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PI FLOWSIC 600 d_2

1. Flange Width of the Internal Nominal Connectio Sandan Weight Length Height diameter measuring diameter pipe size n flange A B C section D E kg mm mm mm mm mm cl 150 2250 1 081 63 984 25 7 cl 300 2550 1 135 60 1 092 20 0 cl 600 GE 2800 1 154 65 1 130 30 ere cl 900 3300 1500 1 231 90 1 231 90 PN16 DN750 PN64 Dimensions on request PN100 cl 150 2625 1 144 73 1 060 45 cl 300 2950 1 189 18 1 149 35 cl 600 e 3200 1 211 40 1 193 80 979 720 cl 900 3900 1600 1 314 45 1 314 45 PN 16 DIN2633 2450 1 127 00 1 025 00 SE EMSS Dimensions on request PN 100 cl 150 3050 1 195 13 1 111 25 SN cl 300 3430 1 242 75 1 206 50 SS cl 600 ee 3710 1 261 80 1 244 60 dee cl 900 4800 1700 1 397 00 1 397 00 PN 16 DN850 PN 64 Dimensions on request PN 100 cl 150 3325 1 251 20 1 168 40 z cl 300 3700 1 302 00 1 270 00 E erregen 1 324 26 1 314 45 1082 810 cl 900 5250 1800 1 460 50 1 460 50 PN 16 DIN2633 2750 1 229 50 1 125 00 DN200 ENCE Dimensions on request PN 100 cl 150 4135 1 308 63 1 238 25 M cl 300 4050 1 273 70 1 168 40 SS cl 600 AEMERIBAT 4575 1 324 50 1 270 00 ar 939 cl 900 6000 1900 1 460 50 1 460 50 PN 16 DN950 PN 64 Dimensions on request PN 100 cl 150 4375 1 361 53 1 289 05 P cl 300 4650 1 336 13 1 238 25 0 cl 600 E 5150 1 377 40 1 320 80 1213 900 cl 9
2. Nominal Connectio Standard Weight Length Height Flange Width of the Internal pipe size n flange A B diameter measuring diameter C section D E kg mm mm mm mm mm cl 150 28 250 330 152 4 49 3 cl 300 29 250 340 165 1 49 3 2 cl 600 ANSI B16 5 30 250 340 165 1 160 49 3 cl 900 42 8 1500 43 300 360 215 9 PN 16 DIN 2633 20 150 345 155 48 DN50 PN 64 DIN 2636 31 250 345 180 160 49 1 PN 100 DIN 2637 35 250 350 195 49 1 cl 150 33 335 30 190 50 n cl 300 34 240 344 75 209 50 5 cl 600 E 38 344 75 209 50 cl 900 76 400 360 65 241 30 180 73 PN 16 DIN 2633 33 340 00 200 00 DN80 PN 64 DIN 2636 36 240 347 50 215 00 PN 100 DIN 2637 39 355 00 230 00 cl 150 40 389 30 228 60 a cl 300 50 300 402 00 254 00 S cl 600 DER 60 411 55 273 10 cl 900 90 500 421 05 292 10 240 95 PN 16 DIN 2633 36 385 00 220 00 DN100 PN 64 DIN 2636 47 300 400 00 250 00 PN 100 DIN 2637 55 407 50 265 00 cl 150 85 444 70 279 40 a cl 300 95 450 463 75 317 50 S cl 600 E 120 482 80 355 60 cl 900 195 750 495 50 381 00 300 142 PN 16 DIN 2633 80 447 50 285 00 DN150 PN 64 DIN 2636 100 450 477 50 345 00 PN 100 DIN 2637 115 482 50 355 00 cl 150 130 496 45 342 90 x cl 300 160 515 50 381 00 cl 600 ee 190 534 55 419 10 cl 900 270 600 559 95 469 90 350 190 PN 16 DIN 2633 120 495 00 340 00 DN200 PN 64 DIN 2636 170 532 50 415 00 PN 100 DIN 2637 190 540 00 430 00 cl 150 210 5
3. A A Signal processing unit SPU B B Meter body Path 1 Path 1 Ultrasonic transducer B Path2 NATL E O SC O Pi B N e a ao SS O ss L t x ote Ve I SE CC GE ZIA Ge Ee Wel Path 3 o o K Path 4 Ultrasonic transducer A Fig 2 5 FLOWSIC600 measuring principle The ultrasonic pulses run through the meter body from transducer to transducer With no gas flowing the pulses propagate at the same velocity namely the velocity of sound in both directions When a gas is flowing through the meter body the pulse that propagates in the direction of the gas flow is faster while the pulse that propagates against the flow is slower This means that the transit time is shorter in the direction of flow tag and longer against the direction of flow tga The ultrasonic transducers alternately act as a transmitters and receivers Each transducer iS a piezoceramic element that is coupled with a diaphragm To transmit signals an alternating voltage is applied to the piezoceramic element so that it vibrates mechanically piezoelectric effect These vibrations are then transferred by the diaphragm to the gas The waves are transferred to the piezoceramic element in the form of mechanical vibrations They are then converted into an electrical signal by the inverse piezoelectric effect and used for further signal analysis The signals are then processe
4. Temperature measuring point Flow straightener Fig 3 4 FLOWSIC600 installation in the pipeline for bidirectional use SICK MAIHAK GmbH Germany All rights reserved 8 010 458 04 2007 Operating Instructions 3 3 DANGER 3 3 1 DANGER 8 010 458 04 2007 Installation FLOWSIC600 Ultrasonic Gas Flow Meter Mechanical Installation Work on the pipelines in preparation to installing the gas flow meter is not included in the scope of delivery It is recommended to use the following tools and auxiliaries for correct installation of the FLOWSIC600 e Lifting gear or fork lift carrying capacity according to the load information on the type plate e Suitable sized ring wrench for flange mounting e Seal adhesive and separating agents Bolt lubricant e Leak detection spray Warning 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 to depressurised and vented pipelines Take all necessary precautions to avoid local or plant specific dangers Choosing flanges seals and other parts Use pipeline flanges bolts nuts and seals that withstand the maximum operational pressure and temperature as well as ambient and operational conditions external and internal corrosi
5. 141 9 5 6 Check report leak test Iexample EEN 142 9 6 FLOWSIC600 Installation Diagrams 143 9 6 1 Intrinsically safe installation 143 9 6 2 Non intrinsically safe installation 144 9 7 Seallng Plah E 145 6 SICK MAIHAK GmbH Germany All rights reserved 8 010 458 04 2007 Operating Instructions About this Document FLOWSIC600 Ultrasonic Gas Flow Meter About this Document This manual describes the FLOWSIC600 measuring system which is used to determine the volumetric flow rate volume and the velocity of sound in gases transported in pipelines It provides general information on the measuring method employed design and function of the entire system and its components and on planning assembly installation commissioning maintenance and troubleshooting Contrasting the characteristic properties of available system variants aims to facilitate a decision already in the planning phase on a configuration that is ideally suited to the measuring task This manual covers standard applications which are conform with the technical data specified Additional information and assistance for special applications are available from your SICK MAIHAK representative However it is generally recommended to take advantage of q
6. 101 Troubleshooting unuueanunuunnnnnunuanununununnununnnnunununnununnnnnnununnnnnnunnnnununnnnnnunnnnunnnunnnnunun nun 103 Spare le 107 CA Bi GEERT 109 E TEEN E 110 SICK MAIHAK GmbH Germany All rights reserved 5 FLOWSIC600 Ultrasonic Gas Flow Meter Operating Instructions CT Genscan nn Se ee 113 9 1 Characteristic Properties and Dimensions of the Meter Body 115 9 2 Operation and Menu Structure of the SPU with LC Display 9 2 1 Operation sacha ieee adh a a ee cen cel 9 2 2 Menu str ct re ees 9 2 3 Display of measured values 9 2 4 Editing MODE EE 9 2 5 Definition Of logbook entries EENEG 9 2 6 Acknowledgement of a logbook entry 9 2 7 Resetting the error volume Coupterg EENEG 9 3 SPU Terminal Assignment 9 4 Connection Diagrams for Operating the FLOWSIC 600 in Hazardous Areas in Accordance with North American Guidelines CSA 131 9 5 Device Documentation 133 9 5 1 INSPECTION certificate example u 133 9 5 2 Final CHECK lune 134 9 5 3 Check report SPU example een 136 9 5 4 Check report transducer pair example EEN 137 9 5 5 Zero flow protocol example
7. Ava O AZLEUIA 28 18 sfeuluue Indino ou LS seurue Ajddng semod Zp by seua 1 sindjno Byuo ZS LG steuuue 1 yndyno esind g pue g sindyno Areuig uojpejjejsuj euru Diet uolllie su JOoid uo soldx3 3UOZ UOISAIG s oyowesed Aug 10 abed Z0 00 187 ou Buimesp 39S alqe97 17 lt EI q89O IO lt eO xeu gt 95 Xew gt 90A SUONPUOO Buwollo oy sote yey lueuidinba psyemossy Dee yso 19410 10 Seu lg Ajeyes Dote WSO esn uolnelije sui Aug 104 Aayes oisupjuy edw Aew s u uodwios Jo uonninsqnS ONINHVAA 1 u uidinba papossy se peuyap sI 1x3 o O L ped 939 eut UMA sauepIoage ul jejsul epeueg UI 9 ZL dH VSI ISNV pue 02 YdAN ISNY OIN 8U YUM S9uED10928 ul Eau SN au ul Z AGZ Peexe o Jou eBeljoA Bese snopsezey uoU uunuilxeN L uonellelsui Lag 0 UOZ L uoISIAIQ r e z L um Z ebed 0099ISAO14 PPEMASA gooz uer sd SS CL e 20 00 L on Bumeiq F ANVIWH3S 6 a peer 22 Gury Jousbieg ON payea o Umed 1911069 Haw Duuesufug ms Juorz e Vul 6 9S At 8S 90A Z UOISIAI SSEID 404 Ayjiqeyns Au Aew uonnsqng preze uolsoldx3 ONINYVM sioypweseg Aug Buaoueo out UNA snoprezey uou aq 0 UMOUY SI Base au JO UO Dou Useq seu juayeainba 1
8. s lk Ultrasonic Gas Flow Meter 106 SICK MAIHAK GmbH Germany All rights reserved 8 010 458 04 2007 FLOWSIC600 Ultrasonic Gas Flow Meter List of Parts Tools and Accessories Spare Parts Operating Instructions List of parts FLOWSIC600 Ultrasonic Gas Flow Meter List of parts 8 1 Tools and Accessories Part number Transducer extraction tool 7041772 Special key up to 16 in 7041872 Special key from 18 in 4047937 Coax plug on auxiliary NL200 4047938 LCD control set magnetic pen adhesive straps 2032787 MEPA interface set RS485 RS232 Adam power supply cable 7041773 MEPA interface set RS485 RS232 intrinsically safe 6029957 for DIN mounting rail MEPA interface set RS485 USB converter cable plug software 6030669 MEPAFLOW600 7048511 8 010 458 04 2007 SICK MAIHAK GmbH Germany All rights reserved 109 FLOWSIC600 Ultrasonic Gas Flow Meter 110 List of parts 8 2 Spare Parts SPU housing and electronic module Operating Instructions Part number Power supply terminal box cover with seal 7041671 Set of clips for SPU housing rear cover and front panel 2031000 SICK MAIHAK LCD front panel 7041660 Connection block EMC board and backplane 2040275 Fuse board with parts needed for assembly 2039149 Electronic bl
9. SICK MAIHAK GmbH Germany All rights reserved 93 FLOWSIC600 Calibration Operating Instructions Pm Ultrasonic Gas Flow Meter Correction CCO Correction CC1 Correction CC2 Correction CC3 Reg 7130 Reg 7133 ProfileCor PCO ProfileCor PC1 Reg 7135 Reg 7136 Reg 7137 Reg 7138 SwitchMeasMode Limit Error LimitSNR dB LimitMSE o E Reg 3516 Reg 3514 Correction CC4 Reg 7134 Correction KO Correction K1 Correction K2 Correction K3 Correction K4 Correction K5 Reg 7124 Reg 7125 Reg 7126 Reg 7127 Reg 7128 Reg 7129 LimitWidth Reg 7203 InitWinSize o E MeasWinSize o E AGCInit dB AGCDamping o E MinAmplitude NormAmplitude Reg 3503 Reg 3504 Reg 3505 Reg 3506 Reg 3509 Reg 3510 Path jem2 es Path 4 Reg 7266 Reg 7267 Reg 7268 Reg 7269 Reg 7270 Reg 7271 Path 4 Reg 7272 Reg 7273 Reg 7274 Reg 7275 Reg 7276 Reg 7277 PrePeriods 4 Reg 7284 RingOutTime 4 s Reg 7224 Reg 7296 Reg 7292 Reg 7288 PathCompvalid Reg 5009 SystemConfigReg DOOutputConfigReg FreqOutputConfigReg TotalizerResolution 1 m MaxVelSound m s MaxVelGas m s Reg 3498 Reg 5101 Reg 5102 Reg 5014 Reg 7200 Reg 7201 AOGain o E AOOfiset mA Reg 7033 Reg 7034 MepaFlow 3 0 20 Page 3 3 Fig 5 20 Registers listed in the configuration protocol page
10. 04 04 2006 10 57 Rev 2 0 G_Karte_427_Rev_108 Fig 9 17 Zero flow protocol sheet 1 example 8 010 458 04 2007 SICK MAIHAK GmbH Germany All rights reserved 141 FLOWSIC600 Appendix Ultrasonic Gas Flow Meter 9 5 6 Check report leak test example Operating Instructions Pr fprotokoll Dichtheitstest Gasz hler Serien Nr serial no iC 114 o Ident Nr ident no 42T Pr fer approved by j lt 37 Datum Date zi CA C Pr fanweisung Der Test pr ft die Dichtheit der eingesetzten Sensoren In diesem Test wird die Druck nderung P3 im Inneren der Abdeckkappen gemessen Durchf hrung Unterdrucktest Starten mit dem Unterdrucktest P2 in Tabelle Unterdrucktest eintragen Nach dem Abwarten der Haltezeit P2 in Tabelle eintragen und Abweichung kontrollieren Durchf hrung Dichtheitstest 3 Sichtpr fung der Dichtfl chen des Flansches und der Dichtung Verschlie en des Gasz hlers mit Blindflanschdeckeln Montieren der Testkappen Anschlie en des Druckanschlusses an den Gasz hler Pr fen des Betriebsdrucks auf dem Messaufnehmer F llen des Messaufnehmers mit Druckluft gem Ger tekarte Spezifikation Sicherstellen das P1 w hrend der Haltezeit den Sollwert h lt Haltezeit gem Ger tekarte Spezifikation abwarten und P3 in die Tabelle eintragen e Ee eo a8 Unterdrucktest S cc Umgebungstemp EE C Dichtheitstest Leakage Test P3fmbal to to
11. I u uu 36 2 9 3 4 Configuration of the EVC D GEO eeh 3 installat EE 43 SL General Notes ee 45 3 11 RO EE 45 3 1 2 BEE leien Eer 46 32 Installation en 3 2 1 Measuring location 3 2 2 Installation configurations u a 47 3 3 Mechanical Installation 49 334 Choosing flanges seals and other Garten 49 3 3 2 Mounting the FLOWSICG00 to the pipeline EEN 50 3 3 3 SPU allgnmient EE 51 3 4 Electrical Installation 3 4 1 General information i 3 4 2 Cable specifications eege eet 53 3 4 3 Checking the cable 00S seen 54 3 4 4 Terminal Dox OMe GREEN 55 3 4 5 Operating the FLOWSIC600 in non hazardous oreag EENEG 56 3 4 6 Operation in hazardous areas in accordance with Directive 94 9 EC ATEX 57 3 4 7 Hardware SigNal settings scscsccececssicisadeseccssnconsstuseccucerssceciecennietia eduniedncensstisacessitayscibensaiienestoseredsncessiza 60 4 TT TEEN 63 4 1 General Notes IILI EE 65 42 Checking the Functions 4 2 1 FLOWSIC 600 with LED Front Panel 4 2 2 FLOWSIC 600 with LCD Front Panel 4 2 3 Function E 4 2 4 Checking the adjustment factor meter factor and analog output 70 SICK MAIHAK GmbH Germany
12. Power supply 3 18 04 03 12 13 lt ENTER gt 18 Apr 2003 12 20 23 Press STEP or DATA to select an entry which has not yet been acknowledged display is flashing Activate the ENTER function to display the corresponding time stamp of the event The display is still flashing Activate the ENTER function again in order to acknowledge the entry display will stop flashing Return to the list of logbook entries by pressing C CE 9 2 7 Resetting the error volume counters gt EV 70 m lt EV O m lt ENTER gt Counter reset OK Cancel lt ENTER gt gt EV O ms lt EV O ms After having selected the desired display activate the ENTER function A confirmation dialog will appear Activate the ENTER function again to reset the error volume counter to zero This event will be recorded in the logbook together with the time stamp Press C CE to cancel the reset 128 SICK MAIHAK GmbH Germany All rights reserved 8 010 458 04 2007 Operating Instructions 8 010 458 04 2007 Appendix 9 3 SPU Terminal Assignment Connection in accordance with ATEX IIA ae ee I 1 Entity Parameters POWER SUPDIY Vmax 16V Imax 200mA alimentation 2 _ Ci 4nF Li 0 075mH U 12 24V DC EEx e Um 253V EEx ib ia IIA digital out 0 HF2 passive Po 857mW Pi 750mW sortie digital 0 kart C Co 4100nF NAMUR Lo 7mH RL lt 250R RS 485 DJ Uo 588V lo 313mA Po 460mW Co 1000uF Ui 10V li 275mA Pi
13. Fig 2 1 FLOWSIC600 Applications The FLOWSIC600 is ideally suited for a wide range of applications in custody transfer or process measurements such as Production transportation and distribution of natural gas gt Company internal metering and billing gt Power stations and other gas consuming installations gt Chemical and petrochemical industries gt Compressed air distribution systems 8 010 458 04 2007 SICK MAIHAK GmbH Germany All rights reserved 13 FLOWSIC600 Ultrasonic Gas Flow Meter 14 2 2 2 2 1 2 2 2 Product Description Operating Instructions Conformity Configuration Technical Data 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 e EMC Directive 89 336 EC Conformity with above directives has been verified and the equipment given the CE label Standard compatibility and type approval The FLOWSIC600 was developed designed and certified according to the following recommendations OIMLR 6 1989 General provisions for gas volume meters e OIML D 11 2004 General requirements for electronic measuring instruments A G A Report No 9 1998 Measurement of Gas by Multipath Ultrasonic Meters OIML R 32 1989 Rotary piston gas meters and turbine gas meters Annex A Type approval for commercial or custody transfer was gr
14. gt D 1 O lI alla A theoretical velocity of sound can be derived from the gas composition pressure and temperature values This theoretical velocity of sound and the measured velocity of sound should be identical The velocity of sound thus provides an excellent possibility of system diagnosis SICK MAIHAK GmbH Germany All rights reserved 25 FLOWSIC600 Ultrasonic Gas Flow Meter 26 2 5 2 5 1 2 5 2 2 5 3 Product Description Operating Instructions Operating States and Signal Output The FLOWSIC600 has the following operating states e Measurement Maintenance required Configuration Malfunction Any operating states are recorded in the logbook together with the time stamps of begin and end of occurrence Measurement The Measurement status is the standard status of the FLOWSIC600 Frequency outputs and current output are updated cyclically and indicate the actual volume and volumetric flow rate The digital output Direction of flow is updated in accordance with the sign of the volumetric flow The digital output Valid measurement active represents the status ofthe measurement Positive forward and negative reverse volumetric flow rates are integrated and saved in separate internal memory sections The Modbus interface allows to query all parameters and signals at any time without interfering with the function of the system Each measurement initiated by the syste
15. bts Time Offset Register Access EEPROM RAV Game 7140 TimeDifset IAB Os em 714 TimeOliset IBA Os A ww 7148 Tme0lseHw IAB Os Rost GE Wm 7149 TimeDifsetHw 1BA Os wm 7170 DithactionTime1 Os 2 Sir Receive Signal Soy Transmit Signal PEMF Path2 EI Measure Service DAES OO 4 Fig 6 1 Device parameters tab 8 010 458 04 2007 SICK MAIHAK GmbH Germany Al rights reserved 101 FLOWSIC600 Ultrasonic Gas Flow Meter 102 Maintenance Operating Instructions Then check the zero phase position of the transducers as described in Section 6 2 1 of the service manual and optimise it if necessary Now check the criteria e Relative variation of the velocities of sound in the individual measuring paths max 0 1 Absolute variation of the measured velocity of sound compared with the theoretical velocity of sound max 0 3 as described in Section 4 2 3 If the FLOWSIC600 or the pipe section in which it is installed can be shut off completely you should also check the zero point The path velocity must be less than 0 12 m s Take into account the effect that possible thermal circulation in the meter body or adjacent pipe section has on the measuring results Sealing If the test criteria are fulfilled you can mount the transducer cover caps Activate the configuration protection switch screw on the front cap of the SPU and attach the securing clip The device must now be sealed as specified in the sealin
16. 1000 e F 43 F Lo 1 5 0 2 mH Ultrasonic transducer EEx ia IIA EEx ia IIC connections Characteristic curve linear for connecting SICK Man transmission voltage Uo 60 8 V Uo 38 9 V MAIHAK ultrasonic Short circuit current lo 95 mA lo 60 mA transducers ony Po 1444 mW Po 584 mW Co 300 nF Co 34nF 8 010 458 04 2007 SICK MAIHAK GmbH Germany All rights reserved 59 FLOWSIC600 Installation Operating Instructions pe T lt M gt s gt s gt lt vss a 1 2 s s sa a O2J xc qr y nn Ultrasonic Gas Flow Meter 3 4 7 Hardware signal settings The output assignment is determined by jumpers on the backplane in the signal processing unit If the assignment is specified by the order the jumpers are set accordingly before delivery for details see the service manual Backplane Jumper 5 Jumper 6 7 Jumper O Jumper 8 9 Jumper 3 Jumper 2 Jumper 1 Fig 3 11 Backplane with jumpers in the SPU Jumper setting Output assignment Output Assignment Terminals No Setting No Setting Hardware variant 1 Hardware variant 2 L E ooo ama an tT nn RT 29 5 SZ Active AO 0 Measured value 31 32 E Passive Signal current 4 20 mA a Switch O 12 3 Open DOO Measured value frequency BEIN Colector signal inverse val
17. 3D d Gas pu ul dos od pas pulyaq PUD UI ul JaA0I SCD Das Ppulyaq PUD UU U J3A03 DA D S eu addoy uallajsja als SI PUN LJOA RI u j js b ls usoa addoy uayajsjabais UaJUIY PUN UJ0A BIS u l j jsj b ls UL PUN LWOA x2 Laljaysjabars pu U ddI 3D d Des UJoA addoy ualjaysjabas DUUSO Mala apis MalA UOJ JuOJ UI Mala ap s US YDISUBUAYIaS JUDISUDI DIOA UJOA UJISUDU Jl Fig 9 21 Sealing plan part 1 145 SICK MAIHAK GmbH Germany All rights reserved 8 010 458 04 2007 Operating Instructions Appendix FLOWSIC600 Ultrasonic Gas Flow Meter N0 d 1 unN ESAN ON puyaq pun UOJ UI J3A03 3D d ee uayu y addoy u lj jsj B r SU PUN UJ0A 184230 U ll ls B ls UDIIMS 430 J J uDiDd sp Jaays UO v V Im J dunr zInu3sJ l1J uDiDd JDJ G DIA ID Y Y HUE MN PUD 9002 4034 Buunj gt DynuDu WOJ ySdN OOLNO MN 104 ESAN OBNO MN PUN 00Z JYDINDg qp ySdN OOLNC MN 1M4 putu q dp3 opd p s US addoy uajlajsjabals pulyaq dp3 3pld Dos pulyaq Mala apis U ulu JUDISUBUAYIas BD Il 291 II IC Ween aam toy III LC PuIyaq PUD Jos Ul J A03 3D d p s UBJUI4 PUN WGA Ber u lj jsj b is JIDJINS 0 OU SM 1S app IG u q epp UOJ Ul dp3 ado AsaypD ap pas x UJDA addoy axJDWaga y u lj si b ls JU01 U dp3 3pld Dee WOA sddoy uayalsjabais Mala UOJ JUDISUDJaplo UU UI dp3 3p d Ges UJ
18. Fig 9 2 Front panel with LC display The buttons have the following functions Function C CE In a menu to go back one level and finally to return to the measured value display STEP To go forward in the menu DATA To go back in the menu ENTER function To select a menu level to acknowledge logbook entries and to reset the error volume counters If ENTER is pressed after selection of a modifiable parameter and if the configuration protection is disabled this parameter can be edited see Section 9 2 4 Magnetic pen operation Activate the DATA ENTER button for gt 2s Button operation Press STEP and DATA simultaneously or press DATA for gt 2 s SICK MAIHAK GmbH Germany All rights reserved 8 010 458 04 2007 Operating Instructions Appendix FLOWSIC600 Ultrasonic Gas Flow Meter 9 2 2 Menu structure The display menu allows you to call up topically structured information acknowledge logged events and reset the error volume counters using the buttons described above The overview below shows all possible displays Notes Parameters can only be entered or edited after having switched to the Service mode Meaning of the connection lines in the menu structure below Vertical lines to go forward STEP button or back DATA button Horizontal lines ENTER function to change to lower level menu C CE button to change to higher level menu Menu levels Notes Main menu unsecured gt V
19. Operating Instructions Ultrasonic Gas Flow Meter 9 4 Connection Diagrams for Operating the FLOWSIC 600 in Hazardous Areas in Accordance with North American Guidelines CSA amp S d E uoa p ebeg 0099ISAO14 por an Gre Ss S al Aen ARA ON Bumeig ANVWU3O pV wod IIO HOPUSHO Soro HuL e 22 Bury souebieg om Buimesg 0 14U09 e ae dupe e9 q parea Vugel A6 8E I0A Z UOISIAIG sept 404 Ayjiqeyns Weu Aew uonnsqns piezeH uotsoldx3 ONINHVAA snopyezey uou 8q 0 UMOUY SI Bale y 10 Jo PoyolIms useq seu Jemod ssejun Juswd nba 1o8uuoosip jou oq PeIzeH uorsojdxg ONINHVAA Z O3N 40 DAD OU YM S9UEPI09SE UI Wee L uonlle1su 3 9u0Z UOISIAIG vupz Lat eege bg AOE UIA l E t SE siguluue G8FSY ouer ee Sjeujuue UE Indino Ven vywgg 00 AOE u A Z8 Lg sjeuiwa yNdjno Joug Zr y Sieuluu 1ndino Byuog vywog 0 ywog Uull Ave O AZL UIA 2 seua Alddng semod s oyoweseg Aug Bumojlo y yA wuajea nba 10 xxxx 009H1 SI9ONPSUEAL S iuoseni n gordn TOpue msn Si PL epog duet u Boip H g II dnou L auoz Leet pL poO duet u Boip H g H dnog 0 auoz L sselo ZS 1g sjeuuue yndyno esing g pue z sinchno Aug uolnellel1sul EUIWIAL Diet
20. 1 20 2880 DN 300 NPS 80 130 200 G2500 4000 1 50 1 30 1 20 1800 12 65 130 200 320 G4000 6500 1 100 1 50 1 30 1 20 1110 65 G4000 E 7800 1 120 920 80 G1600 2500 1 30 2880 DN 350 NPS 80 130 200 G2500 4000 1 50 1 30 1 20 1800 14 80 130 200 320 G4000 6500 1 80 1 50 1 30 1 20 1110 80 G4000 E 7800 1 100 920 130 200 G2500 4000 1 30 1 20 1800 DN 400 NPS 130 200 320 G4000 6500 1 50 1 30 1 20 1110 16 120 200 320 500 G6500 10000 1 80 1 50 1 30 1 20 720 120 G6500 E 12000 1 100 600 130 G2500 4000 1 30 1800 DN 450 NPS 130 200 320 G4000 6500 1 50 1 30 1 20 1110 18 130 200 320 500 G6500 10000 1 80 1 50 1 30 1 20 720 120 G6500 E 12000 1 100 600 200 320 G4000 6500 1 30 1 20 1110 DN 500 NPS 200 320 500 G6500 10000 1 50 1 30 1 20 720 20 200 320 500 800 G10000 16000 1 80 1 50 1 30 1 20 450 200 G10000 E 20000 1 100 360 320 500 G6500 10000 1 30 1 20 720 DN 600 NPS 320 500 800 G10000 16000 1 50 1 30 1 20 450 24 320 500 800 1300 G16000 25000 1 80 1 50 1 30 1 20 288 320 G16000 E 32000 1 100 225 18 SICK MAIHAK GmbH Germany All rights reserved 8 010 458 04 2007 Operating Instructions Product Description FLOWSIC600 wm wmd 2 3 2 3 1 2 3 2 Ultrasonic Gas Flow Meter System Components The FLOWSIC600 measuring system consists of the following hardware components Meter body e Ultrasonic transd
21. 2 0 Viton LT170 TT natural gas resistant 40 200 C 5314393 O ring 15 2 0 Celrez FFKM 900 15 260 C 5315517 O ring 11 5 1 5 Viton natural gas resistant 25 200 C 5313739 O ring 11 5 1 5 Viton V747 75 25 200 C 5314241 O ring 11 5 1 5 Celrez FFAM 900 15 260 C 5314490 O ring 7 5 1 5 Viton natural gas resistant 25 200 C 7044129 O ring 7 2 0 Viton LT170 TT natural gas resistant 40 200 C 5315493 SICK MAIHAK GmbH Germany All rights reserved 8 010 458 04 2007 Operating Instructions 8 010 458 04 2007 List of parts FLOWSIC600 Ultrasonic Gas Flow Meter Other Part number Plug 1 4 in NPT 7045206 Plug 1 4 in NPT 5310562 Retaining bolt M27 2 7041294 Spring washer B12 7045991 Retaining bolt M22 1 5 4040076 Serrated lock washer 10 5 5313750 Retaining bolt M16 1 5 4039880 Serrated lock washer 8 2 5313705 Sealing cord for cap 2 0 EPDM yard ware 5308767 SICK MAIHAK GmbH Germany All rights reserved 111 FLOWSIC600 List of parts Operating Instructions Ultrasonic Gas Flow Meter 112 SICK MAIHAK GmbH Germany All rights reserved 8 010 458 04 2007 FLOWSIC600 Ultrasonic Gas Flow Meter Appendix Characteristic Properties and Dimensions of the Meter Body Operation and Menu Structure of the SPU with LC Display SPU Terminal Assignment Device Documentation FLOWSIC600
22. DN 50 54 5 54 5 54 5 EU 81 5 80 9 4 102 3 97 2 DN 100 107 1 106 3 104 3 6 157 1 154 1 8 206 4 205 202 7 198 5 193 7 DN 200 206 5 204 9 199 1 10 260 4 257 5 254 5 247 7 242 9 255 4 248 0 12 311 2 307 1 303 2 295 3 288 9 DN 300 309 7 301 9 295 5 14 339 8 336 6 333 3 325 4 317 5 343 0 336 0 16 390 6 387 4 381 0 373 1 363 5 DN 400 390 4 378 441 4 434 9 428 7 419 1 409 5 20 489 0 482 6 477 8 466 8 455 6 DN 500 492 0 590 6 581 1 574 6 560 4 547 7 Tab 9 3 Inner pipe diameter 8 010 458 04 2007 SICK MAIHAK GmbH Germany All rights reserved 119 FLOWSIC600 Ultrasonic Gas Flow Meter 120 9 2 9 2 1 ATTENTION Appendix Operating Instructions Operation and Menu Structure of the SPU with LC Display Operation The current measured values counter readings and diagnosis information can be displayed on the two line LC display on the front panel of the SPU The information you want to be displayed can be selected using a magnetic pen while the front cap is kept closed or using the buttons while the front cap is open see Fig 9 2 Important EMC and protection from accidental contact cannot be guaranteed if the cover is opened SICK MAIHAK FLOWSIC 600 Measured variable LC display Measured value gt V 499820m3 h DATA ENTER STEP C CE Magnet sensors O Buttons DATA STEP C CE L ewen
