I”information
● “W”warning
● “E”error/ malfunction
2 Type of occurrence
● “+”point of time identifying the beginning of a status
● “-”point of time identifying the end of a status
7.4.1
Figure 41
24V DC +
24V Gnd
<= 24V DC
<= 24V DC
<= 24V DC
<= 24V DC
Flowcomputer
RL RL
RL RL
Remark:
SICK recommends to connect all signals
STHAL power supply Service of FLOWSIC 600 with cabels to the non
9143/10-156-160-10s Interface hazardous area.
7+
8+
9-
11
7+
8+
9-
11
12
12
10-
10-
L N 24VDC RS 232
Non Intrinsic savety circuits
24VDC 24VDC STAHL 9185
[EEx ib] MK13-22EX0-T/24VDC MK13-22EX0-T/24VDC
[EEx ib] IIC Intrinsic savety circuits
STAHL [EEx ia] IIC [EEx ia] IIC
Wiring Examples
Ex Ex RS 485
Ex
9143 Ex
s h i e l d RxD TxD
10
11
4-
2+
5-
4-
2+
5-
1+
1+
For Savety/Entity - Parameters see
32-
52-
81+
31+
33+
34-
51+
41+
42-
82-
2 (-)
WARNING! !
1 (+)
internal
Incorrect cabling can cause
DO 1
DO 2
DO 3
RS 485
Modbus
Volume pulse
Status
Status
the FLOWSIC 600 to fail!
AO 0
DO 0
Volume pulse
or 4 .. 20 mA passiv
For further details see
Class1, Division1, Groups B, C and D
Class1, Division2, Groups A, B, C and D operation manual.
Class1, Zone 1 Group IIB + Hydrogene
Class1, Zone 2, Group IIC
I I 1 / 2 G E E x d e i b [ i a ] I I C T4 or
. FLOWSIC 600 I I 1 / 2 G E E x d e i b [ i a ] I I A T4
Attention:
Cable glands
M20 x 1,5 (EU) or
7.4.2
Figure 42
L N
<= 24V DC
<= 24V DC
<= 24V DC
<= 24V DC
Flowcomputer/Systemcontroller
24 VDC
RL RL
RL RL
24 V DC
Imax = 100 mA
Imax = 100 mA
Imax = 100 mA
Imax = 100 mA
Very fast acting type (FF-Type)
In case of blow out lock for reason
before change.
Fuse
Fuse
Fuse
Fuse
Fuse
Fuse
1A 100 mA 100 mA 100 mA 100 mA
fast super fast super fast super fast super fast Additional surge protection is
. . . . . . . . . . . . recommended in case of powerful or
-X recurrent strokes of lightning.
Remark:
SICK recommends to connect all signals
Volume pulse
Modbus
Volume pulse
Status
Status
or 4 .. 20 mA
WARNING! !
32-
52-
81+
31+
33+
34-
51+
41+
42-
82-
2 (-)
Incorrect cabling can cause
the FLOWSIC 600 to fail!
1 (+)
For further details see
internal
DO 1
DO 2
DO 3
operation manual.
RS 485
AO 0
DO 0
Class1, Division1, Groups B, C and D Attention:
Class1, Division2, Groups A, B, C and D
FL600
93
Appendix
7. 5 Sealing Plan
alternatively
SICK worldwide
8010458/2010-01 (V2.0)