23. Depending on loop resistance Minimum input voltage on the FLOWSIC600 12 V Peak current 150 mA Cable diameter 6 12 mm Fixing range of the cable glands Digital output current output Notes Type of cable Twisted pair shielded Connect shielding at other end to ground terminal Min max cross sectional area 2 x 0 5 mm2 Do not connect unused conductor pairs and prevent them from accidental short circuit Maximum cable length Loop resistance under load lt 250 Q Cable diameter 6 12 mm Fixing range of the cable glands Serial port RS485 Notes Type of cable Twisted pair shielded impedance approx 1200 Connect shielding at other end to ground terminal Min max cross sectional area 2 x 0 5 mm2 Maximum cable length 100 m at 0 5 mm 200 m at 1 5 mm Do not connect unused lead pairs and prevent them from accidental short circuit Cable diameter 6 12 mm Fixing range of the cable glands SICK MAIHAK GmbH Germany All rights reserved 53 FLOWSIC600 Installation Operating Instructions I D Ultrasonic Gas Flow Meter 3 4 3 ATTENTION ATTENTION 3 4 4 Checking the cable loops Check the cable loops in order to verify that the cables are connected correctly Proceed as follows gt Disconnect both ends of the cable of the loop to be tes
24. Haltezeit Time 2 min Abweichung Difference Pressurized air Testing Cap Tunnel for transducer cables provides the link between testing cap Inner space and pipe connector to the 3 way valve Ident Nr FDB20020104 Produktgruppe FLOWSIC600 Revision 1 4 03 03 2005 Purpose of the test is to detect ifthere are any leakages at the transducer sealings For this test the pressure P3 inside the mounted testing caps will be observed and compared with ambient pressure Procedure of Underpressure Test Start the underpressure leak check note P2 in the table Underpressure Test Wait Procedure of Leakage Test Visual check of flange sealing faces and gaskets Block the pressure tap atthe meter body Block the meter body with blind flanges Mount the testing caps Check the design pressure of the meter body Fill the meter body with pressurized air up to Make shure that P1 is at least during the leakage test Wait then record P3 again to the table Dichtheitstest P1 Priifdruck Umgebungstemp Abweichung Difference Test o k wenn AP3 lt 2mbar SICK Engineering GmbH Seite 1 1 142 Fig 9 18 Check report leak test example SICK MAIHAK GmbH Germany All rights reserved 8 010 458 04 2007 FLOWSIC600 Ultrasonic Gas Flow Meter ion tallat Ins Intrinsically safe Appendix u 00T yqbueT umurxeu wyo 0ZI eso
25. W Path compensation valid 15 DSP Parameter error 5 5 Monitors System status men eeceeeoceceoece eeceeeoceccedee eeceedocecceeoee ele Fi go 3 enu If the configuration protection is active the switch must be turned to its open position to be able to change any parameters See Fig 5 6 Configuration protection enabled Configuration protection switch Configuration protection disabled Fig 5 6 Configuration protection switch gt Disconnect the FLOWSIC600 from the power supply Take off the front cap of the signal processing unit Move the switch to the desired position Mount the front cap again Reconnect the power supply 8 010 458 04 2007 SICK MAIHAK GmbH Germany All rights reserved 81 FLOWSIC600 Ultrasonic Gas Flow Meter 5 3 Calibration Operating Instructions Calibrating the FLOWSIC600 Before you can start the calibration the process parameters Temperature fixed register 7040 and Pressure fixed register 7041 must be set to the actual conditions during the calibration these parameters can be edited on the Device parameters tab The FLOWSIC600 must be switched to the configuration mode in order to be able to edit parameters inj Vleparlow 3 2 00 3 tho Screen_shots 3 in steel 05258747 ver II Tuesday FSF Eile Connection Operating Mode Monitors Options Help eS Cease Owe lt A B o G m P I
26. e g every 30 seconds and the 7001 7002 Tab 2 1 Configuration for the volume correction calculation calculated SGERG compressibility e g every 30 seconds 8 010 458 04 2007 SICK MAIHAK GmbH Germany All rights reserved 39 FLOWSIC600 Product Description Operating Instructions Ultrasonic Gas Flow Meter D GA Meter Identification EN E Meter Setup E Ae Process parameter E R Fixed values masa 7040 Pressure fixed we 7042 7041 L Base values wi 3540 T_Address 7024 7025 m 7026 7750 m 3541 7751 7752 17753 7754 7755 Fig 2 14 Device parameters tab Temperature fixed 273 15K 1 01325 barla Compressebility fixed 1 o E P_Address loE 20 TemperatureBase 273 15K PressureBase CompressBase Heating Value H2 0 001 Mol CO2 1Mol 1 01325 baal lo E 11 1 kwh n Mass Density at Base 0 7 kg m Pressure Transm Offset 0 barfa GergKon_K0 GergKon_K1 GergKon_K2 GergKor_K3 GergKor_K4 0 257838 o E 0 00438677 o 0 000152824 ot 1 24832e 006 o E 1 94576e 009 o E Beside the registers always described additional registers may require the input of parameter values particularly if the SGERG compressibility calculation is being implemented See the following table for a description of each of those registers 40 SICK MAIHAK GmbH Germany All rights reserved 8
27. sheet 2 example SICK MAIHAK GmbH Germany All rights reserved 135 FLOWSIC600 Appendix Operating Instructions Ultrasonic Gas Flow Meter 9 5 3 Check report SPU example 136 SICK MAIHAK Elektronik Electronic Pr fschein Check report Analogplatinennummer Analoge board no 2005420165 Durchgefiihrte Tests Checks Seriennummer Seriel number TT Pr fen Barrierenspannung EX voltage check 06020023 C Referenzlaufzeitmessung Reference check Variante Ex Barriere Ex proved ATEX IA TT Funktionstest Function check Messwerte Measuring values Referenzlaufzeitmessung Reference check Pfad 1 Path 1 Pfad 2 Path 2 Pfad 3 Path 3 Pfad 4 Path 4 Elektronik Zeitoffset s AB Electronic time offset BA Diffraction time s Elektronikparameter Electronic parameter Pfad 1 Path 1 Pfad 2 Path 2 Pfad 3 Path 3 Pfad 4 Path 4 HW Zeitoffset AB Register 7148 7150 7152 7154 HW Time offset AB Wert s 2 528E 0 Bl HW Zeitoffset BA Register 7149 7151 7153 7155 HW Time offset BA 2 338E 07 2 287E 07 2 516E 07 i Die Funktion des Ger tes wurde unter o g Bedingungen nachgewiesen 37 3 0 PA Datum Date Priifer Approved by Eingebaut in Gaszahler Seriennummer Used in device with serial number 06078749 Der zu setzende Parameter TimeOffsetHW Register 7148 7155 ergibt sich als Summe aus Zeitoffset Laufzeitreferenz und nennweitenabh ngigen Zeitof
28. 010 458 04 2007 Operating Instructions Product Description FLOWSIC600 Ultrasonic Gas Flow Meter Register number Name Description 3026 3542 See Tab 2 1 See Tab 2 1 3545 3540 P_Address Communication address of the pressure transmitter must be identical in the transmitter and gas flow meter 3541 T_Address Communication address of the temperature transmitter must be identical in the transmitter and gas flow meter 7024 TemperatureBase Standard condition for temperature to which the measured volume is normalized 7025 PressureBase Standard condition for pressure to which the measured volume is normalized 7750 Heating Value Average heating value of the gas 7751 H2 Average hydrogen concentration 7752 C02 Average carbon dioxide concentration 7753 Mass Density at Base Average standard density of the gas 7754 PressureTransmOffset Mean local atmospheric pressure as an offset when overpressure transmitters are used When absolute pressure transmitters are used the parameter remains O 7040 Temperature fix Is used for volume correction when no current values provided by transmitter e g at HART_Readintervall 0 7041 Pressure Is used for volume correction when no current values provided by transmitter e g at HART_Readintervall 0 7042 Compressebility Is used for volume correction when the feature calculation of compressibility is not act
29. 1420mW Lo 1 5mH L cake Vo 30V 10 100mA Pi 750mW N digital out 1 HF1 passive C Usat lt 2V 2mA lt IL lt 20mA E E sortie digital 1 i Ui 30V de 100mA fmax 6 kHz NAMUR _ Pi 750m digital output 2 passive DJ Usat lt 2V 2mA lt IL lt 20mA sortie digital 2 Ui 30V li 100mA Pi 750mW digital output 3 passive Usat lt 2V 2mA lt IL lt 20mA ia digi Ui 30V li 100mA A e sortie digital 3 D NAMUR B G 750mW Uo 5 88V lo 313mA Po 460mW Co 1000uF RS 485 O Ui 10V li 275mA Pi 1420mW Lo 1 5mH For further details see user manual and EC Typ Examination Certificate T V 01 ATEX 1766 X Fig 9 3 Terminal assignment in accordance with ATEX IIA Connection in accordance with ATEX IIC 1 Entity Parameters power supply Vmax 16V Imax 200mA alimentation 2 Ci 4nF Li 0 075mH U 12 24V DC EEx e Um 253V EEx ib ia IIC E Uo 224V Ui 30V u 4 20 mA U active b 155mA i i 100mA digital out 0 HF2 passive _ Po 857mW Pi 750mW sortie digital 0 Co 163nF Wair Olo RL lt 250R fra 6 KHz NAMUR 1mH L Uo 5 88V lo 313mA Po 460mW Co 4311 gt RS 485 L Ui 10V li 275mA Pi 1420mW Lo 0 2mH Gg Vo 30V lo 100mA Pi 750mW NW digital out 1 HF1 passive Usat lt 2V 2mA lt IL lt 20mA a sortie digital 1 Ui 30V li 100mA fmax 6 kHz NAMUR _ Pi 750mw digital output 2 passive _ Usat lt 2V 2mA lt IL
30. 2 UItrASOMIC transducets secsiecsectisecesececcacaicensssiuaccusertscteauerieartetctdecesaecensiisuectndeouutcasertbsnnasdedeentincentesnecda 19 2 3 3 Signal processing upitu u ek il 20 2 3 4 MEPAFLOW600 diagnosis and configuration Software EEN 20 2 4 Measuring Principle 2 4 1 Determining the gas velocity EENEG 22 2 4 2 Calculating the volumetric flow rate EEN 23 2 4 3 Calculating the actual volume 2 4 4 Determining the velocity of sound 2 5 Operating States and Signal Output 26 2 5 1 SET EE 26 2 5 2 Maintenance Ee le siccecicsccsssecusccedcacasecossttanctustensicenstiaueerasedsusncanerbyecsanceSsnciasecainecetstuuvedsisaicensttduet e 26 2 5 3 Configuration SS ea a oe eh a 26 2 5 4 Eier e E 27 2 6 Self dlagnosis nn eech saus asas 29 2 7 Event LOS BUNS eessen 30 2 8 Path Failure Compensation 31 SICK MAIHAK GmbH Germany All rights reserved 3 FLOWSIC600 Ultrasonic Gas Flow Meter Operating Instructions 2 9 Configuration 2 9 1 Hardware variants and signal outputs 2 9 2 System configuration with external volume conector EENEG 34 2 9 3 System configuration with integrated Electronic Volume Corrector 35 2 9 3 1 Genel CN 35 2 9 3 2 Assembly dE UEL 36 2 9 3 3 Measurement of pressure and temperature
31. 3 94 SICK MAIHAK GmbH Germany All rights reserved 8 010 458 04 2007 Operating Instructions Calibration FLOWSIC600 Ultrasonic Gas Flow Meter FLOWSIC 600 configuration protocol constants 23 03 2007 13 42 00 Reynolds correction CorrTreshold Correction CCO Correction CC1 Correction CC2 Correction CC3 Correction CC4 0 0 0237706 72103 3 1796 71 1 1 1e 006 CorrLowPr CCO CorrLowPr CC1 CorrLowPr CC2 CorrLowPr CC3 CorrLowPr CC4 0 0 1 1 0 Profile corection Correction KO Correction K1 Correction K2 Correction K3 Correction K4 Correction K5 1 053 0 07 0 07 0 0413 0 0328 0 051 Corr en_lo Cor en_hi ProfileCor PCO ProfileCor PC1 0 7 0 8 2 3 0 65 Limits SwitchMeasMode Limit Error LimitSNR dB LimitMSE o E LimitWidth 70 95 13 0 0 012 80 Signal detection InitWinSize o E MeasWinSize o E AGCinit dB AGCDamping o E MinAmplitude NormAmplitude 2200 600 66 10 20 75 Signal models Sensor A Path 1 Path2 Path 3 Path 4 TxFreq Hz 2 08e 005 2 08e 005 2 08e 005 2 08e 005 TxPeriods o E 4 4 4 4 TxPhase o E 3 3 3 3 TxDuration s 6e 005 68 005 6e 005 68 005 TxDampOut o E 60 60 60 60 TxAmplitude o E 123 123 123 123 Sensor B Path Path2 Path3 Path 4 TxFreq Hz 2 08e 005 2 08e 005 2
32. 34569870 m3 Sub menu Indication of the current operating volume counter readings lt 0 m3 Configuration protected for each direction of flow first line positive direction second line negative direction gt EV 2145 m3 Counter Indication of the current error volume counter readings for lt EV O m3 reset each direction of flow top line positive direction bottom protected Reset counter After selection of the desired display activate the ENTER OK Cancel function A confirmation dialog will appear gt EV O m3 Activate the ENTER function again to reset the error volume lt EV O m3 counter to zero This event will be recorded in the logbook together with the time stamp To cancel the reset press C CE Operational mode Indication of the current operational mode Service To switch the operational mode between Measurement Yes No and Service FLOWSIC600 To display and edit the system configuration for Configuration commissioning and parameterisation Configuration To enter the basic parameters for calibration of the meter Calibration according to the field conditions Correction forw To display and configure the forward correction factor 1 00 Correction backw To display and configure the backward correction factor 1 00 Working pressure The parameters pe_min and pe_max will be calculated from 20 00 bar the entered average working pressure Test mode 1 bar To turn on off the calibration mode ON Air Test OF
33. 685 80 570 360 cl 900 1060 1200 753 40 704 80 PN 16 DIN 2633 520 691 00 580 00 DN400 PN 64 DIN 2636 670 736 00 670 00 PN 100 Dimensions on request cl 150 750 768 50 635 00 o cl 300 850 806 60 711 20 620 405 i cl 600 Ge 1000 822 50 743 00 cl 900 1400 1350 844 70 787 40 PN 16 DN450 PN 64 Dimensions on request PN 100 cl 150 940 800 25 698 50 z cl 300 1100 838 35 774 70 2 cl 600 l 1235 857 40 812 80 670 450 cl 900 1850 1500 879 60 857 20 PN 16 DIN 2633 900 808 50 715 00 DS See Dimensions on request PN 100 cl 150 1425 907 40 812 80 e cl 300 1700 958 20 914 40 a cl 600 RRS 1900 970 90 939 80 760 540 cl 900 2300 1800 1 021 70 1 041 40 PN 16 DIN 2633 1350 921 00 840 00 BINGO ENS Dimensions on request PN 100 cl 150 1500 947 48 869 95 x cl 300 1800 1 025 28 971 55 2e cl 600 MEBLE 2050 1 047 50 1 016 00 SS pee cl 900 2500 1300 1 085 85 1 085 85 PN16 DN650 PN64 Dimensions on request PN100 cl 150 1950 1 028 00 927 10 S cl 300 2200 1 081 97 1 035 05 SS cl 600 ASMEBISAT 2400 1 101 02 1 073 15 862 630 cl 900 2900 1400 1 168 40 1 168 40 PN16 DIN2633 1800 1 019 45 910 00 DN700 PN64 2 e Dimensions on request PN100 8 010 458 04 2007 SICK MAIHAK GmbH Germany All rights reserved 117 FLOWSIC600 Appendix Operating Instructions Ultrasonic Gas Flow Meter
34. Device status boxes for possible malfunctions 0 16 01 09 16 01 09 16 01 09 16 01 09 16 01 09 16 01 09 16 01 09 L l 0 its 0 0 0 000 0 00 H m Fre Flow rate a c 0 fe h Forward volume a c Average flow velocity 0 000 His Reverse volumen Lac 0 00 Forward error volume a c LL Reverse error volume a c Configuration Service OFFLINE Fig 5 8 Measuring values tab detail SICK MAIHAK GmbH Germany All rights reserved 8 010 458 04 2007 Operating Instructions Calibration FLOWSIC600 n i IU IU K K KK K K NK NK K K KK KK KK KK K K K K K K K K K K X XK K K KK K K K K K K K K U UY uuu Ultrasonic Gas Flow Meter Correction of settings Now check the ZeroPhase parameter in all paths Correctly adjusted zero phases of the see Service manual individual paths are the basis for accurate transit time measurement of the ultrasonic Section 6 2 1 signals The ZeroPhase parameters are correctly adjusted if the red cursor COR corrected runtime is at least close to and the blue cursor RT runtime is exactly on the second positive zero passage of the received ultrasonic signal see Fig 5 9 Fig 5 9 Received ultrasonic signals position of the evaluation lines COR and RT Correctness of the zero passages can be verified with the help of the deviations of the velocity of sound among the individual paths Monitor VOS relat
35. Division 2 Groups D T4 Class I Division 1 Groups B C D T4 Class I Division 2 Groups A B C D T4 Ultrasonic transducers intrinsically safe ia Ambient conditions Temperature range ATEX 40 60 C 40 F 140 F Storage temperature 40 60 C 40 F 140 F IP classification IP 67 Relative humidity lt 95 ATTENTION 8 010 458 04 2007 Within Q Qmax and with straight inlet outlet section of 10 D 3 D or 5 D 3 D with flow straightener Approval for operation the ultrasonic transducers within zone O only valid under atmospheric conditions 20 C lt Team lt 60 C 0 8 bara lt Pmedium lt 1 1 bara Warning When used in hazardous areas comply with the required type of explosion protection during installation intrinsically safe or increased safety SICK MAIHAK GmbH Germany All rights reserved 17 FLOWSIC600 Product Description Operating Instructions Ultrasonic Gas Flow Meter Remarks in case the meter is used according to PTB German rules Any flow rates given above are also valid in the bidirectional mode Meter sizes marked with an asterisk must only be used in configuration no 2 see Section 3 2 Meters sizes 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 Q results from the flow range the meter is
36. E 0 1382 0 3618 0 3618 0 1382 Ultrasonic sensors Path 1 Path 2 Path 3 Path 4 SensorLength A m 0 03897 0 03901 0 03899 0 03897 SensorLength B m 0 03902 0 03903 0 03900 0 03900 TimeOffset AB s 1 74974e 005 1 74139e 005 1 74105e 005 1 74694e 005 TimeOifset BA s 1 74979e 005 1 74121e 005 1 74122e 005 1 74704e 005 ZeroPhase AB rad 0 3 0 3 0 7 0 7 ZeroPhase BA rad 0 3 0 3 0 7 0 7 SerlalNumberSensor A 05470085 05470070 05470072 05470197 SerialNumberSensor B 05470025 05470030 05470032 05470040 Signal Processing Unit SPU Path 1 Path2 Path 3 Path 4 TimeOffsetHW AB s 2 4741e 007 2 2481e 007 2 3697e 007 2 5287e 007 TimeOffsetHW BA s 2 4609e 007 2 2409e 007 2 4093e 007 2 5413e 007 DiffractionTime s 0 0 0 0 SerialNumberAnalog 05420160 SampleRate 10 AvgBlockSize 100 Process parameters fixed Base conditions Temperature fixed K Pressure fixed bar a Compressebility fixed TemperatureBase K PressureBase bar a CompressBase 285 15 30 0 1 293 15 1 0 1 Warning levels WamingDuration s WamingSNR dB WamingAGC dB WamingAGCDeviation dB WamingSOSDeviation ms 30 13 0 93 6 10 0 MepaFlow 3 2 00 Page 1 3 Fig 5 17 Example of a configuration protocol page 1 8 010 458 04 2007 SICK MAIHAK GmbH Germany All rights reserved 91 FLOWSIC600 Calibration Operating Instructions Pr Ultrasonic Gas Flow Meter Adjust mode Adjust CRC Reg 3051 Reg 3052 LowFlowCutoff m3 h ZeroFlowOffset m h
37. Ee i sun TOA Sie SALYIS peztremion snacow s a L 1 203981109 MTOA 139919 Ebaaeibeaut ts oosorsmotd rL weal HLI Zr irr resod Cer wotyolumass gt LUVR manner INNS OFFA T KZ D EW psao doe og Aen uoTaelr6er Teuctaen PT 6L009 NB ate ecSuwpiooomFw UT na ur So op ei uTweap TOTIUS ees BD PUY DEN yaqm SouTpPITOSON UT eoTIAeWY YIACN UT x FUOFIE TTEISUF OFSUFIJUF UON Bufugydrt JO s yotrze zusrmoat ass XO t njrtemcd yo euro uy pepueumuosexr ST otizeiotd eGans Teuctatpry e6ueuo e3aogeq UOSGI IOJ YOOT MO MOT JO gwo UI sdiL 44 SAKI Buypqoe yeey Arse OTEUTWISI prey 103 eeen Sq A 24 u 09T ya ust pute g wyo ot s5urpsdur xordde enqpom Sersu aaa PE ZeiemgeIp arges um ZT 9 wolTreuwv YQION L n ot T ao sa at x OZN spuert etq gt UOTJUSJIY WTJe007 prezeg uorsordxz Peary prezep wy zT E i EE 1 GE SE L s dl EECHER s C s lI y CI Ce Cl Ce O I Fig 2 15 Connection plan FLOWSIC600 with integrated EVC 8 010 458 04 2007 SICK MAIHAK GmbH Germany All rights reserved 42 FLOWSIC600 Ultrasonic Gas Flow Meter Installation General Notes Installation Mechanical Installation Electrical Installation Operating Instructions Installation FLOWSIC600 vA SCS Ultrasonic Gas Flow Meter 3 Installation 3 1 General Notes 3 11 Delivery The FLOWSIC600 is delivered in a pre assembled condition in a sturdy package The sea
38. Flow Meter 62 SICK MAIHAK GmbH Germany All rights reserved 8 010 458 04 2007 FLOWSIC600 Ultrasonic Gas Flow Meter Commissioning General Notes Checking the Functions Operating Instructions Commissioning FLOWSIC600 Ultrasonic Gas Flow Meter Commissioning 4 1 General Notes see the software manual 8 010 458 04 2007 Before starting commissioning all activities that are described in Chapter 3 have to be completed We recommend to use a laptop PC with installed MEPAFLOW 600 program for the commissioning for installation instructions see the software manual The FLOWSIC600 is wet or dry calibrated when delivered to the end user The dry calibration contains the 3 D measurement ofthe meter body zeroflow and velocity of sound test and other system specific examinations which belong to the manufacturing and quality insurance process The wet calibration is performed at a flow calibration test stand All parameters determined by the mentioned tests as well as custom designed data are preset and stored in the FLOWSIC600 in a non volatile memory before delivery Custom designed data that are known before manufacturing the device don t have to be changed during commissioning It s important to know this especially in cases when the FLOWSIC600 is Officially sealed after an authorized flow calibration Generally the parameters are protected by a password If the FLOWSIC600 shall be used fo
39. The information provided in the boxes marked OO to 12 see Fig 5 3 of the type plate at the signal processing unit must conform with the information in the device documentation Type plate at the signal processing unit Type plate at the meter body SICK MAIHAK HCKIMAIHAK novscso ID CZ TS C gt FLOWSIC 600 Yan SE GG S FLSOO f DN NPS PT C z ber CE xs Saal Na Weicht Ce Uke AudGr 1 Made in Gemary CE wez Made in Genen Greet e 11 4 2G EEx de b bn QE T sarc TAOL ATEX FGX U 25W P 2 6 Hu os jn U JE 200m4 ere ve DCH For Brba de kb see Ecominaton Ceria t Fig 5 3 FLOWSIC600 type plates Information on nominal size DN NPS design temperature TS design pressure PS and test pressure PT can be found on the type plate at the meter body Warning The operating pressure must not exceed the design pressure PS during the calibration Connecting the FLOWSIC600 with the MEPAFLOW600 program Connecting the FLOWSIC600 with a PC or laptop The serial interface at the FLOWSIC600 conforms with the RS485 standard An RS485 RS232 cable and an 1 1 interface cable pin 2 pin 2 and pin 3 pin 3 are required for data transfer to the PC or laptop see Fig 5 4 Because MEPAFLOW600 does not support RTS CTS data transfer the adapter must be able to distinguish between transmission and reception mode automatically Terminals Coir i 33 L i
40. a new one that contains the new factor 70 SICK MAIHAK GmbH Germany All rights reserved 8 010 458 04 2007 Operating Instructions 8 010 458 04 2007 Note Commissioning FLOWSIC600 Ultrasonic Gas Flow Meter The new meter factor can be calculated by using the following formula fmax 3600 Pulse Meter factor Qmax Volume unit fmax Max pulse frequency Hz Qmax Max volumetric flow m h ft2 h Analog output To adapt the FLOWSIC 600 at the different application conditions you have to adjust the analog output using the MEPAFLOW600 software field Analog output in the Device parameters tab see the software manual The output current lout is calculated as follows Q AORangeLow lor 4 mA 16 mA out 4 MAT AORangeHigh AORangeLow M Q Actual volumetric flow rate normalised volumetric flow rate mass flow rate melecular weight AORangeHigh Upper range limit has to be set AORangeLow Lower range limit has to be set If components that may affect the flow profile e g valves are installed in the pipe ata distance of less than 20 DN upstream the adaptive path failure compensation routine must be deactivated see Section 2 8 and Fig 4 8 Path fail compensation box Sealing After having completed the electrical installation seal the signal processing unit in accordance with the sealing plan see Section 9 7 Fasten the magnetic pen which is
41. and duration of the next measuring point New Measurement Poin MP1 Stop logging after s 300 Enabled Vv The data are structured and saved chronologically in the session file They can be exported later with the help of the menu item File Session history Determining and entering the adjust factors Determining the adjust factors is based on the weighted mean error WME of the flow rates Q The WME is calculated by the test labs according to the equation WME where kj for Qi lt 0 7 Qmax n Qmax a o EH andk 14 for 0 7 Qmax lt Qi lt Qmax max Q Tested flow rate Q max Tested maximum flow rate fi Weighted mean error in established at the tested flow rate If the meter is calibrated for bidirectional use the weighted mean error is determined using the values established separately for each direction of flow The new adjust factor is calculated as follows 1 WME 100 AF 1 DO A SICK MAIHAK GmbH Germany All rights reserved 8 010 458 04 2007 Operating Instructions Calibration FLOWSIC600 Ultrasonic Gas Flow Meter The new adjust factors must now be entered in the FLOWSIC600 as follows In the MEPAFLOW600 programme switch the measuring system to the configuration mode and call up the Device parameters tab Enter the new adjust factors in the Calibration box Change back to the measuring mode Then verify the adjustment by repeating a measurement at a cert
42. design ia All screw type terminals as well as air gaps and creepage distances of the FLOWSIC600 comply with EN 50019 Connection characteristics Field connections Separate terminal box separated from the field connections with partition wall in the housing and cover to EN 50020 Separate terminal box separated from the power supply connections with partition wall in the housing and cover to EN 50020 Cable routing via EExe cable gland M5 Cable routing via 2x EExe cable gland ground terminal integrated into housing section cast on part Connection options The protection concept for the FLOWSIC600 permits the following connection options Power supply connection and field connections with increased type of protection e e Intrinsically safe power supply connection and field connections i 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 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 Uy 253 V Requirements regarding cabling in hazardous areas Europe The cables must fulfil the requirements set forth in EN 60079 14 Cables that are subject to exceptional thermal mechanical or chem
43. designed for according to the main plate It is for a flow range of 1 20 Q 0 20 Qmax and for a flow range of 1 30 Q 0 15 Den and for a flow range of gt 1 50 Q 0 10 Qyax Example Meter sizes and measuring range for custody transfer applications according to PTB Min flow rate Qrin Meter size Max flow rate Qmax Measuring range Pulse value m h m h pulses ms 13 G160 250 1 20 28800 DN 80 NPS 3 13 20 G250 400 1 30 1 20 18000 13 20 32 G400 650 1 50 1 30 1 20 11100 20 G250 400 1 20 18000 DN 100 NPS 4 20 32 G400 650 1 30 1 20 11100 20 32 50 G650 1000 1 50 1 30 1 20 7200 32 G400 650 1 20 11100 32 50 G650 1000 1 30 1 20 7200 DN 150 NPS 6 32 50 80 G1000 1600 1 50 1 30 1 20 4500 32 G1000 E 2200 1 70 3272 32 50 80 130 G1600 2500 1 80 1 50 1 30 1 20 2880 50 G650 1000 1 20 7200 50 80 G1000 1600 1 30 1 20 4500 DN 200 NPS 8 50 80 130 G1600 2500 1 50 1 30 1 20 2880 40 G1600 E 3600 1 80 2000 40 80 130 200 G2500 4000 1 100 1 50 1 30 1 20 1800 50 80 G1000 1600 1 30 1 20 4500 DN 250 NPS 50 80 130 G1600 2500 1 50 1 30 1 20 2880 10 50 80 130 200 G2500 4000 1 80 1 50 1 30 1 20 1800 50 G2500 E 5600 1 100 1285 50 130 200 320 G4000 6500 1 130 1 50 1 30 1 20 1110 80 130 G1600 2500 1 30
44. eo gt oejgz qur K e ze snopzezey uou pue orA p useMmqeq SOTAISS p eTqeo TTe TTeIsuT 07 spusuwoos VIe let 52 1 WESER i xaeuoyg r Ta Ta 7 H er Ty Uy Id D gi n Te qgnduoomoTy Y Y wf 2 2 x MM Fer 8 8 8 ao I Bzessetere siereteg bett j SOEREN EE TER 4 pus 20 Ab 9 6 FLOWSIC600 Installation Diagrams 9 6 1 Operating Instructions 143 Fig 9 19 FLOWSIC6O0 intrinsically safe installation SICK MAIHAK GmbH Germany All rights reserved 8 010 458 04 2007 u oot y2adust umurxeu wuo 0ZI Suep dur xozdde snqpow cgPrsy Zeyewuetp etqeo ww ZT 9 eoOTTSWY UNION LdN uZ T azo Na S T X OZW ep xaa z t n ep xa3 D L n JII dnozp z uog Tssera susboap H II dnozp T uoz TSSeTI 009 DISMOTA Appendix Operating Instructions 9 6 2 Non intrinsically safe installation Ultrasonic Gas Flow Meter FLOWSIC600 spuer stage a pue 9 q y sdnoas guotstatq Teser Sn eee ue 9 g sdnozo TuoTsTATa ISSU TuoTJuoIIY q pue o g Sr ZE ATG ees Tenueu uorqea do ees srrea p AayJ nJ 104 iTFPF 03 009 OISMOTH SU sneo ued Burrqeo 4eTTOOUTL Kar 7 ONTHSN peazesqo eq 4snu uorqeTno rz Teuor3eN il S N Teuzsgur astnd sumoa astnd unToA PI 6L009 NH YITM souepxoose UT A ur ZO OO T8L PBurtmeap Tozquoo s 73923 pue OWN UITM SOUePTODOeS UT dL
45. find our local subsidiary or agency at www sick maihak com 8 010 458 2007 04 V1 0 Your local sales and service partner SICK MAIHAK GmbH Analyzers and Process Instrumentation SICK MAI HAK Nimburger Str 11 79276 Reute Germany www sick maihak com Phone 49 7641 469 0 Fax 49 7641 469 11 49 info sick maihak sick de Analyzers and Process Instrumentation
46. i 34 RS485 nz Connection cable nn 10 30 V DC Fig 5 4 Wiring example of the ADAM 4520 RS485 RS232 converter SICK MAIHAK GmbH Germany All rights reserved 79 FLOWSIC600 Calibration Operating Instructions Pm Ultrasonic Gas Flow Meter Run the MEPAFLOW600 programme Details on installation and gt Run the MEPAFLOW600 control operation of the and configuration programme Pass word level 1 7 Connection e MEPAFLOW600 In the Connection menu select u Device address f H 3 programme can be found the level Authorized operator 3 Wie Protocol manuell Service EE i Mod l in the Software Manual and enter the password odem initialisizing m ES a Password Fe Prfine D sickoptic Select an avaleble COM porto e the computer gt Click on the Connection button Pormes ne A confirmation dialog box will appear Ifthere is an existing file of an earlier calibration and if you want to use that file click Yes Otherwise a new session file must be created as described below 5 2 5 Creating a new session file If you want to open an Open New session from the File File Connection Operating Made existing session file menu New session Open session select the menu item Save Session Open session Select the menu item Save session as Enter a file name The file name should contain serial number and size of the
47. in a tabular form for this After selection of the desired correction method click on the Calculate adjust button The correction factors will now be calculated In order to check the result of the adjustment click on Show curve and analyse the diagram that will appear 8 010 458 04 2007 SICK MAIHAK GmbH Germany All rights reserved 85 FLOWSIC600 Calibration Operating Instructions Ultrasonic Gas Flow Meter File Connection Operating Mode Monitors Options Help Deh mm R G m gt MHA A r Method T Artest C None Adjustfactor C Polynomial Piece wise Polynom forward A 2 Q A 1 Q A0 A1Q A2Q v Polynom reverse A2 0 A 1 Q A0 A1Q A20 Ne Reset parameters on this page to default i Device adjparam CRC 1617hex Progamm adj param CRC 1474hex Different ES Peces tem deve Waste device Configuration Service Fig 5 11 Adjustment tab Adjustment with constant factor The adjust factor is calculated from WME as follows 1 WME 100 AF 1 After setting the adjust factor to the meter see Fig 5 7 return to the measuring mode Then check the WME AF by repeating a flow measurement at a certain test flow rate 100 110 Information Adjust method ies aoe Adjust par ea ah error curves based on progam data after write to device data are valid Show direction Omax m h fi 000 IV Show po
48. lifting gear It is strongly recommended only to use the eye bolts supplied with the device To lift the FLOWSIC600 please pay attention to Fig 3 2 During FLOWSIC600 transport and storage operations make sure that The measuring device is firmly secured at all times Measures are taken to avoid mechanical damage Humidity and ambient temperature are within specified limits see Section 2 2 4 If the device is to be stored outside for more than one day sealing surfaces of the flanges and the interior of the meter body must be protected from corrosion e g with Anticorit spray not required for stainless steel meter bodies The same measure shall be taken if the device is to be stored in dry condition but for more than a week Due to natural temperature fluctuation in the course of a day or if the measuring device is transported to a place with different temperature and humidity moisture will condense on any material Carbon steel surfaces may corrode if left unprotected Fig 3 2 Lifting requirements SICK MAIHAK GmbH Germany All rights reserved 8 010 458 04 2007 Operating Instructions Installation FLOWSIC600 Ultrasonic Gas Flow Meter 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 existing plant It is particularly importan
49. measurement reasons the equipotential bonding must as far as possible be identical to the pipeline potential Additional grounding with the protective conductor PE via the terminals is not permitted Notes for safe operation in hazardous areas Type of explosion protection Il 1 2G EEx de ib ia IIC T4 or Il 2G EEx de ib ia IIA T4 e Ambient temperature 20 C to 60 C In the extended temperature range from 40 Cto 60 C metal cable glands shall be used only The cable glands included in the delivery are black If terminals are assigned with intrinsically safe circuits it is recommended to replace the black ones with the light blue RAL 5015 cable glands provided For the temperature class according to the ambient temperature and gas temperature see the EC Type Approval Certificate The type of protection for the field connections and power supply connection is determined by the external circuits that are connected for options see Connection options above e Safety relevant data for intrinsically safe circuits is provided in the EC Type Approval Certificate Ensure that the cover on the power supply connection is properly sealed In intrinsically safe installations the terminal box can be opened and cables connected and disconnected while the system is live Ifthe meter body is insulated the insulation thickness must not exceed 100 mm The SPU housing must not be insulated Important Always observe the t
50. my r oE j Pressure fed P bat CeCe E E r rara Output DO3 Tenninal 81 82 nom open Data echt IL OEP Path failure compensation Language Pe Pe eocryctSoumd el Het vy Tam lb t Gas E Configuration Authorized operator OFFLINE gt Fig 4 8 Device parameters tab Adjust factors Reading onthe LC display For each direction of flow forward and reverse exists one adjustment factor registers in the Register menu 7037 and 7038 Both have to be checked by using the configuration protocol to secure correct measurements If the meter is not yet flow calibrated the adjust factor must be 1 If the meter is calibrated this factors must correspond to the values in the flow calibration protocol Meter factor Reading onthe LC display The meter factor specified on the main type plate must be identical to the software in the Pulse output parameter value register 7027 The meter factor is set at the factory according to the menu customers statement If this doen t exists the meter factor is set to a standard value such that the maximum pulse output frequency is approx 2 KHz at the maximum flow rate see Section 2 2 4 Note Any changes of the meter factor during commissioning in case of required adaption to the current application and using the meter for fiscal purposes have to be agreed with the authorities In addition in such cases the main type plate has to be exchanged with
51. of the flow velocity In such a case a replacement value may be determined for the faulty path in order to compensate the failure see Section 2 8 SICK MAIHAK GmbH Germany All rights reserved 8 010 458 04 2007 Operating Instructions VA Wi Kr Flow velocity Weighting factor of a measuring path Register 7120 to 7123 Weight i 2 4 2 Internal diameter of the meter body Register 7100 PipeDiameter see also Section 5 1 3 Register 7040 TempAbsrix Register 7041 PressureAbsrFix Register 7118 ExpCorrTemperature Register 7117 ExpCorrPressure 8 010 458 04 2007 Product Description FLOWSIC600 Ultrasonic Gas Flow Meter Flow velocity The mean value of the weighted sum of all four path velocities is the flow velocity through the profile of the meter body register 7004 AvgVelGas A 1 VA gt Wi Vavg i i 1 Calculating the volumetric flow rate The uncorrected volumetric flow rate oh is calculated from the determined flow velocity va and the open cross sectional area in the meter body ie D2 7t Q Va 4 This intermediate result is still dependent on the Reynolds number and the properties of the flow profile asymmetry swirl It is corrected using the following formula Q Q 1 f QV Dabs CCo PF Ko s Profile factor Vavg 1 T Vavg4 Vavg 2 Vavg3 Gas pressure working point mean pressure in the workin
52. part of the measuring system and which is used to operate the LC display on the signal processing unit to the FLOWSIC600 using the straps provided so that it cannot be lost Data back up As a final step of the commissioning procedure generate a diagnosis and status log using the MEPAFLOW600 software see the software manual You can use this information for comparing during subsequent testing SICK MAIHAK GmbH Germany All rights reserved 71 FLOWSIC600 Commissioning Operating Instructions Ultrasonic Gas Flow Meter 72 SICK MAIHAK GmbH Germany All rights reserved 8 010 458 04 2007 FLOWSIC600 Ultrasonic Gas Flow Meter Calibration General Notes Preparation Calibrating the FLOWSIC600 Operating Instructions Calibration 8 010 458 04 2007 5 1 5 11 5 1 2 Calibration FLOWSIC600 Ultrasonic Gas Flow Meter This chapter is a summary of all information about calibrating the FLOWSIC600 that are contained in different parts and documents It can also be used as a single document to support the staff of flow test stands when calibrating the meter The information below relates to FLOWSIC600 devices marked IIt and the MEPAFLOW600 programme version 3 x xx General Notes The FLOWSIC600 can be calibrated at a certified flow test stand to reduce the measurement uncertainty and to relate it to the national standards The following conditions must be fulfilled before the FLOWSIC600 can be
53. shunt board against Kex Code Form without D T4 MA T4 B C D T4 IIC T4 Check puls factor with sticker and configured parameter Save parameter file at LAN The following tests are carried out successfully and their protocols are put into the device file 8 Wareneingangstest Meter acceptance test Kl Nullpunkttest Zero flow test amp Funktionstest Function test H Flowkalibrierung Option Flow calibration optional amp Dichtheitstest mit installierten Sonden Leak test with installed transducers KM Isolationstest Electrical isolation check Beschriftung HM Aufkleber im Deckel entspricht der richtigen Gasgruppe D Typschild auf Messumformer NM Klemmen f r die Spannungsversorgung mit Aufkleber kennzeichnen Q Sicherungsklemmen an den Deckeln montiert Arbeiten bei eichpflichtigem Ger t x Eichpflichtig JA NEIN W Hauptschild auf Messumformer amp Br cke f r Parameterschutz gesteckt ys pes Plombenschrauben an den Sicherungsklemmen vorn und hinten LI Plombefischrauben an den Sondendeckeln Registration D Seriennummer ist in der Ger tekarte eingetragen B Ger tekarte auf Vollst ndigkeit berpr fen DN Ger tebegleitkarte vollst ndig ausgef llt 8 Ger teakte komplett Vollst ndigkeit Protokolle Si Vergleich Typschild mit den Daten in der Ger tekarte Auftragsdaten RI Vergleich Typschild mit den Daten in der Ger tekarte Auftragsdaten Ident Nr FDB20020103 Produktgruppe FLOWSIC600
54. the official verification procedure The LC display shows by default the two major counters one for each direction of flow In the course of the official verification procedure it is possible to define an alternative display content such as the error volume counters for each direction of flow The display then switches between these two contents every 5 seconds Changes in the logbook status are indicated by a flashing character at the far right end of the first line of the display The character depends on the status for information W for warning E for error The character will disappear after acknowledgement Details on reading the logbook entries their acknowledgement and about the menu structure can be found in Section 9 2 SICK MAIHAK GmbH Germany All rights reserved 8 010 458 04 2007 Operating Instructions Product Description FLOWSIC600 Ultrasonic Gas Flow Meter 2 6 Self diagnosis In the measurement status the ratios of sound and path velocities amplification settings and signal to noise ratios are continuously monitored If these values exceed fix set thresholds a warning signal will be generated This allows immediate measures to be taken to prevent possible system malfunctions During commissioning or operation the signal thresholds can be adapted to suit individual application requirements This allows the status warning system to be optimised N
55. the parameters e Geometrical length Offset time Sender model specified on the check report of the new transducer pair see Section 9 5 4 must be entered in the FLOWSIC600 To do so open the signal processing unit turn the configuration protection switch to the open position see Section 5 2 6 and connect the FLOWSIC600 with the MEPAFLOW600 program Enter the password Expert and select the Service level in the Connection menu see Section 5 2 4 Click on the Device parameters tab and select the concerned path see Fig 6 1 Now enter the transducer parameters Hi MepaFlow 3 1 04 C Programme SICK MEPA FLOW600_M16 DEFAULT SF gt gt Mode Factory access Du Oa A B O S m gt Il id H b DIM Measuring values Device parameters Adjustment Device diagnosis Path diagnosis Device logbook Log Trend Flash tool Factory settings Parameters Parameter editor Sin FLOWSIC 600 Register number BA Meter Identification 7103 SensorLength 1A Meter Setup Register value LH ve Process parameter nosso Meter body d 2 ah Limits Description SensorLength 1A E Profile Conection x Le Calibration pa d DI Status pulse Output Deia setting 0 039 AA Analog Output Input high range 0 1 Gun Poth fee Sensor Length peatiareue 10 Register T 4Byte real ws 7110 SensorLength 1B 0 03900 m bei mer
56. to noise lt 13 dB Warning SNR This alarm will be activated if the signal to noise ratio becomes too small ratio Possible causes for this include interfering noise caused by fittings in the pipeline valves that are not fully open sources of noise near the measuring location or defective ultrasonic transducers 8 010 458 04 2007 Additional signal and system diagnosis functions monitor the reliability of the measured values by checking the plausibility of the ultrasonic signals received and the ultrasound signal transit times calculated from them SICK MAIHAK GmbH Germany All rights reserved 29 FLOWSIC600 Product Description Ultrasonic Gas Flow Meter Operating Instructions 2 7 Event Logging Important system events max 250 are stored in a logbook Each entry consists of the event time stamp and the volume counter readings valid at that time along with acknowledgement status The events are logged continuously in the order they occur Each event can be acknowledged manually Logbook queries provide information on the number of registered events and the remaining memory space The entries are classified as follows Active events e Inactive acknowledged and unacknowledged events e Acknowledged events If there is no space left in the logbook the logbook is closed and the system signals a malfunction Until the logbook is reset deleted the measured volumes are stor
57. unit under test e g 04458703_NPS8 Dateiname res Speichem Dateityp Session FSF Abbrechen y ech In the Session information dialog box only activate FLASH segment this will do for a calibration session Set user infos for new sess User name pEGDDM00010 Location r Automatic download u T Logbook ee x 80 SICK MAIHAK GmbH Germany All rights reserved 8 010 458 04 2007 Operating Instructions Calibration FLOWSIC600 Ultrasonic Gas Flow Meter 5 2 6 Open close the configuration protection switch In order to be able to calibrate the FLOWSIC600 the configuration protection must be disabled You may call up System status from the Monitors menu to check the setting Monitor Device state _ __________ Lamp is on Bit Sys System state register f Pi P2 P3 P4 Path state registers Ct Systemcontrolreaister configuration Measuemode Wanns Configuationmade erg 9 Waring AGC Deviation protection i active s Limit uamg NW warning SOS Deviation Lamp is off configuration protection is Path evvor3 disabled Path error 4 MAXPOS too late WW Reset error volumen counters I Imperial system of measurement SNR exceeds limit W Filter mode Maximum Iterations W Testing watchdog Time plausibility W Reset path conditions MPT Check cycle Parameter invalid Adjust range yw 10 Range error
58. 0 XxXXx 009H L Jemod ssejun Juswd nbe 1o uuoosip jou oq pesze uoiso dx3 ONINHVAA Z SISONPSUEIL Sluosenin Sodn DAN 40 939 SU YUM 89UEPIOODE U IESU EEN UODEIIEISuL Z uoZ Z UOISIAIG ywgg ul WPZL Ul run nl on ge seutua oeg lul ele gi dnog ve ee sIputuue 1 S9pSu Gelee S eulu Vtu0z INdjno Juaundg PL poo duet y II dnou uoz 1 sse O 0 uoz sse YUIGE ul AOE u A WWOG 01 WWOg ull Te pupAA Sm HW e Juorz eI VWL6 9S AF 8S 90A s sjowesed Au Burmoyoy ay UNA 1u l eAInb 10 XXXX 009H L SISONPSUBLL luos ni n gordn PPE M SN PL epog duet y II dnou Z euoz sselO rL apog duet y II dnoug L eu0z Leen FL p09 duet q sdnog Z uolslAIG L est pL epog duet q sdnoip I UOIsIAIG L sept Z Fig 9 8 Control drawing CSA 781 00 02 page 2 8 010 458 04 2007 SICK MAIHAK GmbH Germany All rights reserved 132 Operating Instructions Appendix FLOWSIC600 Ultrasonic Gas Flow Meter 9 5 Device Documentation 9 5 1 Inspection certificate example SICK MAIHAK Abnahmepr fzeugnis Inspection certificate EN 10204 3 1 B Zeugnis Nr Certificate No 427 1 Allgemeine Angaben General Kunde Customer Bestell Nr Order No 30600147 SICK Auftrags Nr SICK Order No 912239 Bezeichnung Name FLOWSIC6
59. 00 6450 2000 1 511 30 1 511 30 PN 16 DIN2633 4400 1 344 50 1 255 00 A PNGA Dimensions on request PN 100 cl 150 5150 1 414 54 1 346 20 cl 300 5125 1 385 97 1 289 05 SS cl 600 us 5850 1 443 12 1 403 35 SC SE cl 900 7150 2100 1 562 10 1562 10 PN 16 DN1050 PN 64 Dimensions on request PN 100 118 SICK MAIHAK GmbH Germany All rights reserved 8 010 458 04 2007 Operating Instructions Appendix FLOWSIC600 Ultrasonic Gas Flow Meter Flange Width of the Internal Nominal Connectio Standard Weight Length Height diameter measuring diameter pipe size n flange A B C section D E kg mm mm mm mm mm cl 150 5925 1 468 68 1 403 35 cl 300 5900 1443 28 1 352 55 cl 600 PME BIOL 6600 1494 08 1 454 15 cl 900 8200 2200 1 647 95 1 647 95 PN 16 DIN1100 PN 64 Dimensions on request PN 100 cl 150 7075 1 573 65 1 511 30 5 cl 300 7150 1 551 43 1 466 85 cl 600 ec 8100 1 614 96 1 593 85 1416 1080 cl 900 9400 1 784 35 1 784 35 PN 16 DIN2633 6600 1 560 50 1 485 00 De F 1 Be Dimensions on request PN 100 Tab 9 2 Meter dimensions Pipe dimensions in accordance with ANSI B36 10M 1985 DIN 2633 DIN 2636 DIN 2637 SC20 SC30 SC40 SC60 SC80 PN16 PN64 PN100 2 52 5 49 3
60. 00 a Typ Type FL600 4P3D08CL06000203 2RFON S1 3DC1N1Y Serien Nr Serial No 06078749 Baujahr Year of manufacturing 2006 Max Betriebsdruck Max operating pressure 100 bar Arbeitstemperatur Working temperature Min 25 C Max 85 C _ 2 Spezifikation Bauteil und Pr fungen Specification item and tests 2 1 Geh use Body Abnahmepr fzeugnis f Material Inspection certificate for material 7137 05B Pos Pos No 0005 0 0000 Werkstoff Material Schmeizen Nr Heat No Messaufnehmer meter body GS 20Mn5V 19821 ND Pr fungen ND tests Magnetpulverpr fung Magnetic particle powder el Farbeindringpr fung Liquid penetration test O E d Ultraschallpr fung Ultrasonic inspection Durchstrahlung X ray examination Festigkeitspr fung Dichtheitspr fung Strength test Leakage test 2890427 ProfmediunvTest medium Wasser Water gt Prof ruck Test pressure Fr I C C PrafdauerTest duration 30min 2 2 Komplettes Messger t Assembled measuring device _Dichtheitspr fung Leakage test Hiermit best tigen wir dass an o 9 Bauteil die spezifizierten Pr fungen ohne Beanstandungen durchgef hrt wurden We hereby certify that the specified tests were performed on the above described itern without any objections Qualit tsstelle Quality Department SICK MAIHAK ene 10 04 2006 Ort Datum Place Date Ottendorf Okrilla SI
61. 038 AdjustFactorReverse Uu cal Hu corr AF forwara ZO for a positive direction of flow standard value 1 0 ZO Register 7039 Uu cal Hu corr AF reverse ZO for a negative direction of flow ZeroFlowOffset standard value 0 0 m h The calculation of the factors is based on the weighted mean error WME equivalent to OIML recommendation no 32 n Q Checked flow rate gt ki f with ki for Q lt 0 7 Qmax Q max Checked maximum Tag max flow rate WME fi Error in 2 Qi determined for the gt ki and kj 1 4 for 0 7 Qmax lt Qi lt Qmax checked flow rate i 1 max The corresponding factor is then calculated as follows 1 WME 100 The result of the volumetric flow calculation is stored in register 7001 VolumeFlow AF 1 2 4 3 Calculating the actual volume The operating volume is calculated from the operating volumetric flow rate Qy ca by integration over time of the measuring intervals Ts Measuring interval between Vi Qy cal Ts two measurements P The total aggregated volume is stored in the operating volume counters for both directions of flow The operating volume counters cannot be reset 5010 ForwardVolume 5012 ReverseVolume While the system is in the Invalid measurement status the volumes determined are stored in separate error volume counters These counters can be reset Such a reset is recorded in the logbook together with dat
62. 08e 005 2 08e 005 TxPeriods o E 4 4 4 4 TxPhase EI 3 3 3 3 TxDuration s 6e 005 6e 005 6e 005 6e 005 TxDampOut o E 60 60 60 60 TxAmplitude o E 123 123 123 123 PostPeriods PrePeriods 1 PrePeriods 2 PrePeriods 3 PrePeriods 4 0 5 4 0 4 0 4 0 4 0 InitTime s RingOutTime 1 s RingOutTime 2 s RingOutTime 3 s RingOutTime 4 s 0 005 0 01 0 01 0 01 0 01 Path fail compensation Path 1 Path 2 Path 3 Path 4 PathCondStatic 0 91500 1 03000 1 03000 0 91500 PathCondLow 1 21943 1 17047 0 91270 0 59108 PathCondHigh 0 86530 1 02933 1 05305 0 91820 PathCompAverWeight PathCompClassLo m s PathCompClassHi m s PathCompStoreLimit o E PathCompValid 0 0001 1 0 8 0 0 005 10000 Miscellanous SystemConfigReg DOOutputConfigheg FreqOutputConfigReg TotalizerResolution 1 m MaxVelSound m s MaxVelGas m s 279B hex 080401 10 hex 10007003 hex 100 535 0 45 0 AO Adjustment AOGain o E AOOffset mA 1 0000 0 00000 MepaFlow 3 2 00 Page 3 3 8 010 458 04 2007 Fig 5 21 Example of a configuration protocol page 3 SICK MAIHAK GmbH Germany All rights reserved 95 FLOWSIC600 Calibration Operating Instructions Pm Ultrasonic Gas Flow Meter 96 SICK MAIHAK GmbH Germany All rights reserved 8 010 458 04 2007 FLOWSIC600 Ultrasonic Gas Flow Meter Maintenance General Routine Checks Replacing the Transducers Operating Instructions Maintenance 8 010 458 04 2007 6 1 6 2 Main
63. 13 Adjustment Show curve tab representing adjustment using a polynomial Change back to the measurement mode after having entered the polynomial coefficients Then check the weighted mean error calculated after adjustment by repeating a measurement with at least two different test flow rates The test flow rates used shall lie between two already examined test flow rates For example if the errors at 100 and 70 Qmax have already been found the correction using a polynomial shall be tested at 80 Amar The flow rate specific correction is calculated by the meter as follows 8 010 458 04 2007 SICK MAIHAK GmbH Germany All rights reserved 87 FLOWSIC600 Calibration Operating Instructions E Ultrasonic Gas Flow Meter Adjustment using piece wise linear error interpolation This adjustment method is carried out just as the polynomial adjustment In this method the error is corrected exactly to zero at the individual calibration points Now a linear interpolation and error correction is carried out between the individual calibration points xl 100 110 Information Adjust method Piece wise Adjust parameter Displayed error curves based on progam data after write to device data are valid Show direction Omax eh fico Show points E Eror curve w coefficients factors forward Amin bein E Points as found funadiusted C revers de fi Points as left adiusted Fig 5 14 Adjustment Show curve
64. 43 20 406 40 2 cl 300 225 562 25 444 50 cl 600 gt 300 594 00 508 00 cl 900 390 750 613 05 546 10 410 235 PN 16 DIN 2633 195 542 50 405 00 DN250 PN 64 DIN 2636 240 575 00 470 00 PN 100 DIN 2637 290 592 50 505 00 cl 150 300 596 30 482 60 cl 300 350 615 35 520 70 SS cl 600 EE 420 634 40 558 80 cl 900 540 900 659 80 609 60 470 270 PN 16 DIN 2633 275 585 00 460 00 DN300 PN 64 DIN 2636 370 620 00 530 00 PN 100 DIN 2637 460 647 50 585 00 Sandwich design without flanges 116 SICK MAIHAK GmbH Germany All rights reserved 8 010 458 04 2007 Operating Instructions Appendix FLOWSIC600 Ultrasonic Gas Flow Meter Flange Width of the Internal Nominal Connectio Weight Length Height diameter measuring diameter pipe size n flange Standard A B C section D E kg mm mm mm mm mm cl 150 425 644 20 533 40 a cl 300 525 669 60 584 20 Ei cl 600 Ee 595 679 15 603 30 cl 900 760 1050 698 15 641 30 540 315 PN 16 DIN 2633 420 637 50 520 00 DN350 PN 64 DIN 2636 550 677 50 600 00 PN 100 DIN 2637 680 705 00 655 00 cl 150 560 699 45 596 90 H cl 300 630 724 85 647 70 Ee cl 600 aie B tee 790 743 90
65. 58 04 2007 Operating Instructions Calibration FLOWSIC600 Ultrasonic Gas Flow Meter FLOWSIC 600 configuration protocol parameters 23 03 2007 13 42 00 User name LAP312 Location Device identifikation DeviceType SerialNumberDevice SoftwareVersion ProgramCRC ParameterCRC ConstantscRC 841 22078700 2202 9FEY hex BE6B hex 5D95 hex Date Time 06 06 2006 18 08 58 Interfaces impulse output MeterFactor 1 m FreqSourceReg PulseUpdateRate 1800 7001 0 1 Analog output AORangeLow AORangeHigh AOSourceReg AOTimeConstant s AOError mA 0 0 4000 0 7001 0 0 22 0 Ser interfaces ModBus 1 BaudRate ModBus 1 ResponceDelay ModBus 1 ControlReg DeviceBusaddress 9600 0 01080101 hex 1 Service 2 BaudRate Service 2 ResponceDelay Service 2 ControlReg DeviceBusaddress 9600 0 01080101 hex 1 Extended 3 BaudRaie Extended 3 ResponceDelay Extended 3 ConirolReg DeviceBusaddress 9600 0 01080101 hex 1 LCD Display LCDLanguage LCDSource 1 0021 hex Meter body InnerDiameter mj PipeDiameter m NumberPaths ExpCorrTemperature ExpConPressure MaxPressure bar g 0 18999 0 20000 4 4 12e 005 6e 006 100 0 Path 1 Path 2 Path 3 Path 4 Length 1 m 0 20798 0 28698 0 28699 0 20800 Angle 1 rad 1 04765 1 04756 1 04762 1 04798 Weight 1 o
66. AK GmbH Germany All rights reserved Always comply with the statutory provisions and the associated technical rules and regulations relevant for the present equipment when preparing and carrying out any work on the measuring system Pay particular attention to potentially hazardous parts of the equipment such as pressure pipes and explosion protection zones Always observe the relevant regulations Always consider local and equipment specific conditions and process specific dangers when carrying out any work on the equipment FLOWSIC600 Ultrasonic Gas Flow Meter 10 13 1 DANGER Note 1 3 2 DANGER 1 3 3 Safety Instructions Operating Instructions Operating and service instructions and equipment documentation shall always be available on site Always observe the safety instructions and notes on the prevention of injuries and damage given in these manuals e Make sure appropriate protective accessories are available in sufficient supply Always use such protective accessories Check that appropriate safety devices are fitted and working correctly 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 shall be 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 temperat
67. ARIAZET eOSr4 uv UIAON UT En uoTJeTleJsutr OTSUTIJUT UON I uorqaeooT prezey uorsoTdxq D D b H amp 31 AF292211 DEREN aped postal al zune S 0XZXF zu SIT X Z es e snopIezey uou pue orA p u wmq q rqeo TTe TTeIsUT oi spusumoas YOIS a p yzeuoy buruauqbrT Jo seyorq4s qu zzno rx zo TNJIsSMmod Jo seo ur p pu uuroo rx sr U0OT398901d bans TEUOTITPPY 0 0 o o o 9 al ox bueuo ezoyeq sey aedns asez z dns qsey z dns 3sej zedns wees end E song sdAL 14 d q Buraoe jeet Area STeUTWISI PISTF ios sosn xeu es y p ezey uoN uoses TOJ YOOT MO MOTA Jo eseod ul wu 007 wur 00T wu 00T wu oot E Sq A S Oly ee oor OdA FE ZeaNndwoomoT gq K E 8 010 458 04 2007 FLOWSIC600 non intrinsically safe installation SICK MAIHAK GmbH Germany All rights reserved Fig 9 20 144 FLOWSIC600 Appendix Operating Instructions Ultrasonic Gas Flow Meter g Plan 7 Seali 9 NV ld DONS 0093ISM014 L mM j E E E l aa En pam U3JHMS 3430 Jajewdsod Djap S S UO v V jn J dunr zInu3SJ lJJ uDiDd 108 S OIG ND Y Y UU SAN OSINO lt MN J04 BGH OSINO lt MN IN UOJ U dp3 ap p s UJDA addoy uajjajsjebalg x Wio do2 Jad ege OM SD D addoy oud Dar jamz suajsapuw puiyaq dos opd pas Lee J SQA U l j ls b ls putu q dp3 ap Des pulyeq PUD UI u J9A03
68. All rights reserved 8 010 458 04 2007 Operating Instructions 8 010 458 04 2007 5 6 7 8 FLOWSIC600 Ultrasonic Gas Flow Meter Calibration IILI a saa asss 73 5 4 General Notes Kul IILI ctoeiveusndueescestaenstioutivaiaserctimedchupebceaesuensiceanes 75 5 1 1 Definition of test points test flow rates 5 5 1 2 Flow Calibration at atmospheric pressure I u uuuuuu 75 5 1 3 Flow Calibration at high pressure I I uuu 76 5 1 4 E el E ee EE 77 5 2 EI 78 5 2 1 Installation on the flow test stand I u u u 78 5 2 2 Electrical CONNEC N eesreeteteetieee eg 78 5 2 3 Checking the device design 79 5 2 4 Connecting the FLOWSIC600 with the MEPAFLOW600 program 79 5 2 5 Creating a new session len 5 2 6 Open close the configuration protection switch 5 3 Calibrating the FLOWSIC600 5 3 1 Data logging Optional a aa a aa ua an 5 3 2 Determining and entering the adjust factors I u u 5 3 3 Finding the adjust factors using the MEPAFLOW600 software 5 3 4 Documentation EES 5 3 5 ele Maintenance he Eeer 97 6 1 General nahen enden nenne 99 62 ROUTING checken eege 99 6 3 Replacing the transducers
69. C Maintenance req d NC Configuration of the current output Possible sources are Actual volumetric flow rate Normalised volumetric flow rate Molar mass Volumetric flow rate at max current Volumetric flow rate at min current SICK MAIHAK GmbH Germany All rights reserved 8 010 458 04 2007 Operating Instructions Appendix Menu levels FLOWSIC600 Information System FLOWSIC600 Device logbook d N AO during malfunction 22 mA AO attenuation 10s Device type 8 4 path Meter serial no 03138703 Analogue serial no 00112233 System date 2 April 2003 System time 09 10 00 Version 3 0xx 17 Sept 2005 CRC16 program OxFFFF CRC16 parameters OxFFFF CRC16 constants OXFFFF FLOWSIC600 Ultrasonic Gas Flow Meter Notes Current output in the Malfunction status Averaging period for the current output in order to smoothen peaks Display of information on the measuring system Display of parameters of the measuring system Nominal width of the meter body and number of measuring paths Serial number of the meter Serial number of the analogue circuit board installed Present system date Present system time Information on the installed software and activated parameter sets The following information can be called up by activating the ENTER function Version number and corresponding time index 16 bit check sum for the entire
70. C display of the FLOWSIC600 for details on the menu structure and operation with a magnetic pen see Section 9 2 Test with PC and MEPAFLOW600 software Connect the serial port of the FLOWSIC600 with the USB port of a PC and start the MEPAFLOW600 program see the software manual Chapter 2 The following description relates to the function test using a PC and the MEPAFLOW600 software After having linked PC and FLOWSIC600 run the MEPAFLOWGOO program and call up the Connection menu Specify an available PC port COM1 COM2 in the Connection box and enter the password SICKOPTIC by activating the Authorised operator box See Fig 4 2 The default device address is 1 SICK MAIHAK GmbH Germany All rights reserved 67 Operating Instructions FLOWSIC600 Commissioning Ultrasonic Gas Flow Meter E Security Connection C Operator Device address KI Authorized operator Protocol manuell E C Service Modem intialsizing H Password x pomoi c ees Fig 4 2 MEPAFLOW600 Connect to menu Note Ifyou cannot get connected with the FLOWSIC600 refer to the software manual for details on troubleshooting If you are connected successfully the current measured values counter readings and system status information will be displayed as shown in Fig 4 3 Wu MepaHow 3 2 04 C Programme MEPA FLOWSIC FLOWSIC600 DEFAULT SF Eifel Eile Connection Operatin
71. CK Engineering GmbH J Bergener Ring 27 Unterschrift Hersteller A tg D Okri Signature Manufacturer l A gt ge Doc No FDB20040054 FLOWSIC600 Rev 2 3 vom 23 12 2005 Seite Page 1 von of 1 8 010 458 04 2007 Fig 9 9 Inspection certificate example SICK MAIHAK GmbH Germany All rights reserved 133 Operating Instructions FLOWSIC600 Appendix Ultrasonic Gas Flow Meter 9 5 2 Final check example SICK MAIHAK Pr fprotokoll Endpr fung Gasz hler Serien Nr serial no 078749 Ident Nr ident no 47 Pr fer approved by 72 Pr fanweisung Datum Date 4 4 06 Hardware MEPA Service Modus starten und Parameterdatei ausdrucken Si berpr fen Typschl ssel mit Ger tekarte D Pr fen der Kabeldurchf hrungsgewinde mit dem Typschl ssel CSA NPT oder ATEX M20 8 Verwendung von Verschlussstopfen NPT 1 4 Kennzeichnung an der Schliisseiflache mit NPT 1 4 4 berpr fen der Gasgruppe Platine Shunt board mit dem Typschl ssel ohne D T4 HA B C D T4 IIC T4 8 berpr fen Impuswertigkeit von Hauptschild und Ger teparameter f Speichern der Parameterdatei auf dem Server _ Durchqef hrte Tests Protokolle vorhanden Hardware Start MEPA and print out Configuration Protocol Check Typecode with G Karte Check cable feed through threat with Kex Code Form Check the plug for pressure tap The plug has to be Marked with NPT 1 4 Check gas group of
72. 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 99 DN 750 NPS 30 650 45 000 22 950 1 589 000 30 99 DN 800 NPS 32 800 50 000 28 250 1 766 000 30 99 DN 900 NPS 36 1000 66 000 35 320 2 331 000 30 99 DN 1000 NPS 40 1200 80 000 42 380 2 825 000 30 99 DN 1050 NPS 42 1300 85 000 45 910 3 002 000 30 99 DN 1100 NPS 44 1400 90 000 49 440 3 178 000 28 92 DN 1200 NPS 48 1600 100 000 56 500 3 531 000 27 89 SICK MAIHAK GmbH Germany All rights reserved 8 010 458 04 2007 Operating Instructions Product Description FLOWSIC600 Ultrasonic Gas Flow Meter Other information Meter size up to DN600 24 Body with flanges in carbon steel 1 1120 ASME A216 WCC Body with flanges in stainless steel 1 4408 ASME A351 Gr CF 8M Meter size gt DN600 24 Body in carbon steel 1 1120 ASME A216 WCC flanges ASTM105 Body in stainless steel 1 4408 ASME A351 Gr CF 8M flanges in 1 4404 A182 Gr F316L Common data Number of measuring pa
73. F Measurement 8 010 458 04 2007 SICK MAIHAK GmbH Germany All rights reserved 121 FLOWSIC600 Appendix Ultrasonic Gas Flow Meter 122 Menu levels Configuration Pulse output Pulse source Actual volumetric flow rate Pulse factor 3600 m3 Pulse rate 0 1s Pulse mode Flow Dir NO Configuration Digital output DO 1 Inactive i DO 2 Malfunction NO DO3 Warning NO DO4 Inactive Configuration Analogue output AO source Actual volumetric flow rate Qv at 20 mA 1000 m3 h Qv at 4 mA 0 m3 h Operating Instructions Notes Pulse output configuration the following information may be called up by activating the ENTER function Value to be supplied to pulse output Depending on the number of available pulse outputs this menu can exist once or twice Possible sources are Actual volumetric flow rate Normalised volumetric flow rate Number of pulses to be output per cubic meter fmax 6 kHz Refresh rate of the frequency output The following settings may be chosen see also Section 2 5 5 Flow Dir NO Flow Dir NC Flow Malf NO Flow Malf NC Flow F R NO Flow F R NC Digital output configuration The following signals can be chosen Inactive e g if used as frequency output Malfunction NO Warning NO Direction NO Maintenance req d NO Malfunction NC Warning NC Direction N
74. Installation Diagrams Sealing Plan Operating Instructions Appendix FLOWSIC600 Ultrasonic Gas Flow Meter Appendix 9 1 Characteristic Properties and Dimensions of the Meter Body Material Application Carbon steel 1 1120 A216 WCC Nominal width lt DN 600 NPS 24 1 0460 A105 Flanges gt DN 600 NPS 24 LT carbon steel 1 6220 A352 LCC Nominal width lt DN 600 NPS 24 1 0566 A350 LF2 class 1 Flanges gt DN 600 NPS 24 Stainless steel 1 4408 A351 Gr CF8M Nominal width lt DN 600 NPS 24 1 4571 A182 Gr F316 Flanges gt DN 600 NPS 24 Duplex 1 4470 A995 Gr 4A UNS J92205 Nominal width lt DN 600 NPS 24 1 4462 A182 Gr F51 Flanges gt DN 600 NPS 24 Tab 9 1 Material Weights and dimensions Model for nominal sizes of 12 to 24 o B Dimension F must be specified by the customer as it depends on the internal pipe diameter at the installation location Model for nominal sizes of up to 48 Fig 9 1 Dimensioned drawing 8 010 458 04 2007 SICK MAIHAK GmbH Germany All rights reserved 115 FLOWSIC600 Ultrasonic Gas Flow Meter Appendix Operating Instructions
75. K MAIHAK r Parameters ae DEE FA Meter Identification m Meter Setup Se Process parameter amp ts Meter body et Limits BD Profile Corection L Calibration TIR Status pulse Output 3026 FreqSourceReg 70010 E 3027 TestFreqForward 0 Hz 3028 TestFreqReverse OHz 3036 TestDO Dot 5101 DOOutputConfigReg 00000511 o E 5102 FreqOutputConfigReg m 7027 MeterFactor 1 1 m m 7043 PulseUpdateRate 1s Fig 2 13 Device parameters tab r Parameter editor Register number Register value Raad ranie Depending on the contents of the registers 3026 3542 and 3545 the functionality of the volume correction can be specified see Tab 2 1 The configuration of these values is performed under the Device parameters tab Fig 2 14 3026 3542 3545 Functionality FreqSourceReg HART_Readintervall GergCalelntervallMax Volume correction is not activated FL600 gives actual values 0 0 0 Volume correction is activated correction is carried out by use of constant values Temperature fix 7040 Pressure fix 7041 Compressebility fix 7042 Volume correction is activated correction is carried out with the pressure and temperature readings e g every 30 seconds and the constant value Compressebility fix 7042 Volume correction is activated correction is carried out with the pressure and temperature readings
76. Measurement E error More than one path must be substituted by the Value is assigned with the four path invalid replacement value calculation routine or the activated states adaptive path failure compensation has not been activated System error E error Reliable operation of the system is not guaranteed Cause of the fault CRC program code CRC parameters CRC counter reading CRC replacement path weights Implausible parameter DSP fault Logbook full E error No memory space further events cannot be logged The system will turn into the Malfunction status 30 SICK MAIHAK GmbH Germany All rights reserved 8 010 458 04 2007 Operating Instructions 2 8 TYPE APPROVAL Va Mean area velocity N Number of measuring paths w Weighting factor of a measuring path 8 010 458 04 2007 Product Description FLOWSIC600 Ultrasonic Gas Flow Meter Path Failure Compensation For a 4 path system the FLOWSIC600 is able to compensate the failure of one max two paths using a static or an adaptive compensation routine Path failure may be caused by an invalid signal the AGC level exceeding the limit and or problems in processing received signals in the DSP The measured value of the failed path is substituted by a calculated replacement value This replacement value is calculated on the basis of the current valid values measured in other paths and the relation of gas ve
77. O O gt gt FLOWSIC600 Ultrasonic Gas Flow Meter 6 7 8 9 10 11 12 13 14 15 Material Carbon Steel 1 1120 Stainless steel 1 4408 LT CS 1 6220 Duplex 1 4470 Connection for Extraction Tool Yes No ULTRASONIC TRANSDUCER SIGNAL PROCESSING UNIT Ex proof design CSA Group D T4 CSA Group B C D T4 ATEX IIA T4 M20x15 ATEX IIC T4 M20x1 5 ATEX IIA T4 1 2 NPT ATEX IIC T4 1 2 NPT Will be selected by SICK MAIHAK on the basis of the technical data Power supply 12 24V DC Data outputs Hardware variant 1 4 digital outputs Hardware variant 2 1 analog current output and 3 digital outputs Hardware variant 3 with integrated volume corrector Hardware variant 4 1 analog current output and 2 RS485 HART Protocol By selection of hardware variant 2 only Yes No Front panel LED SICK MAIHAK LCD SICK MAIHAK Custody Transfer design Yes No Fig 2 2 Common key code used for short description of meter design SICK MAIHAK GmbH Germany All rights reserved 15 FLOWSIC600 Product Description Operating Instructions Ultrasonic Gas Flow Meter 16 2 2 4 Technical data Common meter sizes and flow rates TYPE APPROVAL Flow rate a c in m h Flow rate in ft h Max Velocity in Min Max Min Max m h ft3 h DN 50 NPS 2 6 400 210 14 000 65 213 DN 80 NPS 3 12 1 000 280 35 000 65 213
78. O0A addoy ualjaysjabais dod Jad sjpas om nal JD addoy od Gar jamz su js pulu x pulyaq PUD UU U J3A03 al D S uajui PUN UJ0A BS u j sj b x 110430 SdN 08N puiyaq oun WOU UI J3A03 3D d Ces UaJUIY PUN WOA Bet vallajsjaba g WO Ul Mala apis UJOA JUJISUDU JI S 7SdN O0ING Fig 9 22 Sealing plan part 2 8 010 458 04 2007 SICK MAIHAK GmbH Germany All rights reserved 146 Operating Instructions Appendix Sicherungsb gel Safety hoop Kreuzlochschraube M4 DIN404 Cross pin screw M4 DIN404 FLOWSIC600 Ultrasonic Gas Flow Meter 7779 I Sicherungsb gell amp Siegeldraht Safety hoop Seal wire ll SAA Ge r D r Kreuzlochschraube M4 DIN404 Cross pin screw M4 DIN404 Siegelstellen Deckel vorn und hinten seal place cover in front and behind Siegeldraht hinter Sicherungsb gel und durch Kreuzlochschraube f hren Lead the seal wire behind the safety hoop and through the cross pin screw Detail Sicherungsb gel massive Ausf hrung Ma stab 1 1 Detail safety hoop massive version scaling 11 Fig 9 23 Sealing plan part 3 8 010 458 04 2007 SICK MAIHAK GmbH Germany All rights reserved 147 FLOWSIC600 Appendix Operating Instructions Pe PO yObb Y Y C H YYY YT T T T T T Ultrasonic Gas Flow Meter 148 SICK MAIHAK GmbH Germany All rights reserved 8 010 458 04 2007 FLOWSIC600 SICK MAIHAK worldwide You will
79. OPERATING INSTRUCTIONS FLOWSIC600 Ultrasonic Gas Flow Meter for Custody Transfer and Process Applications II SICK Analyzers and Process Instrumentation MAIHAK Operating Instructions Content 8 010 458 04 2007 FLOWSIC600 Ultrasonic Gas Flow Meter About this Document 7 Safety Instructio NS n ai maaa a aeaaeae aiana ai a sS ss sss 9 1 1 Intended Use of the Equipment 9 1 2 Authorised Staff 2222 eins 1 3 General Safety Instructions and Protective Measures 13 1 Dangers due to hot corrosive and explosive gases and high pressure 10 1 3 2 Dangers due to heavy IAS eren 10 Product Description 11 2 1 Features and Applications 13 2 2 Conformity Configuration Technical Data 14 2 2 1 Ee UE 14 2 2 2 Standard compatibility and type approval u uuu u 14 2 2 3 KEY CODE oniani osh a aadA aaeeea a aaa Na aaia aE Aaa aaas daia abaa 15 2 2 4 TECHNICAL e E 16 2 3 System Compon nts III sss 19 2 3 1 Meter OGY ere EE 19 2 3
80. Revision 1 5 01 12 2005 Identification Sticker inside the back cap with correct gas group Type sign is sticked onto the SPU Power terminals labeled Are the clamps mounted at the caps Works for Custody Transfer Meters Custody transfer YES NO Main sign is mounted at the SPU housing Locking jumper for parameter access denial is set Locking screws at the front cap and the back cap are used Locking screws at the meter caps are used Registration Serial No Is written down in the G Karte The G Karte is checked to be complete The G Karte is filled in The meter file is complete Compare original sticker with device map SICK Engineering GmbH Seite 1 2 134 Fig 9 10 Final check sheet 1 example SICK MAIHAK GmbH Germany All rights reserved 8 010 458 04 2007 Operating Instructions d Appendix Pr fprotokoll Endpr fung Gasz hler Pr fanweisung Kundendokumentation Ger tekonfigurationsblatt 1 Seite Nullpunkttest Protokoll 1 Seite MEPA Konfigurationsprotokoll 2 Seiten Original SICK Maihak Zertifikat 3 1b 1Seite Kopie Material Abnahmepr fzeugnis 3 Seiten Konformit tserkl rung nach PED DGRL 97 23 EWG 1Seite Konformit tserkl rung nach NSP 73723 EWG EMV 89 336 EWG 94 9 EG 1 Seite Zertifikat CSA 4 Seiten Baumusterpr fzeugnis 4 Seiten Bedienungsanleitung Normal oder PTB version gem Auftrag Pr fprotokoll Endpr fung Gasz hler ausgef
81. Temperature fixed K Pressure fixed bar a Pe min bar g Pe max bar g Reg 7036 Reg 7039 Reg 7040 AdjustFactorForward AdjustFactorReverse Reg 7037 Reg 7038 EE k factor MepaFlow 3 0 20 Page 2 3 Fig 5 18 Registers listed in the configuration protocol page 2 92 SICK MAIHAK GmbH Germany All rights reserved 8 010 458 04 2007 Operating Instructions Calibration FLOWSIC600 Ultrasonic Gas Flow Meter FLOWSIC 600 configuration protocol adjustment constants 23 03 2007 13 42 00 Calibration Adjust mode Adjust CRC 1 0000 hex LowFlowCutoff mYh ZeroFlowOffset mYh Temperature fixed K Pressure fixed bar a Pe min bar g Pe max bar g 10 0 0 0 285 15 30 0 14 5 58 0 Adjust factors AdjustFactorForward AdjustFactorReverse 1 00340 1 00000 Polynominal coefficients Adjust A 2 fw Adjust A 1 fw Adjust AO fw Adjust A1 fw Adjust A2 fw 0 0 1 0 0 Adjust A 2 re Adjust A 1 re Adjust AO re Adjust A1 re Adjust A2 re 0 0 1 0 0 Flow calibration Adjust Points foreward Adjust Points reverse 0 0 Qact mYh Dev as found Adj factor Qact mYh Dev as found Adj factor MepaFlow 3 2 00 Page 2 3 8 010 458 04 2007 Fig 5 19 Example of a configuration protocol page 2
82. VC The MEPAFLOW600 software supplied with the meter is used for the set up and configura tion of the EVC The software should be opened on the Service access level with the pass word factory See Fig 2 11 The P and T transmitters should be configured with the following HARTBUS adresses Pressure transmitter 1 Temperature transmitter 2 These addresses must also be entered in the meter configuration in registeres 3540 and 3541 See Fig 2 14 After start up of the configured system the meter can analyze the transmitters actual long address which is then used to communicate the measured values The recommended read cycle for the pressure and temperature is 30 s see Tab 2 1 and Fig 2 14 The set up of the interface parameters for the HART Bus which provides the pressure and temperature measurements is performed by configuring the Factory settings Interface settings tab see Fig 2 12 HART MASTER D Baud rate fizo d me Bj if Tx Delaym E w vm Fig 2 12 Factory settings Interface settings tab The integrated EVC is activated by setting register 3026 FreqSourceReg to the value 7002 see Fig 2 13 38 SICK MAIHAK GmbH Germany All rights reserved 8 010 458 04 2007 Operating Instructions Product Description FLOWSIC600 Ultrasonic Gas Flow Meter Eile Connection Operating Mode Monitors Options Help Dee Oe lt A S 6 G m gt H Id H P PIM SIC
83. ain test flow rate and repeat the steps above if necessary Finally in the parameters Pressure fix and Temperature fix see Fig 5 11 enter the values that apply to the original installation of the meter if known in the configuration mode After completion of the steps above reactivate the configuration protection Disconnect the FLOWSIC600 from the power supply Take off the front panel of the signal processing unit Move the switch to the desired position see Section 5 2 6 Mount the front cap again Reconnect the power supply Create the documentation according to Section 5 3 4 After establishment of the documentation the standard calibration is finished The following section describes two other possibilities of adjustment procedures using MEPAFLOW6OO software 5 3 3 Finding the adjust factors using the MEPAFLOW600 software The following methods are implemented in the FLOWSIC600 firmware Adjustment with constant factor Adjustment using an error polynomial TYPE APPROVAL Adjustment with piece wise linear error interpolation Note The method correction with piece wise linear error interpolation is not approved for use in custody transfer applications in every country Use the Adjustment tab in the MEPAFLOW600 control and configuration programme see Fig 5 11 in order to calculate the required adjust factors The tested flow rates and the corresponding errors must be listed
84. anted by the relevant authorities e g Germany PTB Physikalisch Technische Bundesanstalt code number 7 421 03 05 Netherlands NMI Netherlands Meetinstituut code number B35 SICK MAIHAK GmbH Germany All rights reserved 8 010 458 04 2007 Operating Instructions Group 10 11 12 13 14 15 8 010 458 04 2007 22 3 Key code indicated on type plate METER BODY Path configuration 1 Path 2 Path 4 Path 1 Path redundant 2 Path redundant 4 Path redundant 4 1 Check meter 2 Path crossed 4 Path crossed ANMNAANMHA bh xxODDDVIVG Overall length 3D standard length 5D Other size Nominal size 2 DN 50 3 DN 80 4 DN 100 6 DN 150 8 DN 200 10 DN 250 12 DN 300 16 DN 400 Other size xX 00000 gt o rS O O G ro Connection flange type ANSI CLASS 150 ANSI CLASS 300 ANSI CLASS 600 ANSI CLASS DIN ISO PN16 DIN ISO PN 64 DIN ISO PN 100 DIN ISO PN D 0 D O G G Cy O n n et Pre P PP xoooxooo x 00xow GO Oz Soo Product Description xoR0oxooo Inner diameter Schedule 40 ANSI Schedule 80 ANSI Schedule ANSI Specified in mm DIN Flange type sealing face Raised Face ANSI B16 5 Ring Type Joint ANSI B16 5 Glatt Form C DIN 2526 Glatt Form E DIN 2526 Form B1 EN 1092 1 Form B2 EN 1092 1 Special design gt 1 2 3 4 5 Keycode uso gt x D
85. are easily disassembled and do not contain toxic radioactive or any other enviromentally hazardous materials Mainly the instrument consists of steel stainless steel plastic and aluminium and consequently there are no difficulties for disposal Only the printed circuit boards must be disposed of as electronic scrap SICK MAIHAK GmbH Germany All rights reserved 8010458 04 2007 FLOWSIC600 Ultrasonic Gas Flow Meter Product Description Features and Applications Conformity Configuration Technical Data System Components Measuring Principle Operating States and Signal Output Self diagnosis Event Logging Path Failure Compensation Configuration Operating Instructions Product Description FLOWSIC600 wm wmd Ultrasonic Gas Flow Meter Product Description 2 1 Features and Applications System features The FLOWSIC600 measuring system is the first compact gas meter used for ultrasonic volumetric gas flow measurements The measuring system is characterised by the following features e Specially designed compatible modules e Ultrasonic transducers integrated into the meter body Concealed cabling As a result this measuring system is extremely robust and provides maximum accuracy even under extremely rough operating conditions Its compact design also provides protection from mechanical damage thereby ensuring a long term stable measurement that is insensitive to mechanical or electrical interference
86. are of an intrinsically safe design class ia 8 010 458 04 2007 SICK MAIHAK GmbH Germany All rights reserved 19 FLOWSIC600 Ultrasonic Gas Flow Meter 2 3 3 Event logging see Section 2 7 2 3 4 Information on installation and use of the program can be found in the software manual 20 Product Description Operating Instructions Signal processing unit The SPU contains all the electrical and electronic components required for controlling the ultrasonic transducers It generates transmission signals and uses the received signals to calculate the measuring values The SPU also contains several interfaces for communication with a PC or standardised process control system The current volume count faults warnings and power failure alarms are stored in a non volatile data memory FRAM together with a time stamp On system restart the counter reading that was last saved is restored as the start value for the volume counter The FRAM back up provides an unlimited number of writing cycles and protects the saved data for at least 10 years The SPU is supplied with a front panel containing a two line LCD to display current measured values diagnosis and logbook information See Fig 2 4 You can select the values you want to be displayed using a magnetic pen while the front cover stays closed for details on operation and menu structure see Section 9 2 in the appendix SICK MAIHAK FLOWSIC 600 LC
87. ating Instructions Installation FLOWSIC600 Ultrasonic Gas Flow Meter HSK K type cable glands M 20 x 1 5 plastic EU or Le in NPT North America Bridge Cover for power supply terminals Power supply 2x 1 5 mm LiYCY or equivalent Digital output current output 4x2x0 5 mm Li2YCY TP or equivalent Cable entry for internal 10 core cable 10 pole terminal block Modbus for signal inputs and outputs 4x2x0 5 mm Li2YCY TP or equivalent Fig 3 9 Terminal assignment for use in safe areas Note Terminals 2 and PE are bridged internally i e there is no insulation between PE and negative potential see Fig 3 8 8 010 458 04 2007 SICK MAIHAK GmbH Germany All rights reserved 55 FLOWSIC600 Ultrasonic Gas Flow Meter Installation 3 4 5 Operating the FLOWSIC600 in safe areas Operating Instructions Assign the terminals in the SPU terminal box see Fig 3 9 in accordance with the following serial port RS485 Alternative assignment with second 16V lt Uce HS 30 V 0 mA lt ler HS 0 2 mA H High Direction of flow alternative Warning table Connection for Function Terthina Value Notes Power supply 1 2 12 24 20 VDC Digital output DO 0 Passive 31 32 fmax 6 kHz pulse duration 0 05 s 1 s With NAMUR contact HF 2 Range for connection to Variable number of pulses per volume unit switching am
88. ave not been acknowledged are identified by a flashing display To acknowledge a logbook entry Go to the unacknowledged entry using the DATA or STEP button Activate the ENTER function to show the corresponding time stamp display is still flashing Activate the ENTER function again in order to acknowledge the entry display will stop flashing Return to the list of logbook entries by pressing C CE The classification and type of event the position in the list of entries and the type of occurrence are always shown in the first line Further information may be shown in the second line depending on the type of entry Activate the ENTER function to display the time stamp of the event Return to the list of logbook entries by pressing C CE Example Failure of the power supply on 18 April 2003 at 12 13 Activate the ENTER function to display the time stamp of the event In the present case it is the time from which the measuring system was available again 18 April 2003 12 20 FLOWSIC600 system diagnosis Display of the ratio of incorrect and correct measurements Display of further information on path x x 1 to 4 Activate the ENTER function to call up the following information Display of the actual values of flow rate velocity of gas VOG and velocity of sound VOS in path x Display of the actual signal to noise ratio SNR and reception sensitivity automatic gain control AGC in path x one value for each direction of
89. ble PTB approve example lt gt 48 Installation Unidirectional use FLOWSIC600 23 DN Operating Instructions DN Flow straightener Temperature measuring point Fig 3 3 FLOWSIC600 installation in the pipeline for unidirectional use 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 Fig 3 4 gt 10 DN FLOWSIC600 gt 10 DN gt ra gt 5DN 5DN Ot i O gt a J e pen lt l en ata wegl H IN L A gt 5DN gt b DN La gt min 2 DN min 2 DN min 2 DN min 2 DN La ra La gt 15DN 1 5 DN ra ei M H i op I Flow straightener Temperature measuring point gt 10 DN gt 10 DN ra min 2 DN min 7 DN min 7 DN min 2 DN La gt La gt ra 5 DN 5 DN a I e lla j
90. c Normalized pressure Vne Vac D Pa c Actual pressure Tac Pnc K a Tn c Normalized temperature Ta c Actual temperature K Compressibility according to DVGW G486 SGERG 2 9 3 2 Assembly Installation The meter is installed in the same way as a standard FLOWSIC600 without the EVC see chapter 3 To facilitate the added functionality of the EVC a pressure and temperature transmitter will need to be installed and wired to the SPU 2 9 3 3 Measurement of pressure and temperature The analog output of the meter is used for the input of the pressure and temperature signals The HART protocolis modulated onto this analog signal so that the measured values may be queried by the gas flow meter EVC in a fixed cycle In order to realize pressure and temperature sensing HART capable transmitters have to be used as a necessity Since the transmitters are fed from the gas flow meter the transmitters have to be supplied as SMART 2 wire devices 36 SICK MAIHAK GmbH Germany All rights reserved 8 010 458 04 2007 Operating Instructions SMART 2 wire transmitter HART Communiication Ground P Transm 100 bar a ia IIC Product Description FLOWSIC600 Ultrasonic Gas Flow Meter Tested pressure transmitters e Manufacturer Fisher Rosemount Type 3051 CA HART capable 3051 S HART capable etc e Manufacturer ABB Type 264 HS HART capable Tested temperature measuring transmitters Manu
91. calibrated e To use a FLOWSICG6OO in fiscal metering applications a national pattern approval certificate must exist The requirements of the pattern approval documents have to be covered by this FLOWSIC600 The meter body must be approved for the maximum gas pressure that is applied e The FLOWSIC600 must be installed according to Chapter 3 e The FLOWSIC600 must be commissioned according to Chapter 4 Definition of test points test flow rates Flow rate calibration aims to find the deviation of the meter under test from a standard or norm It is conducted on flow rate test bench Number and position of test points are defined in the literature but may alternatively be defined individually by the customer Measuring range turn down 1 20 1 30 1 50 gt 1 50 S H Omin Omin 2 S 3 3 5 5 5 5 10 10 10 10 15 15 25 25 25 25 25 25 40 40 40 40 40 40 70 70 70 70 70 70 100 100 100 100 100 100 Flow calibration at atmospheric pressure Verification is based on PTB Testing Specification vol 29 Gas volume flow meter testing using air at atmospheric pressure For a further increase in the measuring accuracy the FLOWSIC600 provides Reynolds number and velocity related impact correction routines These nominal size dependent parameters were determined prior to the verification procedure and are s
92. cessing unit SPU can be turned such that the display can be read easily and that cable routing is facilitated see Fig 3 5 A stop on the housing prevents the SPU from being turned by more than 330 This aims to prevent damage to the cables that come from the meter body Signal processing unit EA V EEN Loosen the hexagon Position the SPU Tighten the hexagon socket head screw socket head screw Fig 3 5 Positioning the SPU Do not forget to tighten the hexagon socket head screw after having positioned the SPU SICK MAIHAK GmbH Germany All rights reserved 51 FLOWSIC600 Ultrasonic Gas Flow Meter 3 4 3 4 1 DANGER Installation examples see Section 9 6 52 Installation Operating Instructions Electrical Installation General information Pre requisites Wiring work routing and connecting the power supply and signal cables which is necessary when installing the FLOWSIC600 is not included in the scope of delivery The mechanical installation described in Section 3 3 must be completed Comply with the minimum requirements of the cable specs in accordance with Section 3 4 2 Notes on cable routing Cables shall be laid in conduits or on cable trays to provide protection from mechanical damage Observe the permitted bending radiuses generally min six times the cable diameter for multi conductor cables e Connections outside of conduits shall be as short as possible Warning Al
93. d content If the multiplex configuration is active the two display contents are shown alternately display changes every 5 s 9 2 4 Editing mode It is possible in this mode to modify parameters which are relevant for commissioning To be able to do so the configuration protection switch must be open Select the parameter and activate the ENTER function Options depending on the type of data O 1 2 3 4 5 6 7 8 9 sign Integer Floating point List of registers O 1 2 3 4 5 6 7 8 9 space decimal point sign List of all registers which are plausible for this parameter 8 010 458 04 2007 SICK MAIHAK GmbH Germany Al rights reserved 125 FLOWSIC600 Ultrasonic Gas Flow Meter 9 2 5 126 Appendix Data editing Operating Instructions Entering or editing data will be explained with the help of the following example Action Initial display Y Change to the menu Service Measurement Change to Service Y Scroll to pulse menu Y Select the menu Change to pulse factor entry Y Change to editing mode Y Enter desired value Confirm new value Y Exit this menu Definition of logbook entries 1 Classification Buttons ENTER 1 x STEP ENTER gt Change mode ENTER gt Confirm input 1 x CE C 2 x STEP ENTER 1 x STEP ENTER STEP DATA ENTER 3 x CE C Display gt V 34569870 m3 lt 0 m3 FLOWSIC600 Configu
94. d to calculate the transit times of the acoustic signals through the flowing medium The measured values can then be calculated from the transit times thus determined SICK MAIHAK GmbH Germany All rights reserved 21 FLOWSIC600 Ultrasonic Gas Flow Meter 2 4 1 With four paths gt 40 measurements per second Vpath Vpath 22 Measuring path length Velocity of sound Path velocity Angle between the longitudinal axis of the meter body and the path Path number 1 4 Measuring values in the registers 7507 to 7510 V P Register 7101 to 7104 Product Description Operating Instructions Determining the gas velocity Measuring cycle In the operating status Measurement the FLOWSIC600 determines the gas velocity on every measuring path 10 times per second One measuring cycle consists of a velocity measurement per path the integration of the operating volume several internal procedures and the update of the measuring value output channels Such a cycle takes about 100 ms Determining the transit time of the ultrasonic signals A full analysis of the ultrasonic signals makes it possible to determine the point of time of signal reception and thus the delay to the point of time of signal transmission The signal propagation times in the flowing gas tag and tga are determined on the basis of this delay Sound transit time in the direction of flow typ L c Vpath COS a tas Sound transi
95. display Selected measured variable device status Current measured value Control buttons for the magnetic pen O DATA STEP L ENTER H Fig 2 4 FLOWSIC 600 SPU front panel The power supply and interface terminals are located on the back of the SPU in a separate terminal box see Section 3 4 4 The electronics is mounted in a housing certified to EN 50018 or IEC 60079 1 with type of protection d flameproof enclosure The transducer circuits are of an intrinsically safe design type ia MEPAFLOW600 diagnosis and configuration software The MEPAFLOW600 program menu based configuration and diagnosis of the FLOWSIC600 system allows all system parameters to be accessed displays diagnosis information and can be used as a convenient tool for data recording SICK MAIHAK GmbH Germany All rights reserved 8 010 458 04 2007 Operating Instructions 8 010 458 04 2007 2 4 Product Description FLOWSIC600 Ultrasonic Gas Flow Meter Measuring Principle The FLOWSIC600 takes advantage of the principle of measuring the transit time difference of an ultrasonic pulse It is equipped with one two or four pairs of ultrasonic transducers The transducers of a pair are integrated into a meter body and arranged opposite one another at a defined angle to the flow axis thereby forming a direct measuring path see Fig 2 5
96. ditions is normally caused by dirt on the ultrasonic transducers See the service manual for cleaning instructions SICK MAIHAK GmbH Germany All rights reserved 99 FLOWSIC600 Ultrasonic Gas Flow Meter 100 Maintenance Signal to noise ratio Operating Instructions These values are generally plant specific and do not change provided the conditions remain the same A reduction in the signal to noise ratio while the reception sensitivity stays unchanged hints at sources of acoustic interference e g pressure regulator near the measuring location Overview of typical values Typical value Error Comment Velocity of sound Deviation from the theoretical velocity of sound less than 0 3 Greater than 0 3 When calculating the theoretical velocity of sound attention shall be paid to ensuring that the gas composition pressure and in particular temperature at the measuring location are identical to those when the test measurements were conducted The differences between the velocities of sound in the individual paths should not exceed 1 5 m s Greater than 1 5 m s Temperature stratification can occur with low flow rates Signal to noise ratio 20 dB This depends on the nominal width of the meter body and the current process Permanently less than 10 dB Possible sources of interference include electrical noise caused by bad contact of the connectors or
97. e and time stamp 5011 ForwardVolumeErr 5013 ReverseVolumeErr The resolution of aggregated volumes per volume unit m3 is defined in register 5014 TotalizerResolution When reading the volume counters 5010 to 5013 the corresponding resolution see Table below must be considered Counter resolution V Volume register value __ m5 1000 24 SICK MAIHAK GmbH Germany All rights reserved 8 010 458 04 2007 Operating Instructions 8 010 458 04 2007 2 4 4 Product Description FLOWSIC600 Ultrasonic Gas Flow Meter Counter resolution Resolution m Register 5014 DN 80 NPS 3 0 01 10 DN 100 NPS 4 DN 150 NPS 6 DN 200 NPS 8 DN 250 NPS 10 01 100 DN 300 NPS 12 DN 450 NPS 18 DN 500 NPS 20 1 0 1000 DN 350 NPS 14 DN 400 NPS 16 DN 600 NPS 24 Low flow suppression If the current flow rate falls below a preset threshold register 7036 LowFlowCutOff the calculated volumetric flow is set to zero The current calculated flow velocity is not affected by this The threshold is set to 0 25 Qmin at the factory Determining the velocity of sound The actual velocity of sound c in the gas under current operating conditions is calculated from the sum of the two measured propagation times tap and tga of a path L 1 1 T 2 tapi Tea
98. e is turned off static path relations as shown in the table below are used for path failure compensation These static values are based on data of several installations Path no 1 Path no 2 Path no 3 Path no 4 2 1 000 1 000 0 915 1 030 1 030 0 915 32 SICK MAIHAK GmbH Germany All rights reserved 8 010 458 04 2007 Operating Instructions Product Description FLOWSIC600 Pm Ultrasonic Gas Flow Meter The system indicates this status with the Measurement invalid signal The volume measured during that time is stored in separate error volume counters for each flow direction This enables the gas quantities transported to be determined despite an increased measurement uncertainty Note In order to ensure that the system is able to compensate path failure at both high and low flow velocities it is recommended to run the FLOWSIC600 during commissioning for 30 minutes at low gas velocities lt 8 m s first and then for 30 minutes at high gas velocities gt 8 m s5 Deactivation of the adaptive path failure compensation If path failure compensation is not required the calculation of the path relations can be suppressed by setting the attenuation constant register 7206 to zero or by unchecking the corresponding checkbox in the MEPAFLOW6OO program see Fig 2 6 In that case only the static compensation described for single or multiple path failure will be active vo MepaFlow 3 2 00 D 2_Fl
99. e parameter modifications do not trigger any reaction so that they do not affect the measuring value Fi Fig 4 4 Validation rate gt Monitor OS EI Speed of Sound Fig 4 5 Absolute sound velocity in the individual paths 0 10 Fig 4 6 Relative variation of the sound velocity among the individual paths Test criteria The proportion of invalid measurements at a max operating volumetric flow should be less than 25 Call up the Devive state sub menu in the Monitors menu in order to find the cause for the error The status indicators of the measuring paths P1 to P4 show the most frequent cause of errors for each path If Bit 13 Time plausibility is active See Fig 4 7 the zero phase position must be optimised details on the procedure can be found in the FLOWSIC600 service manual Monitor System state a a Bit Sys _ System state register P1 P2 P3 P4 Pathstateregisters Cut W Measuemode RW Measure valid WE Check Request LEE EEEE RW Hardware write lock Wi Path error W Pathenor2 WE Patherror 3 WG Patherror 4 kel Parameter invalid W Adjust range RW 10 Range error GECELE Dr c O a Gss OOE RE Path compensation valid W DSP Parameter error KE ES 2 EN EE KS LE EN EN HR 12 DI 14 LS ka go 4 7 Device status sub menu 8 010 458 04 2007 SICK MAIHAK GmbH Germany All rights
100. e range the meter has been applied for Warning The maximum operating pressure must however not exceed the maximum pressure resistance of the meter body The maximum permitted operating pressure is specified as Ps on the type plate of the meter body The permitted working pressure range of the meter is derived from the Pressure fix parameter Pix Prior to the verification procedure this parameter must be set to the working pressure applied during testing The gas pressure applied during testing should be identical to the average working pressure in the installation If the final working pressure exceeds 50 bar testing at 50 bar will be sufficient The maximum ratio of minimum and maximum operating pressure is De max lt 4 Pe min Generally Da Pe min Pe max 1 bar where Pe min 9 5 Da De max 2 Pax if De lt 0 5 Ps otherwise Ps SICK MAIHAK GmbH Germany All rights reserved 8 010 458 04 2007 Operating Instructions 8 010 458 04 2007 Note 5 1 4 Calibration FLOWSIC600 Ultrasonic Gas Flow Meter If the calibration is based on several test pressures the Pressure fix parameter must be reset to the applicable test pressure before each test The corresponding operating pressure range is displayed on the FLOWSIC600 as calculated in accordance with these equations The test pressure which comes closest to the average plant working pressure shall be entered as the Pres
101. ed in the error volume counters in accordance with the direction of flow irrespective of the measuring accuracy Overview of event entries Class Description Value second line on the display Power on information System was cold started or rebooted after a watchdog Time stamp of the last stored counter reset reading is considered to be the time of the Power off event Change of information System was changed to the configuration mode after Activated password level operating mode password input or back from the configuration mode to the measurement mode Parameters that affect the measured values may have been modified Error volume information Resetting the error volume counters to zero Reset volume counter reset Counter overflow I information One of the four volume counters has run through completely Logbook reset information Entire logbook was deleted Reset is always the first entry and indicates the point of time the logbook was opened Set clock information Date and or time register of the real time clock was Time stamp of the change were changed Maintenance W warning The measured value of one path must be substituted Path index and cause for deactivation required by the replacement value calculation routine Output range W warning The current measured value can no longer be represented by the pulse output because the maximum output frequency was reached
102. elations The results are saved in the high flow class registers 7285 7288 path 1 4 Adaptive compensation of one or more path failures If the self diagnosis routine implemented in the system detects a path failure the velocity value for the failed path will not be used for the calculation of the mean area velocity v Equation 2 If this occurs the following formula will be used to calculate the mean area velocity based on the applicable measured values for the remaining paths and the stored adapted path relations bi Status bit for path i y VPathi I bi O Path inactive Ken Ppath i j N gt bi wi i 1 bi 1 Path active VA The system indicates that a path failure is being compensated with the Maintenance required signal A greater measurement uncertainty of less than 0 35 must be accepted with four path systems when operating in this mode The volume measured during that time is stored in the normal counters for each flow direction Multiple path failure is also compensated using the principle described above but the system indicates this status with the Measurement invalid signal The volume measured during that time is stored in separate error volume counters for each flow direction This enables gas quantities transported to be determined despite an increased measurement uncertainty Static compensation of one or more path failures If the adaptive path compensation routin
103. emperature specifications for use in hazardous areas SICK MAIHAK GmbH Germany All rights reserved 8 010 458 04 2007 Operating Instructions Installation Power supply Field connections Digital output Digital output Digital output Bl 81 Terminal box e i FLOWSIC600 Ultrasonic Gas Flow Meter Signal processing unit Pressure resistant space d Meter body Fig 3 10 FLOWIC600 components and their type of protection Safety relevant data of inputs and outputs Output circuit Intrinsically safe EEx ia IIA IIC Non intrinsically safe Um 253 V Active current output Uo 22 1V Ug 18 V Terminals 31 32 lo Po EEx ia IIA EEx ia IIC la 35 mA mA mW Co nF Lo mH Co nF Lo mH 155 155 857 857 4100 7 163 1 Characteristic curve linear Internal capacity C 4 nF internal inductance L 0 075 mH Only for connection to passive intrinsically safe circuits or intrinsically safe circuits with the following maximum values V 30 V Passive current output U 30 V Ci 4nF Ug 30 V Terminals 31 32 100 mA L 0 075 mH Ip 35 mA P 750 mW Digital output U 30V C 4 nF Ug 30 V Terminals 31 32 51 100 mA L 0 075 mH Is 100 mA 52 41 42 81 82 P 750 mw RS485 Characteristic curve linear Ug 5V Terminals 33 34 and Uo 5 88 V Ui 10 V lp 175 mA 81 82 lo 313 mA li 275 mA Po 460 mW Pi 1420 mW Co
104. eral Metrology Office in Germany Remote Terminal Unit Signal Processing Unit Verband der Elektrotechnik Elektronik Informationstechnik Association of German Electrical Engineers SICK MAIHAK GmbH Germany All rights reserved 8010458 04 2007 Operating Instructions Safety Instructions FLOWSIC600 Ultrasonic Gas Flow Meter Safety Instructions 8010458 04 2007 11 12 13 Intended Use of the Equipment The FLOWSIC600 measuring system is used for measuring the actual volumetric flow rate of gases transported in pipelines The FLOWSIC600 measuring system can further be used for measuring the actual volume and velocity of sound in gases The measuring system shall only be used as specified by the manufacturer and as set forth below Always observe the following information Make sure the use of the equipment complies with the technical data information about the permitted use assembly and installation specifications and ambient and operating conditions Any relevant information is provided in the order documentation type plate certification documents and this manual Any actions aiming at maintaining the value of the equipment e g service and inspection transport and storage etc shall be performed as specified Do not expose the equipment to mechanical stress such as pig cleaning Authorised Staff Persons responsible for safety issues shall ensure the following Any work on the measuring system sha
105. et as manufacturer constants at the factory The important assignment of the Reynolds number range is carried out with the help of the Pressure fix parameter SICK MAIHAK GmbH Germany All rights reserved 75 FLOWSIC600 Ultrasonic Gas Flow Meter 76 ATTENTION 5 13 ATTENTION Calibration Operating Instructions For calibration with air at atmospheric pressure call up the Calibration function on the LC display This will reset the Pressure fix parameter to 1 0 bar a The word Calibration will appear on the display while the device is being calibrated After calibration and adjustment the FLOWSIC600 must be set to one of the following operating pressure ranges by setting the Pressure fix parameter see Fig 4 8 Rated pressure range Pe min Pe max 1 bar a O bar 0 1 bar 1 5 bar a 0 1 bar 1 0 bar 3 2 bar a 1 0 bar 4 0 bar Warning The maximum permitted operating pressure of a gas flow meter verified at atmospheric pressure must not exceed 4 bar g Flow calibration at high pressure Verification is based on PTB Testing Specification vol 30 High pressure testing of gas meters The FLOWSIC600 should be tested under the same conditions and using the same type of gas which will be used during normal operation Determining the test pressure The minimum Pe min and maximum Pe max operating pressure must be identical to the operating pressur
106. facturer Fisher Rosemount Type 644H A HART capable 248H A HART capable etc e Manufacturer ABB Type THO1 Ex HART capable Electrical connection The transmitters are parallel connected to terminal 31 32 Through the connecting cables the supply voltage is provided by the gas flow meter for both transmitters and at the same time the serial data protocol is transmitted according to HART Volume pulse Status Modbus Power supply T Transm PT100 gt 4 20 mA EEx ib IIC 20 60 C ATTENTION 8 010 458 04 2007 OW TI FL 600 Fig 2 10 Wiring of pressure and temperature transmitters Important In this configuration with EVC the analog I O is used as input for the pressure and tempe rature transmitters As such the analog I O is not available as a standard output To obtain an analog output signal an additional DIN rail module may be used for frequency analog conversion Pepperl amp Fuchs KFD2 UFC with internal Ex barriers analog and frequency output The design and wiring of the transmitters can be intrinsically safe Ex i as well as with increased safety Ex e When Ex i transmitters are connected all other wires in the terminal compartment must also be connected to equipment having an EEx i marking SICK MAIHAK GmbH Germany All rights reserved 37 FLOWSIC600 Product Description Operating Instructions a U MMM Ultrasonic Gas Flow Meter 2 9 3 4 Configuration of the E
107. fset Diffractioneffekt Parmeter TimeOffsetHW Register 7148 7155 is calculated as summary with Electronic G_Karte_427_Rev_108 04 04 2006 Rev 2 0 Page 1 of 2 Fig 9 12 Check report SPU example SICK MAIHAK GmbH Germany All rights reserved 8 010 458 04 2007 Operating Instructions Appendix FLOWSIC600 Ultrasonic Gas Flow Meter 9 5 4 Check report transducer pair example Sondenseriennummer Serial number Seriennummer Sonde A Serial number A Seriennummer Sonde B Serial number B G DEE EE EEN L nge Sonde A m Transducer length A m L nge Sonde B m Transducer length B m Offsetzeit Time offset Zeit Sonde A s Timeoffset AB Zeit Sonde B s Timeoffset BA H Pr fer Approved G_Karte_427_Rev_108 04 04 2006 05470078 05470055 0 038994 0 039006 1 73975E 05 1 74007E 05 Rev 2 0 Pr fschein Check report Sondenpaar 1 Transducer pair 1 Sendefrequenz Hz Tx Freque Anzahl Gesamtperioden Tx Pe Anz ungebremste Perioden T 208000 4 3 Durchgef hrte Tests Reports D I Muttertest Master check II Laufzeittest gegen Referenzelektronik Reference check MO Ot Oc Datum Date Page 1 of 4 8 010 458 04 2007 Fig 9 13 Check report transducer pair sheet 1 example SICK MAIHAK GmbH Germany All rights reserved 137 FLOWSIC600 Appendix Operating Instructions Ultrasonic Gas Flow Meter Pr fschein C
108. fthe normalized volume Vn c is available as displayed value on the LC display as a MODBUS register value and as a pulse output The calculation methodology for determination ofthe compressibility is based on the SGERG method and is applicable up to a pressure of 100 bar 1450 psi Limitation of use When using the FLOWSIC600 with the integrated EVC the flow computer normally required to standardize the volumentric flow may not be required The EVC is not intended or approved for custody transfer applications fiscal measurement Reqirements The use of the FLOWSIC600 with integrated EVC requires the following program releases Firmware 3 0 00 or higher MEPA 10 0 10 or higher SICK MAIHAK GmbH Germany All rights reserved 35 FLOWSIC600 Product Description Operating Instructions Ultrasonic Gas Flow Meter Calculation schematic Pressure and temperature sensing Ultrasound transit time measurement Calculation of actual flow actual volume HART Constant values analog signal Calculation of normalized flow normalized volume GERG 88 Standard density Heating value H2 concentration CO2 concentration MODBUS LC Display Analog output Pulse output V n c V n c errors Q n d V n c V n c errors Q n c V n c Fig 2 9 Schematic diagram The following formula is used to calculate the normalized volume Vn c Normalized volume Va c Actual Volume Pac Tnc 1 Pn
109. g Mode Monitors Options Help Dae gt Mm s A B G m gt H id H h X Measuring values Device parameters Adjustment Device diagnosis Path diagnosis Device logbook Log Trend Flash tool SICK MAIHAK 15 49 07 15 49 07 15 49 07 15 49 07 15 49 07 15 49 07 15 49 07 15 49 07 15 49 07 0 ZC Flow rate a c mh Forward volume a c Average flow velocity m s Reverse volumen a c Average speed of sound 0 V Forward eror volume a c Device state mees Reverse eror volume a c Measure Service morm OO N Fig 4 3 Measured values tab The values for validation rate invalide measurements velocities of sound and more are be displayed in the Monitors menu see Fig 4 4 to Fig 4 7 Note The validation rate is the ratio of rejected measurements and total measurements It is an indicator for the quality of the measurement in the ultrasonic measurement path 68 SICK MAIHAK GmbH Germany All rights reserved 8 010 458 04 2007 Operating Instructions Commissioning FLOWSIC600 ss ua gt GC s x xsxsss sl EEE Ultrasonic Gas Flow Meter Device state zg x SNR AGC Levels ath 1 0 Velocity of Sound f ath 2 0 Relations of sound Path 3 0 Velocity of Gas Path 4 0 Turbulence Monitor YOS Relations eo x If the zero phase parameters are optimised properly thes
110. g plan See Section 9 7 Attach the test record of the transducer pair installed to the operations data logbook SICK MAIHAK GmbH Germany All rights reserved 8 010 458 04 2007 FLOWSIC600 Ultrasonic Gas Flow Meter Troubleshooting Operating Instructions 8 010 458 04 2007 Troubleshooting Troubleshooting FLOWSIC600 Ultrasonic Gas Flow Meter If the routine tests described in Section 6 2 or the function tests described in Section 4 2 3 indicate that the device is not functioning properly the following table will help you finding the cause of the fault If the cause of the fault cannot be localised the MEPAFLOW600 program can be used to conduct a more detailed fault diagnosis see software manual service manual No display No pulse frequency e No active status signal Possible cause Faulty power supply Corrective action e Check the input voltage at terminals 1 and 2 e Check cables and terminal connections Caution Take the relevant safety precautions Defective device Contact the manufacturer Warning on the LC display Different velocities of sound in the individual paths Transducer s are dirty Clean the transducer s Transducer s are defective Replace the transducer s see service manual Cables mixed up when transducer was cleaned Faulty transducer or electronic module Check and correct if necessary Replace the transducer s See ser
111. g range register 7041 PressureAbsFix p Pmin Pmax 1 bar The sets of factors CCg to CC and Kg to Ks are nominal width dependent constants which were determined by the manufacturer and which are related to a particular FLOWSIC600 Correcting the impact of pressure and temperature on the geometry of the meter body The geometry parameters of the meter body are related to an ambient temperature of 20 C and 1 bar a and have been optimised with view to minimum deviations due to the influence of pressure and temperature However there is still an impact of pressure and temperature on the geometry of the meter body and thus on the measured value This impact is corrected as follows Qy corr Qy 1 Kr T 293 15 K p The temperature coefficient K is material specific and amounts to 4 12 10 Kt for carbon steel and 5 23 10 Kt for special steel The pressure coefficient K was determined to be 6 10 part SICK MAIHAK GmbH Germany All rights reserved 23 FLOWSIC600 Product Description Operating Instructions Ultrasonic Gas Flow Meter Correcting the characteristic line The characteristic line may be corrected using a factor dependent on the direction of flow AF forward Register 7037 AF forward AF reverse In addition a zero offset ZO may be entered However it should have AdjustFactorForward the value O with a properly working device standard value 1 0 AF reverse Register 7
112. gen Referenzelektronik L nge Sonde A mJ Transducer length A m 0 038992 Reference check L nge Sonde B mJ Transducer length B m 0 038982 Offsetzeit Time offset Zeit Sonde A s Timeoffset AB 1 73440E 05 Zeit Sonde B s Timeoffset BA 1 73457E 05 OQ G amp W 10 OC Pr fer Approved Datum Date G_Karte_427_Rev_108 04 04 2006 Rev 2 0 Page 3 of 4 Fig 9 15 Check report transducer pair sheet 3 example 8 010 458 04 2007 SICK MAIHAK GmbH Germany All rights reserved 139 FLOWSIC600 Appendix Operating Instructions Ultrasonic Gas Flow Meter Pr fschein Check report Sondenpaar 4 Transducer pair 4 Sondentyp Transducor type s1 SendemodellTransmit model Sendefrequenz HzYTx Freque 208000 Sondenseriennummer Serial number Anzahl Gesamtperioden Tx Pe 4 Anz ungebremste Perioden T 3 Seriennummer Sonde A Serial number A 05470090 Seriennummer Sonde B Serial number B 05470071 Durchgef hrte Tests Reports gt Muttertest Master check G trische L nge T l length S P Laufzeittest gegen Referenzelektronik Lange Sonde A mJ Transducer length A m 0 03898325 Reference check L nge Sonde B mJ Transducer iength B m 0 038986 Offsetzeit Time offset Zeit Sonde A s Timeoffset AB 1 73488E 05 Zeit Sonde B s Timeoffset BA 1 73503E 05 Campy j Ca TO Oa OC Pr fer Approved Datum Date cy G_Karte_427_Rev_108 04 04 2006 Rev 2 0 Page 4 of 4 Fig 9 16 Check
113. hase agreement This agreement also includes the complete and solely valid warranty conditions 8010458 04 2007 SICK MAIHAK GmbH Germany All rights reserved 7 FLOWSIC600 Ultrasonic Gas Flow Meter About this Document Operating Instructions Abbreviations used in this manual ASCII ANSI ASME CSA DC DIN DN DSP EC EN Ex HART act IEC norm LED MEPAFLOW MDR NAMUR OIML PC PTB RTU SPU VDE American Standard Code for Information Interchange American National Standards Institute American Society of Mechanical Engineers Canadian Standards Association Direct Current Deutsches Institut fur Normung German Standards Institute Nominal Diameter internal Digital Signal Processor European Community Euro Norm European Standard Potentially explosive atmosphere hazardous area Communication interface actual under operating conditions International Electrotechnical Commission normalised under standard conditions Light Emitting Diode Menu assisted Parameterisation and Diagnosis for FLOWSIC600 Manufacturer Datal Report Normenarbeitsgemeinschaft fur Mess und Regeltechnik in der chemischen Industrie now Interessengemeinschaft Prozessleittechnik der chemischen und pharmazeutischen Industrie Association for Instrumentation and Control Standards in the Chemical Industry Organisation Internationale de Metrologie Legale Personal Computer Physikalisch Technische Bundesanstalt Fed
114. heck report Sondenpaar 2 Transducer pair 2 Sondentyp Transducer type Si SendemodellTransmit model Sendefrequenz HzJ Tx Freque 208000 Sondenseriennummer Serial number Anzahl Gesamtperioden Tx Pe 4 Anz ungebremste Perioden T 3 Seriennummer Sonde A Serial number A 05470093 Seriennummer Sonde B Serial number B 05470057 Durchgef hrte Tests Reports D4 Muttertest Master check G ische L nge T l h C PDT Laufzeittest gegen Referenzelektronik L nge Sonde A m Transducer length A m 0 03903375 Reference check L nge Sonde B mJ Transducer length B m 0 039001 Offsetzeit Ti ffset Zeit Sonde A s Timeoffset AB 1 74835E 05 Zeit Sonde B s Timeoffset BA 1 74831E 05 O amp N4 eos 6 Pr fer Approved Datum Date ww G_Karte_427_Rev_108 04 04 2006 Rev 2 0 Page 2 of 4 Fig 9 14 Check report transducer pair sheet 2 example 138 SICK MAIHAK GmbH Germany All rights reserved 8 010 458 04 2007 Operating Instructions Appendix FLOWSIC600 Ultrasonic Gas Flow Meter Pr fschein Check report Sondenpaar 3 Transducer pair 3 Sondentyp Transducer type Si SendemodellTransmit model Sendefrequenz Hz Tx Freque 208000 Sondenseriennummer Serlal number Anzahl Gesamtperioden Tx Pe 4 Anz ungebremste Perioden T 3 Seriennummer Sonde A Serial number A 05470175 Seriennummer Sonde B Serial number B 05470064 Durchgef hrte Tests Reports Muttertest Master check WW P Laufzeittest ge
115. i 0075mH Class1 Division1 Groups B C and D Class1 Division 2 Groups A B C and D Class 1 Zone 1 Group IIB Hydrogene Class 1 Zone 2 Group IIC Fig 9 5 Terminal assignment in accordance with CSA Group B C D Connection in accordance with CSA Group D Entity Parameters Vmax 16V Imax 200mA Ci 4nF Li 0 075mH power supply alimentation VB 12 24V DC 4 20 mA D active g Voc 2241V Vmax 30V S digital out 0 HF2 passive DJ Isc 155mA Imax 100mA sortie digital 0 Ca 4 14uF Ci 4nF 2 pore gigia CID laun Li 0 075mH RS 485 TT Voc 5 88V Isc 313mA Ca 1000uF La 1 5mH Vmax 10V Imax 275mA Ci 4nF Li 0 075mH Vmax 30V Imax 100mA Ci 4nF Li 0 075mH digital out 1 HF1 passive C Vmax 30V N ee Imax 100mA Ka sortie digital 1 Ci 4nF _ fmax 6 kHz NAMUR 15 0 075mH digital output 2 passive Vmax 30V wC sortie digital 2 8 ImaxJ00mA J NAMUR i 0 075mH digital output 3 passive Vmax 30V Ci 4nF A 7581 sortie digtals H re Imax 100mA Li 0 075mH Voc 5 88V Isc 313mA Ca 1000uF La 1 5mH RS 485 _ vimax 10v imax 275mA Ci 4nF Li 0 075mH Class1 Divisionl Group D Class1 Division 2 Group D Class 1 Zone 1 Group IIA Class 1 Zone 2 Group IIA Fig 9 6 Terminal assignment in accordance with CSA Group D 130 SICK MAIHAK GmbH Germany All rights reserved Operating Instructions 8 010 458 04 2007 FLOWSIC600 Appendix
116. ical loads must be specially protected e g laid in open ended conduits Cables that are not fire proof must demonstrate fire resistance according to DIN VDE 0472 Part 804 test type B Attach ferrules to the wire ends to ensure that they do not split up The applicable requirements regarding air gaps and creepage distances must be observed in accordance with EN 50019 The available air gaps and creepage distances in the terminal box must not be reduced when connecting the cables Unused cable glands must be replaced by the EExe plugs included in the delivery The equipotential bonding must be in accordance with EN 60079 14 The meter body and SPU housing must be connected to the potential equalizer In intrinsically safe circuits provide equipotential boding along the wiring runs of the current outputs The applicable national specifications shall also be observed 8 010 458 04 2007 SICK MAIHAK GmbH Germany All rights reserved 57 FLOWSIC600 Ultrasonic Gas Flow Meter Approval of the ultrasonic transducers in zone O only ATTENTION valid for operation under atmospheric conditions 58 ATTENTION Installation Operating Instructions Terminal assignment The terminal assignment in the SPU terminal box See Fig 3 9 is the same as for the installation of the FLOWSICGOO in non hazardous areas see table in Section 3 4 5 Important The protective conductor must not be connected within the hazardous area For
117. ignal active inactive active inactive Measurement valid Compensation of path failure Direction of flow Status Status undefined undefined Status signal active inactive active inactive Positive or negative Positive or negative direction of flow direction of flow Warning Status Status undefined undefined active inactive active inactive LC display gt V 123456 ms 1234 ms FLOWSIC600 gt V 123456 m lt V 1234 ms lt V 1234 ms Display flashing Display flashing Serial port RS485 Measured value diagnosis information and parameters Measuring data logging diagnosis and configuration through the MEPAFLOW600 program see software manual Connection with external process control equipment through implemented MODBUS protocol data polling 28 The active or inactive state can be assigned to the electric switch status normally open or normally closed by configuration in the MEPAFLOW600 control and configuration program see software manual The default setting for Maintenance required Configuration and Malfunction is normally closed Digital output 2 is assigned by default with the status signal Maintenance required and digital output 3 with the status signal Direction of flow Alternatively digital output 3 may be assigned with the status signal Warning in the course of
118. ing the current sample rate and executes all calculations as in the Measurement mode Frequency output and analog output may represent test values and do thus not necessarily indicate measured values Any parameter modifications are applied immediately to the running calculations with the exception of the sample rate baud rate of the Modbus interface device address SICK MAIHAK GmbH Germany All rights reserved 8 010 458 04 2007 Operating Instructions Product Description FLOWSIC600 Ultrasonic Gas Flow Meter The test cycle can be activated for a measuring path by setting the corresponding control bit in the System Control Register 3002 see software manual In a test cycle the transmitted signal is fed to the received 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 status It is used to test a path specific electronic module Possibly active test cycles are automatically cancelled when leaving the Configuration status 2 5 4 Malfunctio
119. ings which may adversely affect the gas flow directly upstream the FLOWSIC600 Seals atthe flange connections between meter body and pipeline must not protrude into the pipeline Otherwise the flow profile and thus the measuring accuracy may be adversely affected Pressure measuring devices shall be connected to the pressure tap provided see Fig 2 3 The pressure tap is a 1 4 in NPT female port irrespective of the meter size The NPS 2 DN 50 meter forms an exception its pressure tap is a 1 8 in NPT female port e Temperature probes shall be arranged as shown in Fig 3 3 and Fig 3 4 3 2 2 Installation configurations The choice of the installation configuration See Fig 3 3 and Fig 3 4 depends on type and extent of the flow disturbance at the installation position according to TR G13 Possible installation configuration None Elbow reducer Configuration 1 or 2 Double elbow out of plane T piece Gas pressure controller with without muffler Diffuser Configuration 2 Diffuser with swirling flow 8 010 458 04 2007 SICK MAIHAK GmbH Germany All rights reserved 47 FLOWSIC600 Ultrasonic Gas Flow Meter Configuration 1 Configuration 2 Configuration 1 Configuration 2 Not applicable for meters marked with an asterisk in Section 2 2 4 Table PTB approve example Configuration 2 Applicable for meters marked with an asterisk in Section 2 2 4 Ta
120. ints Eror curve w coefficients factors forward Amin kend Points as found unadiusted C revers E fi L Points as left fadiusted Fig 5 12 Adjustment Show curve tab representing adjustment with constant factor 86 SICK MAIHAK GmbH Germany All rights reserved 8 010 458 04 2007 Operating Instructions Calibration FLOWSIC600 wm wmd Ultrasonic Gas Flow Meter Adjustment using a polynomial The following polynomials are implemented in the FLOWSIC600 firmware in order to provide for a flow specific adjustment of the error characteristic E Q a 07 tal a a Q a Q 1 8 sample points E Q a Qt a a Q a Q 2 7 sample points E Q ac a Q a Q2 3 6 sample points The adjustment using a polynomial must only be used if the minimum number of sample points for finding the polynomial coefficients in the range to be calibrated have been determined The adjustment factor is in this case calculated by the FLOWSIC600 depending on the actual flow rate EE xl 100 110 Information Adjust method Polynomial gt Points and coefficients factors not in directly mathematic relation Adjust parameter Displayed error curves based on progam data after write to device data are valid Show direction Gmax m h fi 000 Show points E Eror curve w coefficients factors forward Amin b Points as found unadjusted C revers L HE Points as left fadiustedl Fig 5
121. ion 18 04 03 12 13 Error volume counter Error volume counters were reset to zero Counter reading at the time of reset the event Reset EV S Counter overflow One of the four volume counters has run through completely Overflow S Logbook reset Entire logbook was deleted Reset log S Reset is always the first entry and indicates the point of time the logbook was opened Maintenance required WwW The measured value of one path had to be substituted by the Path index W Service req S replacement value calculation routine Path no Output range w The current measured value can no longer be represented by W Output S the pulse output because the maximum output frequency was reached Measurement invalid E More than one path had to be substituted by the replacement E Measurement S value calculation routine or the adaptive path failure compensation is not yet active System error E Reliable operation of the system is not guaranteed Cause of the fault E System S CRC program code parameters CRC parameters CRC counter reading CRC replacement path weights Parameters implausible DSP Logbook full E No memory space further events cannot be logged E System S The system will turn into the Malfunction status 8 010 458 04 2007 SICK MAIHAK GmbH Germany All rights reserved 127 FLOWSIC600 Appendix Ultrasonic Gas Flow Meter Operating Instructions 9 2 6 Acknowledgement of a logbook entry
122. ionship menu see Fig 5 10 and a comparison of the velocity of sound measured by the FLOWSIC600 with the theoretical value see Service manual Section 6 2 1 Monitar YoS Relatianship u Hy EUTIN 7 Max deviation 0 1 Fig 5 10 MEPAFLOW600 Monitors VOS relationship menu 8 010 458 04 2007 SICK MAIHAK GmbH Germany All rights reserved 83 FLOWSIC600 Ultrasonic Gas Flow Meter 5 3 1 5 3 2 See Section 2 4 2 Adjustment with constant factor Calibration Operating Instructions Data logging optional It is recommended to record the measured values and diagnosis information for documentation purposes and later use Operating Mode Monitors Options l Start data recordng ape I lid H yarametere Adjustment Device diagnosis Path diagnosis Create log Session DEFAULT SF rrr tere Den n r Measpoint logging Enabled Specify a file name Activate the measuring point logging and enter name and duration of the first measuring point First Measpoint name MP1 Stop logging after sec ao r Log limits Limits enabled 2 Ellen No limit X No limit v Limit time Limit records Limit size a Enable ASCII export to file Data are not stored in session _ toot JS Start data logging at the first measuring point When the measuring period has elapsed a dialog box will appear where you are requested to enter name
123. ivated e g at GergCalcintervallMax 0 7755 GergKorr_KO Correction factor for high pressure polynomial adjustment gt 100 bars for natural gas only 7756 GergKorr_K1 Correction factor for high pressure polynomial adjustment gt 100 bars for natural gas only 7757 GergKorr_K2 Correction factor for high pressure polynomial adjustment gt 100 bars for natural gas only 7758 GergKorr_K3 Correction factor for high pressure polynomial adjustment gt 100 bars for natural gas only 7759 GergKorr_K4 Correction factor for high pressure polynomial adjustment gt 100 bars for natural gas only Tab 2 2 Configuration for the volume correction calculation 2 9 3 5 Outputs The following signal outputs are available on the meter Terminal 51 52 Terminals 41 42 81 82 Terminal 33 34 8 010 458 04 2007 1 x pulse output or analog signal via external frequency analog converter 2 x status outputs flow direction warning failure need of maintenance SICK MAIHAK GmbH Germany All rights reserved 1 x MODBUS 41 Operating Instructions Product Description FLOWSIC600 Ultrasonic Gas Flow Meter 0099ISMOTA sesosos Ki UOTIETTEIUT pspusmuossr JO9DISMOTA 5 Irzas Teuruz r z 3 s M D NW R SS SS SS AN f f M Je Le Vee lut SIS v H we Gi lt Kewl D Hi i i H if H I i GE Toe ill HERS ii SFP ezrsuoqen5 oli en sh iN INV EINE IV
124. justment Device diagnosis Device logbook Log Trend SICK MAIHAK Power supply Analog output Current input voltage 24 00V DDM r electr state DO LED ON output closed gray gt output disabled DO0 Teminal 31 32 5 1 42 DO3 Teminal 81 82 We m I bi pp Fig 4 1 Device diagnosis tab Firmware The FLOWSIC600 firmware is stored on a FLASH PROM The program code for the signal processor and system micro controler is identified by a version number register 5002 and a check sum register 5005 and can be verified as mentioned above In case of using the FLOWSIC600 for fiscal metering the approved firmware versions and the associated check sums are documented in the national pattern approval certificates 66 SICK MAIHAK GmbH Germany All rights reserved 8 010 458 04 2007 Operating Instructions 8 010 458 04 2007 4 2 4 2 1 4 2 2 Note 4 2 3 Commissioning FLOWSIC600 Ultrasonic Gas Flow Meter Checking the Functions FLOWSIC 600 with LED Front Panel The FLOWSIC 600 is functioning correctly when the green status LEDs for each measuring path installed start flashing periodically approx 30 s after the power supply is switched on If the yellow LED flashes the FLOWSIC600 works in the operation mode Maintenance required with an insignificantly reduced accuracy e g if one path fails If the yellow LED lights up permane
125. l id H A Pi gt Measuring values Device parameters Adiustment Device diagnosis Device logbook Log Trend SICK MAIHAK If Flow Offset 01 fezh Warning Delay 0 Low flow cutoff 0 0 fh Warning AGC Deviation 6 dB Adjust forward 1 00000 nu Waring AGC 90 dB Adjust reverse 1 00000 nw Warning SOS 0 8 ft s z 7001 Fomate nU z 7001 Flowate _n Meter factor 1700 12 Physical value at 4m 0 0 Qmax at 2kHz 4235 3 fP h Physical value at 20m4 0 0 DOO no frequency when v Damping T90 0 0 g Disabled h Flow Diech ou Output DOO Terminal DI le nl eeaeee a e Term Fyd Output DOT Terminal 51 5 nu a Pressure fixed 0 1 psita Output DO2 Terminal 4174 eet Direct nU Compressibilty fixed as Output DO3 Terminal 81 82 ll nu om RRE Se Val Craso hd English Volume for Volume for k Reset 0 000100 Line 2 Volume rew Y Volume rew Y Configuration Authorized operator OFFENE e 2 Fig 5 7 Device parameters tab Change back to the measurement mode after having edited the parameters Once the first flow rate value has been measured check the error limits Measuring values tab see Fig 5 8 These limits should be lower than 25 per cent in all paths If the velocity of gas is greater than 30 m s the error rate may be significantly higher In addition check the
126. ling surfaces of the flanges are protected with special caps 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 of the flanges Any damage must be documented and reported to the manufacturer immediately Also check the consignment for completeness The standard scope of delivery comprises gt FLOWSIC600 measuring system meter body with signal processing unit and transducers gt MEPAFLOW6OO control and configuration software Operating instructions software manual Manufacturer Data Report MDR Important Make sure the actual site conditions match the information provided on the labels at the meter body and SPU see Fig 3 1 in order to guarantee a safe and reliable operation of ATTENTION the measuring equipment Main type plate see Drawing no 7022 07 Main type plate on the SPU Flange dimensions Type plate on the meter body Fig 3 1 FLOWSIC600 labels and marks 8 010 458 04 2007 SICK MAIHAK GmbH Germany All rights reserved 45 FLOWSIC600 Ultrasonic Gas Flow Meter 46 3 1 2 ATTENTION Note Installation Operating Instructions Transport and storage Important 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
127. ll only be carried out by qualified persons and must be approved by responsible skilled persons Due to their professional training knowledge and vocational experience as well as their knowledge of the relevant standards regulations health and safety regulations and equipment conditions qualified persons shall be assigned by the person responsible for personal and plant safety to carry out such work Qualified persons must be able to identify possible dangers and to take preventive action in due time Skilled persons are defined in DIN VDE 0105 and IEC 364 or comparable standards Skilled persons shall have precise knowledge of process specific dangers e g due to the effects of hot toxic and pressurised gases gas liquid mixtures and other process media and of the design and working principle of the measuring system and shall have received and be able to document appropriate training In hazardous areas wiring and installation shall only be carried out by staff trained according to EN 60079 14 and according to national regulations General Safety Instructions and Protective Measures Using the equipment for any other purpose than intended and improper operation may result in injuries and damage to the equipment Read this section and the notes and warnings in the individual sections of this manual carefully and observe the instructions given therein when carrying out any work on the FLOWSIC600 measuring system Generally SICK MAIH
128. llt und unterschrieben MEPA Handbuch und CD ROM in SlimeCase Bei LCD Ausf hrung Hinweisblatt LCD Bedienset in Kundendokumentation HE UR B GO BS E G Kundendokumentation zusammengestellt und berpr ft Datum D 220 Signum A Der Gasz hler mit der o g Serien Nr wurde berpr ft und kalibriert nach unseren QS Standards basierend auf ISO9001 Dieses Ger t erf llt oder bererf llt alle angegebenen Spezifikation 1 Nichtzutreffendes durchstreichen Ident Nr FDB20020103 Produktgruppe FLOWSIC600 Revision 1 5 01 12 2005 FLOWSIC600 Ultrasonic Gas Flow Meter Copy the following protocols and assemble them for delivery to the customer Device Configuration Sheet Zero Flow Protocol MEPA corfiguration protocol Original SICK Maihak Inspection Certificate Copy of Material Inspection Certificate of Casting EC declaration of conformity acc PED DGRL 97 23 EWG EC declaration of conformity acc NSP 73723 EWG EMV 89 336 EWG 94 9 EG Certificate of Compliance by CSA EC Type Examination Certificate User Manual Normal or PTB version Finally this complete filled and signed protocol MEPA manual and disks The gas counter with the above notified Serial No Has been checked and calibrated according our QS standards which are based on ISO9001 This flow meter meets or exeeds all published specifications SICK Engineering GmbH Seite 2 2 8 010 458 04 2007 Fig 9 11 Final check
129. locities among the individual paths The relation among the paths for valid measurements are defined by the individual flow profile situation in the installation This relation is continuously calculated and saved during undisturbed measurement operation Field studies have shown that it makes sense to distinguish between two regions low velocity and medium to high velocity The relation of gas velocities among the paths are stored separately for each of these two regions It is recommended to teach the path relations during the commissioning procedure because they are different in each individual mounting situation see software manual Device parameters tab Determination of path relations During normal operation the individual path relations Ppan are calculated continuously Path i Path i VA 1 The mean areg velocity is calculated as follows 1 VA N Y wi Vpath i 1 2 These relations are used in an adaptive mean value calculation routine for each individual path Statistical variation caused by turbulence is sufficiently suppressed with the help of this mean value calculation This algorithm further allows the measuring system to adapt to qifferent flow profiles caused by changing operational conditions After starting the system the average path relation values are calculated on the basis of at least 10 000 single measurements parameter Register 5009 PathCompvalid starting from standard values This
130. lt 20mA WC sortie digital 2 ME Ui 30V li 100mA NAMUR _ Pi 750mw digital output 3 passive Usat lt 2V 2mA lt IL lt 20mA Te sortie digital 3 D NAMUR B u SE 100mA Uo 5 88V lo 313mA Po 460mW Co 43uF RS 485 L Ui 10V li 275mA Pi 1420mW Lo 0 2mH For further details see user manual and EC Typ Examination Certificate T V 01 ATEX 1766 X Fig 9 4 Terminal assignment in accordance with ATEX IIC SICK MAIHAK GmbH Germany All rights reserved FLOWSIC600 Ultrasonic Gas Flow Meter 129 FLOWSIC600 Appendix Ultrasonic Gas Flow Meter Connection in accordance with CSA Group B C D Entity Parameters Vmax 16V Imax 200mA Ci 4nF Li 0 075mH power supply alimentation VB 12 24V DC ee Ee ren digital out 0 HF2 j ISC 100M max 100m 32 ee le UI ent Ci4nF f 6 kHz Nate Titan Li 0 075mH RS 485 Voc 5 88V Isc 313mA Ca 43uF La 0 2mH Vmax 10V Imax 275mA Ci 4nF Li 0 075mH PROFIBUS PA Vraciovirecteora OnE oors passive _ Vmax 30V P N digital out 1 HF1 Imax 100mA N 52 sortie digital 1 Ci AnF 52 imax 6 kHz NAMUR U Agzset digital output 2 passive Vmax 30V WC sortie digital 2 O Imax J00mA u NAMUR _ Li 0 075mH digital output 3 passive Vmax 30V Ci 4nF A is sortie digital 3 L NAMUR H Imax 100mA Li 0 075mH Voc 5 88V Isc 313mA Ca 43uF La 0 2mH RS 485 O Vmax 10V Imax 275mA GA L
131. m controller includes one full transit time measurement along and one against the direction of flow in each path The result of each measurement is written to a variable mean value memory to be used in further calculations The size of this memory block and thus the device response delay can be modified through the parameter in register 3502 AvgBlockSize If no result can be calculated due to deficient signal quality this measurement is registered as an invalid attempt in the mean value memory The mean value is formed in a variable averaging process including all valid measured values in the memory If the number of invalid measurements in a path exceeds a predefined limit register 3514 Limit Error the measuring system will turn into the Maintenance required status Maintenance required This status becomes active if one measuring path has failed and the adaptive path failure compensation has been activated For multi path system the FLOWSIC600 is able to compensate this failure Measurement is continued with reduced accuracy If a path fails while the path failure compensation is deactivated the measuring system will turn into the Malfunction status Configuration The Configuration status is used to modify parameters and to test the system and output signals The digital output Measurement valid is deactivated in this mode because invalid measured values may be produced The system continues operation us
132. measurement left along with the gas flow right against the gas flow SICK MAIHAK GmbH Germany All rights reserved 8 010 458 04 2007 Operating Instructions Appendix Menu levels Diagnosis System values FLOWSIC600 Parameters Actual vol flow rate gt Qv 1289 3 m n VOG 8 9 m s VOS 343 2 m s Freq FO 1245 Hz Current AO 14 54 mA Status DO DO2 c DO3 o 9 223 Display of measured values FLOWSIC600 Ultrasonic Gas Flow Meter Notes Display of further system information Activate the ENTER function to call up the following information Display of the actual volumetric flow rate together with the direction of flow positive direction marked by gt Qv and negative direction marked by lt Qv and Display of the actual measured values of flow velocity first line and velocity of sound second line Display of the actual frequency at the frequency output Display of the actual current at the analogue output Display of the current status of the digital switching output c closed o open FLOWSIC6O0 system diagnosis Display of all registers stored in the device Press STEP or DATA to navigate in the list of registers See software manual The indicated measured values can be assigned individually to either line of the display Take advantage of the MEPAFLOW600 program to make this assignment In addition both display lines may be given an alternative assignment Secon
133. n If the quality of received signals is deficient in more than one measuring path the device must mark the measured value invalid However the device will cyclically try to re establish valid measurements As soon as the signal quality and number of valid measurements permit this the device will automatically change back to the Measurement or Maintenance required mode 2 5 5 Pulse output and status information TYPE APPROVAL Output signal Output value in operating status Measurement Maintenance required Configuration Malfunction Measur Inverted with error D01 ed value signal l gt pulse signal DOO Phase Positive D01 shift 90 flow rate a el Ae es Ka Negative DO1 flow rate k MT VER Week e ti Ee Separate Positive DO1 outputs flow rate 2 for each direction DOO ek Negative D01 flow rate h a BE am E Ft f RER Ee ran a Wa e een DOO Used as status output 8 010 458 04 2007 Default setting on delivery Optional setting on customer request SICK MAIHAK GmbH Germany All rights reserved 27 FLOWSIC600 Ultrasonic Gas Flow Meter Product Description Operating Instructions Output signal Output value in operating status Measurement Maintenance required Configuration Malfunction Maintenance required Status Status undefined undefined Status s
134. ng gear to the signal processing unit or its mounting bracket and avoid contact between these parts and the lifting gear The FLOWSIC600 must not turn over or start to swing while being transported Flange sealing surfaces SPU housing and transducer cover caps may be damaged when the lifting gear is not attached properly Take suitable measures to prevent damage to the measuring device when carrying out any other work welding painting near the FLOWSIC600 Check the correct seat of the flange seals after having inserted the first fastening bolts on both sides Align the FLOWSIC600 such that the offsets between inlet pipe meter body and outlet pipe becomes as small as possible Insert the remaining fastening bolts and tighten the nuts cross wise The tightening torque applied must not be lower than specified in the project planning Mount the pressure line between pressure tap and pressure transmitter Fill the pipeline and check the FLOWSIC600 installed for leaks It is recommended to perform a leak test in accordance with the relevant regulations and standards after completion of the mechanical installation SICK MAIHAK GmbH Germany All rights reserved 8 010 458 04 2007 Operating Instructions Tool required for loosening and 3 3 3 tightening the hexagon socket head screw 3 mm Allen key 8 010 458 04 2007 Note Installation FLOWSIC600 Ultrasonic Gas Flow Meter SPU alignment The signal pro
135. ns FLOWSIC 600 configuration protocol parameters 03 05 2006 15 06 35 Device identifikation ConstantscRC Reg 5004 Interfaces FreqSourceReg PulseUpdateRate x omr og 3026 Ag 7043 x 9702 Reg 7029 Reg 3025 es ModBus 1 ControlReg DeviceBusaddress Reg 5023 Reg 5020 Service 2 ControlReg DeviceBusaddress Rog 5026 Reg 5020 Extended 3 BaudRate Extended 3 ControlReg DeviceBusaddress Reg 5029 Reg 5020 LCDSource Pre 9030 E Meter body E pan2 ans Pan Ultrasonic sensors ensorLength A m ensorLength B m imeOffset AB s imeOffset BA s eroPhase AB rad eroPhase BA rad erialNumberSensor A erialNumberSensor B Signal Processing Unit SPU imeOffsetHW AB s imeOffsetHW BA s erialNumberAnalog ampleRate F3E EJE EI ei u x N Process parameters fixed Base conditions emperature fixed K Reg 7021 Reg 7022 Warning levels WarningDuration s Reg 5015 AOError mA Reg 7032 Pressure fixed bar a Compressebility fixed TemperatureBase K PressureBase bar a Reg 7023 Reg 7025 WarningSNR dB WarningAGC dB WarningAGCDeviation dB WarningSOSDeviation m s Reg 7211 Reg 3515 Reg 3507 Rez MepaFlow 3 0 xx Page 1 3 90 Fig 5 16 Registers listed in the configuration protocol page 1 SICK MAIHAK GmbH Germany All rights reserved 8 010 4
136. ntly the measurement is invalid In this case you must diagnose the error See Chapter 7 FLOWSIC 600 with LCD Front Panel The FLOWSIC 600 is functioning correctly if the values are displayed consecutively for 5 s each If measured values are flashing the FLOWSIC600 works in the Maintenance required mode If an error is present the LCD flashes As soon as the cause of the error has been rectified the FLOWSIC600 automatically returns to the measured value display As soon as the system identifies an error the letter E error or W warning flashes on the right hand side of the line at the top of the LCD This continues to be displayed after the error has been rectified thereby enabling fleeting errors to be indicated Detailed information on errors is available in the logbook See the software manual or Section 9 2 The flashing letter disappears once you have acknowledged this message in the logbook You can determine the cause of the error by diagnosing it see Chapter 7 You are advised to check the plausibility of the measured and diagnosis values even if the device is functioning properly see Chapter 6 Function test The major system parameters are configured at the factory The default settings should allow error free operation of the ultrasonic gas flow meter There are two possibilities for testing the functions Test without PC and MEPAFLOW600 software The information listed below is shown directly on the L
137. ock IIA D 135 kHz power SPU I O analogue 2040382 Electronic block IIC BCD 135 kHz analogue board and shunt board 2040383 Electronic block IIA D H 135 kHz analogue board and shunt board 2040384 Electronic block IIC BCD H 135 kHz analogue board and shunt board 2040385 Electronic block IIA D 200 kHz analogue board and shunt board 2040386 Electronic block IIC BCD 200 kHz analogue board and shunt board 2040387 Electronic block IIA D H 200 kHz analogue board and shunt board 2040388 Electronic block IIC BCD H 200 kHz analogue board and shunt board 2040389 Buffer battery 7048533 Ultrasonic transducers Part number Transducer pair type S1 200 kHz 100 bar 85 C titanium P18 7042400 Transducer pair type S2 200 kHz 100 bar 120 C titanium P18 7041787 Transducer pair type 22 200 kHz 250 bar 120 C titanium P18 2039997 Transducer pair type S6 200 kHz 100 bar 120 C titanium P10 7042607 Transducer pair type 26 200 kHz 250 bar 120 C titanium P10 2039441 Transducer pair type S7 135 kHz 16 bar 180 C titanium P18 2040392 Transducer pair type S8 135 kHz 100 bar 180 C titanium P18 2034125 Transducer pair type 28 135 kHz 250 bar 180 C titanium P18 2032538 Transducer pair type M6 200 kHz 10 bar 120 C titanium layer P10 2032592 Transducer pair type L8 135 kHz 100 bar 280 C titanium P18 2040394 O ring 15 2 0 Viton natural gas resistant 25 200 C 7045173 O ring 15
138. on for the flange connections For installation lengths and flange dimensions see Section 9 1 Warning Always strictly observe the safety instructions for the installation of pressure equipment including the connection of several pressure components set forth in the Pressure Equipment Directive 97 23 EC Installation staff must be familiar with the directives and standards applicable for pipeline construction SICK MAIHAK GmbH Germany All rights reserved 49 FLOWSIC600 Ultrasonic Gas Flow Meter 50 3 3 2 ATTENTION Note Installation Operating Instructions Mounting the FLOWSIC600 to the pipeline An arrow on the meter body indicates the main direction of flow It is recommended to install the FLOWSIC600 as indicated by this arrow if the device is to be used for unidirectional flow applications If the device is to be used in the bidirectional mode the arrow indicates the positive direction of flow Installation work to be carried out Position the FLOWSIC600 at the desired place of the pipeline using the lifting gear Only use the lifting eyes provided to lift and transport the device If you use lifting straps wrap them around the meter body Important The lifting eyes are designed for transporting the measuring device only Do not lift the FLOWSIC600 using these eyes when additional loads Such as blind covers filling for pressure tests are attached see also Section 3 1 2 Never attach lifti
139. on open 07 11 2006 10 38 45 closed 07 11 2006 10 39 17 Password 3 Session open 09 02 2007 15 06 28 closed 09 02 2007 15 09 24 Password 1 Session open 09 02 2007 15 09 29 closed 09 02 2007 15 29 42 Password 2 Session open 09 02 2007 15 29 46 closed 09 02 2007 15 34 43 Password 1 x HE amp IT Last session on top IV Only session with entries Compress session Delete entry Save entry Open Print entry Fig 5 15 File Session history Current device configuration menu 5 3 5 Sealing Carry out the following securing measures in accordance with the sealing plan after completion of the calibration See Section 9 7 Turn on the configuration protection switch see Fig 5 6 Note If you use a FLOWSIC600 with LC display the character will appear on the LCD if the configuration protection switch is turned on see Section 9 2 2 gt Close the front cap of the SPU and seal it using the securing bracket and wire lead Seal all transducer cover caps with at least two stickers Attach the main lead to the main type plate on the SPU Attach and secure an additional plate that provides information on permitted type of gas and permitted operating pressure range 8 010 458 04 2007 SICK MAIHAK GmbH Germany All rights reserved 89 FLOWSIC600 Calibration Ultrasonic Gas Flow Meter Operating Instructio
140. ote The Warning status signal does not affect the functionality of the device Threshold Warning Notes message Velocity of lt 5m s Warning VOS This message will be produced if the current measured path sound velocity sound Deviation deviates from the mean value of the mean sound velocities calculated for all the paths by more than the specified threshold value The current flow velocity is used as a weighting factor so that temperature stratification is disregarded at very low flow velocities Used to indicate whether or not the path is measuring the correct transit time Note When setting the parameter take into account plausible conditions for normal operation in particular temperature stratification Signal lt 6 dB Warning AGC The absolute difference between both path gain factors is evaluated and must amplification Deviation remain below the threshold value Caution High flow velocities may also increase the difference in gain lt 93 dB Warning AGC The absolute value of the reception gain is monitored Limit Caution The current reception sensitivity largely depends on the current process pressure inversely proportional in initial approximation that is if the pressure doubles the required reception sensitivity will be halved If one of the alarms is triggered by a path this can indicate a malfunction in the ultrasonic transducers electronic modules transducer cables or parameter settings signal models control thresholds Signal
141. owsic 600 0_DOKUMENTATION Redesign 2006 Softwarehandbuch Gas stallion O07 san File Connection Operating Mode Monitors Options Help Ost See AR D ser UW DS Pe Laser Owca depress Decebgeklig iet l l l l l l l l i l i lili SICK MAIHAK SS end Resetting Activation deactivation Fig 2 6 MEPAFLOWG600 program Device parameters tab Click the Reset button to reset the calculated path relations in the two velocity ranges 8 010 458 04 2007 SICK MAIHAK GmbH Germany All rights reserved 33 FLOWSIC600 Product Description Operating Instructions SS eee Ultrasonic Gas Flow Meter 2 9 Configuration 2 9 1 Hardware variants and signal outputs The output channels of the FLOWSIC6OO can be configured in several ways Different output configurations require different hardware variants of the electronic unit A detailed description is contained in the service manual in section 3 Hardware variant output configuration 1 4 1 2 1 3 2 4 2 5 3 6 4 7 31 32 Pulse Pulse Status Analog Analog p T Sensor HART Analog 33 34 RS485 RS485 RS485 RS485 RS485 RS485 RS485 51 52 Pulse Pulse Pulse Pulse Status Pulse Pulse 41 42 Status Status Status Status Status Status Status 81 82 Status RS485 Status Status Status Status RS485 Can be fitted with HART communication This configuration is used to activate the internal flow correction f
142. plifier closed to DIN 19234 O V lt Uckr lt 2 V 2 mA lt lcg lt 20 mA L Low open 16 V lt Uce HS 30 V 0 mA lt ler HS 0 2 mA H High 3 Serial port Modbus 33 34 9600 Baud 8 data bits no parity 1 stop bit Baud rate to be set RS485 through software 4 Digital output DO 1 Passive 51 52 fmax 6 kHz pulse duration 0 05 s 1s With NAMUR contact HF 1 Range for connection to Variable number of pulses per volume unit switching amplifier closed to DIN 19234 OV lt UceL lt 2 V 2 mA lt Icg lt 20 mA L Low open 16 V lt Uce p lt 30 V O mA lt lcg r lt 0 2 MA H High 5 Digital output DO 2 Passive 41 42 closed OV lt Uckr lt 2 V 2 mA lt Icg lt 20 mA L Low open 16 V lt Uce p lt 30 V O mA lt Iog r lt 0 2 MA H High Maintenance required 6 Digital output DO 3 Passive 81 82 closed OV lt UceL lt 2 V 2 mA lt Il e lt 20 mA L Low open 9600 Baud 8 data bits no parity 1 stop bit Baud rate to be set through software 56 SICK MAIHAK GmbH Germany All rights reserved 8 010 458 04 2007 Operating Instructions 3 4 6 Installation FLOWSIC600 Ultrasonic Gas Flow Meter Operation in hazardous areas in accordance with Directive 94 9 EC ATEX The power supply and field connections are designed with the increased type of protection e The transducer connections are of an intrinsically safe
143. program code range 16 bit check sum for the entire parameter range but excluding the user definable Warning signal thresholds 16 bit check sum for the parameter range whose content is predefined by the manufacturer This range is a subset of the entire parameter range Conformity with the manufacturer settings can be checked by comparing this check sum with the original check sum Unauthorised modification of these parameters may lead to failure of the device Information on the present content of the device logbook The following pieces of information can be called up by activating the ENTER function 8 010 458 04 2007 SICK MAIHAK GmbH Germany All rights reserved 123 FLOWSIC600 Appendix Ultrasonic Gas Flow Meter FLOWSIC600 Diagnosis 124 Menu levels Device logbook Unacknowledged 2 5 Error 0 0 0 0 Diagnosis path 1 2 3 4 Values Power supply 3 18 04 03 12 13 18 April 03 12 20 23 VOG 8 9 m s VOS 343 2 m s SNR 25 dB 25 dB AGC 50 dB 50 dB Operating Instructions Notes Display of the total number of saved logbook entries and of the number of those entries which have not yet been acknowledged Example Five entries were recorded two have not been acknowledged To select the individual entries activate the ENTER function The most recent entry is shown first Press DATA to jump forward and STEP to jump backward in the list of entries Entries which h
144. r Signal processing unit Inlet pipe Outlet pipe E FLOWSIC600 Inlet adapter option Flow straightener Outlet adapter Fig 5 1 Installation of the FLOWSIC600 in the test pipeline Detailed information about the installation in the pipeline and about necessary inlet and outlet pipes can be found in the Operating Instruction Section 3 2 and Section 3 3 5 2 2 Electrical connection 12 0 28 8 V DC Caution Minus is connected with the housing amp of the signal processing unit Pulse output DO O 31 C RS485 interface CR 34 Pulse output DO 1 51 K B After having removed the back cover the FLOWSIC600 must be connected electrically as shown in the Figure below power supply alimentation U 12 24V DC Back cover of the housing with terminal plan Fig 5 2 Electrical connections in the signal processing unit Setting the pulse outputs to Open collector or NAMUR is described in Section 3 4 7 The default configuration is indicated in the terminal assignment plan inside the back cover of the housing 78 SICK MAIHAK GmbH Germany All rights reserved 8 010 458 04 2007 Operating Instructions 5 2 3 DANGER 5 2 4 Adapter cable and power supply unit can be ordered as an interface set from SICK MAIHAK part no 7041773 8 010 458 04 2007 Calibration FLOWSIC600 Ultrasonic Gas Flow Meter Checking the device design
145. r custody transfer applications each changes of parameters and configuration protection switch have to be agreed with the national authorities In all other cases the output parameters of the FLOWSIC600 can be adapted at site by trained staff Commissioning the FLOWSIC 600 involves the following steps no matter whether the device is installed at a test stand or at the final measuring location e Checking the functions Adjusting the output signals Data recording Checking identifications operation and design data Before starting the commissioning cross check the data of the present flow meter with the data of the test protocols which are contained in the Manufacturers Data Report MDR You can do this by using the LCD if available see Section 9 2 or in a easier way by using the MEPAFLOW600 software To do so open the Device diagnosis tab and compare the data in the Device identification field see Fig 4 1 with the data in the check reports of the MDR see Section 9 5 3 and 9 5 4 or when the meter is calibrated with the configuration protocol of the calibration report SICK MAIHAK GmbH Germany All rights reserved 65 FLOWSIC600 Commissioning Operating Instructions Ultrasonic Gas Flow Meter Wa MepaFlow 3 2 04 C Programme MEPA FLOWSIC FLOWSIC600 DEFAULT SF File Connection Operating Mode Monitors Options Help DEHAENE lt A AR Q m gt H ld H h bi M Measuring values Device parameters Ad
146. ration Service OFF Service ON Configuration Pulse output Pulse source Actual vol flow rate Pulse factor 1 m3 Pulse factor Pulse factor 3 m3 Pulse factor Changed value IER gt V 34569870 m3 lt 0 m3 The entries are distinguished into three classes and identified by the initial character in the first line um I information WI warning E error malfunction 2 Type of occurrence e S point of time identifying the beginning of a status e S point of time identifying the end of a status SICK MAIHAK GmbH Germany All rights reserved 8 010 458 04 2007 Operating Instructions Appendix Overview of event entries FLOWSIC600 Ultrasonic Gas Flow Meter Logbook overflow Class Explanation Value Power on l System was cold started or rebooted after a watchdog reset Time stamp of the last stored Power supply counter reading is considered 18 04 03 12 13 to be the time of the Power off event Change of operating System was changed to the configuration mode after password Activated password level mode input or back from the configuration mode to the measurement Operation S mode Password 2 Parameters that affect the measured values may have been modified Clock setting Date and or time register of the real time clock was were Time stamp of the register Real time clock changed modificat
147. report transducer pair sheet 4 example 140 SICK MAIHAK GmbH Germany All rights reserved 8 010 458 04 2007 Operating Instructions Appendix FLOWSIC600 Ultrasonic Gas Flow Meter 9 5 5 Zero flow protocol example Zero Flow Protocol SICK MAI HAK Device SN 06078749 Analogboard SN 2005420165 Sick Engineering GmbH Bergener Ring 27 01458 Electronicblock SN 06020023 Ottendorf Okrilla Germany Device FLOWSIC 600 Date 31 03 2006 Type FL600 4P3D08CL06000203 1RFON S1 3DC1N1Y Operator TMI Path number 4 File name zerologging_427 Laboratory SICK Dresden Log time min 15 Test conditions _ Test Gas rel Humidity Temp C Pressure bara Theoretical VOS m s Ambient air 34 23 1 0 985 345 70 Velocity of sound check max permissible VoS Deviation x perm eviation_ max permissible VoS Path Spread m s Velocity of Sound a en sie C 0 15 ou Q vos Diff totneor pat Rest is 345 657 0 08 345 594 2 0 A Pans Pans 2 uns Path 2 Paths 345 677 ao 345 571 0 1 Dee i 0 15 ec Velocity of gas check max Error VOG m s _ oo O Velocity of Gas Measuring values 0 015 SYN IT Voom I Rem Bin l z 0 005 i Path 1 i 0 000 e Fa pains Path 4 0 005 0 010 0 015 I Diagnosis Values C sure AGC dB up _ AGC dB down Date 27 3 OG Approved by
148. reserved 69 FLOWSIC600 Commissioning Operating Instructions SS AT Ultrasonic Gas Flow Meter The relative variation of the sound velocities in the individual measuring paths should not exceed 0 1 Note In case of a very low flow velocity there may be substantial variation among the measurement paths due to thermal stratification The absolute variation between the measured sound velocity and theoretical sound velocity calculated on the basis of the gas composition should not exceed 0 3 4 2 4 Checking the adjust factor meter factor and analog output An overview of these parameters is provided on the Device parameters tab in the MEPAFLOW600 program password level Authorised operator password sickoptic see Fig 4 8 Switch hy MepaFlow 3 1 04 C Programme SICK MEPA FLOW600_M16 DEFAULT SF Configuration mode Fle Connection Operating Mode Monitors Options Hep oe BG KR m gt I id M HRS Switch Measuring values Device parameters Adjustfiient Device diagnosis Device logbook Log Trend Measurement mode SICK MAIHAK Poot PO Tmm weas PO Adjustment factors losos 00 m Worn GC Devan s p ama a ot wes EECHER adatoms Promo or weas SCO EC x wm j je j RTR E Meter factor ee Lat Ouptsouce fe 7001 Flowrate oE gt 1 1m Physical vale at dma ao EU et CL aE w eee fromal operD0 D1 ometo y o i OOO Pressure fix Oe Alt Less E
149. sit time measurements or at changes in the gas composition A theoretical velocity of sound value can be calculated based on the gas composition pressure and temperature determined during test measurements Implausible measurements can then be indicated by comparing theoretical and measured velocity of sound and identifying any marked discrepancies The velocities of sound in the individual paths should also be approximately identical Number of rejected measurements The number of rejected measurement measuring error for the measuring path s should be as close as possible to O although this largely depends on the flow velocity With high flow velocities the figure can be as high as 50 without affecting the measuring accuracy Marked discrepancies in the values under comparable conditions pressure temperature flow velocity gas composition indicate that changes have occurred in the device or plant e g disturbance caused by a valve that is not fully open Reception sensitivity AGC level The reception sensitivity AGC level set by the device largely depends on the process pressure Under normal conditions this value is highly stable for a long period of time The difference between the ultrasonic transducers of a measuring path is small although it can increase with greater velocities Significant fluctuations in the reception sensitivity indicate a low quality received signal A significant increase under comparable process con
150. sources of acoustic interference such pressure as control valves or very high flow velocities Reception This depends on the Significant deviations The reception sensitivity is sensitivity AGC nominal width of the greater than 50 inversely proportional to the level meter body and the from the historical process pressure if the current process data with comparable pressure doubles the pressure process pressures sensitivity will halve Number of rejected lt 5 with zero flow Permanently greater measurements lt 35 with flow than 50 Deviations from the typical values specified in the table can indicate a malfunction In addition to diagnosing the error as described in chapter 6 you can also create a diagnosis and status log and send it to SICK MAIHAK for analysis See software manual SICK MAIHAK GmbH Germany All rights reserved 8 010 458 04 2007 Operating Instructions Tee Maintenance FLOWSIC600 Ultrasonic Gas Flow Meter 6 3 Replacing the Transducers Pairs of ultrasonic transducers may be replaced if necessary New calibration is not required The transducers shall be replaced as described in Section 8 3 of the service manual and only if the installation is not under pressure However if you take advantage of the optional extraction tool the transducers may also be replaced under process conditions see extraction tool manual After having replaced the transducers
151. sure fix parameter The meter shall then be adjusted with the weighted mean error established at this test pressure Enter the absolute value of the average working pressure when setting the Pressure fix parameter Calibration overview Generally a calibration involves the following steps 1 Flow rate measurement at the U I defined test points Eat i l E i 1 E I O i 2 E EEE Quin Q Flow rate Qmax 2 Flow rate weighted calculation of the error WME over the entire measuring range in blue E arrow o o Q Flow rate Qua 3 Calculation of the adjust factor and entering it as a parameter in the FLOWSIC600 E 8 o Quin Q Flow rate Qhax Test point after the correction The black line is the calculated characteristic line i e the product of the previously measured points and the adjust factor Then the flow rate is determined again at a test point in order to find out whether or not the value measured by the unit under test is identical to the calculated value SICK MAIHAK GmbH Germany All rights reserved 77 Operating Instructions FLOWSIC600 Calibration Ultrasonic Gas Flow Meter 5 2 Preparation 5 2 1 Installation on the flow test stand Pressure transmitter Temperature transmitte
152. t that the meter body and adjacent pipelines are of identical internal diameter Fastening bolts nuts and flange seals used must be suited to the operational conditions and comply with legal regulations and relevant standards Note Any deviation from the planned design of the FLOWSIC600 and installation arrangement shall be agreed with the supplier and documented prior to installing the measuring device 3 2 1 Measuring location General requirements e The FLOWSIC600 can be installed in customary straight inlet and outlet pipes The adjacent pipes must have the same nominal size as the meter body The internal diameter can be learned from the marked flange standard Appendix Table 9 3 and the type key information The max variation of the internal diameter of the inlet pipe from that of the meter body is 1 Any welding beads and rims on the flanges of the inlet pipe shall be levelled or removed The meter body may be installed in horizontal or vertical position In case of horizontal installation the meter body shall be aligned such that the planes formed by the measuring paths are in horizontal position This aims to prevent dirt in the pipeline from entering the transducer ports Vertical installation is only possible if the measuring system is used for dry non condensing gases The gas flow must be free from any foreign material dust and liquids Otherwise filters and traps shall be used e Do not mount installations and fitt
153. t time against the direction of flow tga L C Vpath COS Q tsa Path velocity The path velocity Vpatn d is calculated from the difference between the two transit times Li 1 1 Vi e amp S 2 COS a i tap i tBAi Li Distance between the two transducer diaphragms This distance is calculated by subtracting the length of the transducers used register 7109 to 7116 SensorLength AIB from the distance between the transducer seats in the meter body register 7105 to 7108 Length i Li Liueter body i Liransducer Ai Lrransducer B Mean path velocity The most recent 100 measuring results path velocity and measurement status are stored in a variable mean value memory If no valid path velocity was determined due to a negative plausibility check such condition is also stored in the mean value memory The mean value memory is organised as a FIFO memory This means that the most recent entry always overwrites the oldest one The mean path velocity Vayg i forms the mean value of all valid measuring values stored in the memory gt VPath i all valid values Vu CS Nvalid The ratio of valid and invalid measurements in the mean value memory is used as a quality parameter register 3008 to 3011 Error i If the proportion of invalid measuring results exceeds a certain threshold register 3514 Limit Error manufacturer constant 95 the path is not used in the calculation
154. tab representing adjustment with linear error interpolation 88 SICK MAIHAK GmbH Germany All rights reserved 8 010 458 04 2007 Operating Instructions Calibration FLOWSIC600 wmd Ultrasonic Gas Flow Meter 5 3 4 Documentation After having completed the calibration the current device configuration shall be documented To do so connect a printer to the PC select Current device configuration from the File session history menu and click on Print entry see Fig 5 15 Attach this print to the test records If no printer is available at this point the configuration log can also be printed later all relevant parameters are stored in the session file Therefore do not forget to save the session file see Fig 5 16 to Fig 5 21 Session history J NthoNScreen_shots 3 in steel 05258747 ver II Tuesday FSF by USGUSMO0467 Session open 24 10 2006 13 55 11 closed 24 10 2006 13 57 48 Password 2 Session open 06 11 2006 15 08 35 closed 06 11 2006 15 17 53 Password 3 Session open 06 11 2006 15 17 53 closed 06 11 2006 15 34 57 Password 3 Session open 07 11 2006 09 31 53 closed 07 11 2006 09 33 33 Password 3 Session open 07 11 2006 09 36 36 closed 07 11 2006 09 38 28 Password 3 Session open 07 11 2006 09 41 30 closed 07 11 2006 09 45 39 Password 3 Session open 07 11 2006 09 45 39 closed 07 11 2006 10 06 58 Password 3 Session open 07 11 2006 10 32 51 closed 07 11 2006 10 36 26 Password 3 Sessi
155. ted This is to prevent connected devices from interfering with the measurement Test the entire cable loop between SPU and terminal device by measuring the loop resistance If you want to test the insulation resistance as well the cables must be disconnected from the electronic module before using the insulation resistance tester Important The test voltage applied would seriously damage the electronic module gt Reconnect all cables after the loop resistance test Important In non intrinsically safe installations only open the EExe terminal boxes and connect disconnect cables 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 cause any warranty claims to expire The manufacturer excludes any liability for consequential damage Terminal box on the SPU Opening the rear housing cover gt Loosen the securing clip using a 3 mm Allen key Turn the rear housing cover counter clockwise and take it off A schematic wiring diagram is provided on the inside of the rear housing cover see also Appendix Section 9 3 Open the cover Cover Securing clip Fig 3 7 SPU housing 54 SICK MAIHAK GmbH Germany All rights reserved 8 010 458 04 2007 Oper
156. tenance FLOWSIC600 Ultrasonic Gas Flow Meter General The FLOWSIC600 does not contain mechanically moving parts 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 device is implemented in accordance with the relevant specifications This means that the FLOWSIC600 is a low maintenance system Maintenance is limited mainly to routine checks to determine the plausibility of the measured values and diagnosis results produced by the system for details see the FLOWSIC600 service manual It is recommended to create a diagnosis and status log on a regular basis see software manual and compare the information with the initial situation when the system was commissioned The operating conditions gas composition pressure temperature flow velocity of the individual logs should be comparable or documented separately and taken into account when analysing the data Routine Checks You can check the information displayed on the front panel of the of the FLOWSIC600 to ensure that the system is functioning properly The routine checks relate to the following values See also the table below and chapter 6 Velocity of sound The measured velocity of sound is usually highly stable Sudden changes in the measured value may hint at signal detection problems which can affect tran
157. ths 1 20r4 Min gas velocity 0 3 m s 1 ft s Turn down Vmin Vmax Max 1 130 Measuring medium Gases Natural gas process gases air Ethylene etc Pressure range O barg 250 barg 0 psig 3600 psig up to 450 barg 6500 psig on request Temperature range 30 C 180 22 F 365 F 194 C 280 C 317 F 536 F on request Measuring uncertainty Repeatibility lt 0 1 of reading Typical uncertainty 1 path 2 0 2 paths 10 4 paths 0 5 0 2 after high pressure calibration Power supply Operating voltage 12 28 8 DC minimum 15 V DC for active current output Typ power consumption lt 1W Outputs Measuring variables Flow rate a c volume a c gas velocity speed of sound Analog output 4 20 mA active passive electrically isolated max load 250 Q Pulse and status outputs Passive electrically isolated open collector or acc NAMUR fmax 6 KHz Scalable pulse width 0 05 1 s in accordance with NAMUR EN50227 Interfaces MODBUS ASCII and RTU 2 x RS485 for configuration measured value output and diagnosis HART Configuration measured value output and diagnosis Ex approval Europe ATEX 94 9 EG II 1 2G EEx de ib ia IIA T4 or Il 1 2G EEx de ib ia IIC T4 Ultrasonic transducers intrinsically safe ia USA Canada CSA Class I Division 1 Groups D T4 Class I
158. ualified consulting services provided by SICK MAIHAK experts for your specific application This operating manual is a part of the FLOWSIC600 device documentation That documentation includes the following documents e MEPAFLOWGOO software manual Option for trained staff only e FLOWSIC600 service manual e FLOWSIC6O0 extraction tool operating instructions Symbols used in this document Important information in particular safety instructions are highlighted in this document to facilitate quick access Such information is provided where necessary within each section of this manual Note Provides information about special features of the equipment and further recommendations Indicates a section with data which possibly deviate from the respective national type approval Therefore read the appropriate approval papers when using the FLOWSIC600 for custody transfer application TYPE APPROVAL Important Indicates potential risks for the equipment and possible functional impairment ATTENTION Warning Indicates potential hazards for the operating staff in particular caused by electrical installations and improper use of the equipment Always observe such warnings as they aim DANGER to protect you from serious injuries Note Always read this manual carefully before carrying out any work on the equipment Always observe warnings and comply with all safety instructions Any obligations of SICK MAIHAK are set forth in the relevant purc
159. ucers Signal processing unit SPU The MEPAFLOW6O0 program may be used to facilitate operation configuration and diagnosis SPU Hoisting eye Pressure tap Oo Q 4 vo Cover cap Position of the ultrasonic transducers cover cap taken off Marking for direction of flow defined positively Meter body Fig 2 3 FLOWSIC600 Meter body The meter body consists of a middle section for mounting the ultrasonic transducers and flanges used for installing the equipment in the pipeline The meter body is up to size of 24 made of a single piece casting which is machined on precision equipment to ensure high reproducibility of the geometrical parameters Flanges at meters larger than 24 are welded onto the middle section The internal diameter shape of the sealing surface and standard dimensions of the connection flanges are in accordance with the specifications in the type key definition The meter body material is chosen to suit customer requirements Standard meter bodies are available in carbon steel and stainless steel The meter bodies can be delivered in several nominal sizes see Section 2 2 4 Ultrasonic transducers The FLOWSIC600 ultrasonic transducers are optimised to suit the system requirements The high quality of the transducer parameters provides the basis for accurate and highly stable propagation time measurements with nanosecond precision The ultrasonic transducers
160. ue of DO 1 2 3 NAMUR 1 constantly open in case I au of a malfunction 1 1 2 3 Open Collector DO1 Measured value frequency Measured value 51 52 ea signal frequency signal 12 3 Direction of flow Oia Malfunction NAMUR e Maintenance required Warning 2 1 2 3 Open Collector DO 2 Maintenance required Direction of flow 41 42 muna Malfunction NAMUR e Maintenance required Warning 8 9 3 1 2 3 Open DO 3 Direction of flow 81 82 UI Collector Warning Switch T Z 3 NAMUR DEE RS485 UART RS485 6 7 PA Prepared for Profibus RPA 33 34 DP RS485 or Profibus DP 60 SICK MAIHAK GmbH Germany All rights reserved 8 010 458 04 2007 Operating Instructions Not yet available 8 010 458 04 2007 Installation FLOWSIC600 Ultrasonic Gas Flow Meter Signals are assigned by the MEPAFLOW600 program see software manual Wiring of digital outputs The digital output terminals 31 32 51 52 41 42 81 82 can be wired as Open Collector or as NAMUR contact for connection to a NAMUR amplifier The outputs are wired to NAMUR on delivery unless Open Collector was specified in the purchase order Open Collector Us Imax 100 mA R Us 2V cp Us 2V 0 1 A 0 01 A NAMUR 1k 8 2 V DC 1k OV Fig 3 12 Wiring of digital outputs SICK MAIHAK GmbH Germany All rights reserved 61 FLOWSIC600 Installation Operating Instructions aa Ultrasonic Gas
161. uepedut xoadde snqpow sS8rFSWH z q uerp sTges wu ZT 9 eoTzeuy UNION IdN uZ T 20 nd S T X OZH spueT6h etqeo uotu yY lt QU 009 DISMOTA vavi 20 PL on op xaa Seck u op x33 92 1 n JII dnozg z auog reet aueborpAH QII dnozp I auog TsseTo q pue d a sdno1g zuotstata TsseTD q pue 3 g sdnoig Tuorstarq TsseTD Tenuew uot jeredo ees sTTeqjep ASyJanJ T04 iTteF 03 009 DISMOTI SU esneo ued BUTTAIeD I989X2X09UI NY i DNINUYM l i i i l i i i l I i i i I PSAISSAO 94 Sr uortyertn si TeuoT jen I i i I i i i i i i suae3s snqeas astnd untoA ser sa snqpow 0 o 0 OW b ze asqnd umtToA Teuxsgur Ir SI ra arssed wu oz r z8 EW 18 zt E b E es E 18 ve E E ES TE PI 6L009 H UTM souepxoooe UT na UT z0 00 18 Hutmerq Toxyuoy x ees O90 pue JAN UITM oSuepiaoooe ur eOrI uV Uu334ON UT uorqeoorT paezeH uOTSOTdxg uote iesu AysAes OTSUuTXI3UT 1068621 WSO 9oSuerIduoo JO eyeorzryi1e deer X 99LT XHLV TO AQI u zos usos qeorjra3 o ECKE Ae gd s szejewereg Karauq K3a aes 104 5 on aw pene m Se DII et xaa amp N sqtnoato Aqeaes OTSUTITQUT gt _ N Eer EE EE E Feck d K SqtTnorzto Aianpsg DTSUTAJUI UON BOARS o
162. unction of the FLOWSIC600 Fig 2 7 Terminals in the FLOWSIC600 signal processing unit cover opened 2 9 2 System configuration with external volume corrector Depending on individual requirments exists a wide range of variants to integrate the FLOWSIC600 into a gas facility Fig 2 8 shows a basic configuration 34 SICK MAIHAK GmbH Germany All rights reserved 8 010 458 04 2007 Operating Instructions 8 010 458 04 2007 2 9 3 Product Description FLOWSIC600 Ultrasonic Gas Flow Meter Real gas factor Z Electronic Volume gt Normalised Corrector EVC volumetric flow rate Calorific value H Flow computer FC m Energy content L Actual volumetric flow rate RS485 MODBUS Temperature Service PC higher level control system Ex i isolating transformer only required 12 24 V DC EECH S for intrinsically safe installation Safe area FLOWSIC600 Fig 2 8 FLOWSIC600 connection diagram System configuration with integrated electronic volume corrector 2 9 3 1 General Application description The functions utilized by the integrated electronic volume corrector EVC have been incor porated into the FLOWSIC 600 firmware as software function modules The EVC calculates a normalized volume Vn c at user specified reference conditions from the measured ac tual flow pressure and temperature The output o
163. uollle1su Jooid uoisoldx3 uoz UOISAIG siojowesed Ainu3 10 6ed Z0 00 18Z ou Buweip 895 ep 17 lt 87 lqe5O IO lt BD xew gt OS KEW gt I0A SUONPUOO Buiwollo ou sos yey Juewd nba p leloossv papuo ve Jeu JO si elueq ezes Dote WSO een uonel e1sul AUF 104 9 ees 2ISUUIUL aedu Aew siueuoduuoo Jo uonniiisqnS ONINHVAA S juowd nb3 peyeloossy se pauyep si 1x3 L ped 939 eut UA souRpsodze ul e1su epeueo ul E Zr did WSIISNY pue 02 VdAN ISNV OIN SU YUM S9uep10998 ul IIe su SN OU ul Z AGSZ peexe o1 Jou Be loA eow snopiezeu uou WNWIXEW L uoyejjelsul SUZ 0 UOZ L UOISIAIG KC A HUIL E Jure e ywu09 9S A6 88 90A si uipipeq AUS Bumwoot ep UNA 1lu lgAInb 10 XXXX 009HL SISINPSUEAL AIUOSEINN gordn opus A PL epog duet 9 II dnosy z auoz L ssejg pL apog duet u Boip H g II dnou L uoz sse O FL p09 duet q pue O g y sdno15 Z uolslAIG L SSBID yL apog duet q pue O g sdno19 L uolsiAIq 1 SSBID z L Fig 9 7 Control drawing CSA 781 00 02 page 1 131 SICK MAIHAK GmbH Germany All rights reserved 8 010 458 04 2007 Operating Instructions Appendix FLOWSIC600 Ultrasonic Gas Flow Meter
164. ures the FLOWSIC600 measuring system shall only be mounted and dismounted if the pipelines are vented or if the plant is not working The same applies to repair and service work which involves opening measuring channel or the explosion proof signal processing unit SPU 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 Any relevant information has been taken into account for the particular application as specified in the technical information questionnaire filled out by the customer before commencing order processing Dangers due to heavy loads The FLOWSIC600 measuring system must be safely attached to the carrying structure when being transported and installed Warning Only use lifting gear and auxiliaries e g lifting straps which is suitable for the weight to be lifted Max load information can be found on the type plate of the lifting gear The eye bolts attached to the equipment are suitable for the transport of the measuring device However additional loads e g blind covers filling for pressure tests must not be lifted and transported together with the measuring system Never attach lifting gear to the signal processing unit or its mounting bracket and avoid contact between these parts and the lifting gear Environmental information and instructions for disposal The FLOWSIC600 modules
165. usually takes about 10 min The standard value of this parameter is based on experience and is set by default so that no additional adjustment is necessary when commissioning the FLOWSIC600 When the average path relations have been established based on the required minimum number of single measurements the path relations are marked valid and the system is now able to compensate path failure The variable mean value calculation is turned on at the same time The default attenuation constant for this teaching algorithm Register 7206 PathCompAverWeight ensures that statistical variation is suppressed The mean values for low 1 8 m s and high flow velocities gt 8 m s are determined separately see table below This improves the result of the compensation because the path relations are more stable at higher flow velocities The path relations are not taught below 1 m s SICK MAIHAK GmbH Germany All rights reserved 31 FLOWSIC600 Product Description Operating Instructions Ultrasonic Gas Flow Meter Parameter Description Notes lt 1m s No path relation adaption In case of failure the stored path relations for low flow velocities 1 8 m s are used 1 8 m s 7208 PathCompClassLo_ Continuous calculation and adaption of the path relations The results are saved in the low flow Class registers 7289 7292 path 1 4 gt 8 m s 7207 PathCompClassHi Continuous calculation and adaption of the path r
166. vice manual Note Temperature induced stratification can result in differences between the individual paths especially with very low flow higher temperatures generate higher velocities of sound Even if the plant is being filled or if it is shut down different velocities of sound may occur in the individual paths as a result of stratification Implausible velocity Gas composition reception sensitivity Increased number of rejected measurements in individual paths damaged during maintenance sctivities of sound pressure or temperature measurement is incorrect Lower signal to Individual Replace the transducer s See service manual noise ratio and transducer s Additional sources of noise due to a valve that is not fully open fittings noise sources near the device Check the measurement plausibility and number of rejected measurements and if necessary eliminate noise sources Increased reception sensitivity Different gas composition or process pressure No activity required on the device Transducer s are dirty Clean the transducer s Increased number of rejected measurements in all paths Additional noise sources Eliminate noise sources Gas velocity outside the measuring range SICK MAIHAK GmbH Germany All rights reserved 105 FLOWSIC600 Troubleshooting Operating Instructions ese uuuuu
167. ways observe the general safety regulations and safety instructions given in Section 1 when carrying out any installation work Installation work shall only be carried out by trained staff and in accordance with the relevant regulations issued by the operating company e Take all necessary precautions to avoid local or plant specific dangers General connection of the FLOWSIC600 Real gas factor Z Electronic Volume Corrector EVC Calorific value H Flow Computer FC gt Normalised volumetric flow rate Energy content Pressure Actual volumetric flow rate Temperature RS485 MODBUS Service PC higher level control system Ex i isolating transformer only required 12 24 V DC for intrinsically safe installation Safe area Fig 3 6 FLOWSIC600 connection diagram SICK MAIHAK GmbH Germany All rights reserved 8 010 458 04 2007 Operating Instructions 3 4 2 ATTENTION 8 010 458 04 2007 Installation Cable specifications Warning FLOWSIC600 Ultrasonic Gas Flow Meter The cables must fulfil the requirements for use in hazardous areas e g set forth in EN 60079 14 or other relevant standards Power supply 12 28 8 V DC Notes Type of cable Two conductors Connect shielding if present to ground terminal Min max cross sectional area 0 5 mm 1 5 mm Maximum cable length

PI FLOWSIC 600 d_2

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