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Title Page OPERATING INSTRUCTIONS FLOWSIC300 Ultrasonic Gas Flow Meter Ultrasonic Gas Flow Meter for Natural Gas Measurement and Process Applications Document Information Glossary Product Product name: Firmware: act. in Operating state FLOWSIC300 Version 3.5.10 or higher ANSI American National Standards Institute ASCII Document ID Title: Part No.: Version: Release: American Standard Code for Information Interchange Operating Instructions FLOWSIC300 8014244 1-1 2016-07 AWG American Wire Gage CBM Condition Based Maintenance CSA Canadian Standards Association DC Direct Current Manufacturer SICK Engineering GmbH Bergener Ring 27 · D-01458 Ottendorf-Okrilla · Germany Phone: +49 35 20552410 Fax: +49 35 20552450 E-mail: [email protected] DIN Deutsches Institut für Normung (German Standards Institute) EN Euro Norm Original documents The English version 8014244 of this document is an original document from SICK Engineering GmbH. SICK Engineering GmbH assumes no liability for the correctness of an unauthorized translation. In case of doubt, please contact SICK Engineering GmbH or your local representative. EVC Electronic Volume Corrector Ex Potentially explosive HART Highway Addressable Remote Transducer (standardized communication system for field bus systems) → …http://www.hartcomm.org Legal information Subject to change without notice. DN Standard inner diameter DSP Digital Signal Processor EC European Community IEC International Electrotechnical Commission LCD Liquid Crystal Display LED Light Emitting Diode MEPAFLOW Menu driven configuration and diagnosis for FLOWSIC © SICK Engineering GmbH. All rights reserved. 2 MDR Manufacturer Data Record NAMUR Normenarbeitsgemeinschaft für Mess- und Regeltechnik in der chemischen Industrie (heute "Interessengemeinschaft Prozessleittechnik der chemischen und pharmazeutischen Industrie“) PC Personal Computer (Desktop-PC, Laptop, Notebook, Netbook usw.) PTB Physikalisch Technische Bundesanstalt RTU Remote Terminal Unit SPU Signal Processing Unit std. in Standard state VDE Verband der Elektrotechnik Elektronik Informationstechnik FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH Warning Symbols Information Symbols IMMEDIATE DANGER of serious injuries or death Important technical information for this product Hazard (general) Information on product condition with regard to explosion protection (general) Hazard in potentially explosive atmospheres Tip Hazard through explosive substances/substance mixtures Supplementary information Hazards through electrical voltage Note referring to information at another location Hazards through toxic substances Warning Levels / Signal Words DANGER Risk or hazardous situation which will result in severe personal injury or death. WARNING Risk or hazardous situation which could result in severe personal injury or death. CAUTION Hazard or unsafe practice which could result in personal injury or property damage. NOTICE Hazard which could result in property damage. FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH 3 Contents 4 Contents 1 Important Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 1.1 About this document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 1.2 1.2.1 1.2.2 For your Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Hazards during installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Hazards during operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 1.3 1.3.1 1.3.2 1.3.3 1.3.4 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Purpose of the device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Installation site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Operation in pressure applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Operation in potentially explosive atmospheres . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 1.4 1.4.1 1.4.2 1.4.3 Restrictions of use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Customized versions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Functional restrictions through contamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Voltage limitations for intrinsic safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 Additional information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 1.6 Responsibility of user . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 1.7 Disposal information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 2 Product Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 2.1 2.1.1 2.1.2 2.1.3 Basic system information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Functional principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Measured variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Calculating and calibrating the volume flow rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2 System configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 2.3 2.3.1 2.3.2 2.3.3 2.3.4 System overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . System components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sender/receiver units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Integration in the plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 2.5 2.5.1 2.5.2 Installation accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Spool piece . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Fitting tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 2.6 2.6.1 Output configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Hardware variants and signal outputs (I/O configuration) . . . . . . . . . . . . . . . . . . . . . 30 2.7 2.7.1 Wiring of digital outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Hardware variant C(6/10) with integrated electronic volume corrector (EVC) . . . 33 2.8 2.8.1 2.8.2 2.8.3 Operating modes and signal output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operation mode and Configuration mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Device status. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Signaling pulse output and state . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9 Self-diagnosis with user warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 2.10 2.10.1 2.10.2 2.10.3 2.10.4 Data handling in the FLOWSIC300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Integrated volume counters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Logbooks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DataLogs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagnostics Comparison Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 13 13 13 18 18 19 20 22 22 23 23 25 34 34 35 36 38 38 39 40 41 FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07· © SICK Engineering GmbH Contents 2.11 2.11.1 2.11.2 MEPAFLOW600 CBM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Software installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 3 Preparing for Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 3.1 Overview of installation work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 3.2 3.2.1 3.2.2 3.2.3 Project planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Project planning checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Determining the measuring and installation location . . . . . . . . . . . . . . . . . . . . . . . . . 48 Further notes for project planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 3.3 3.3.1 3.3.2 3.3.3 Preparation work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Checking delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Checking operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Tools required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 3.4 General safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 3.5 Safety information on gas tightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 4 Installing the Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 4.1 4.1.1 4.1.2 Assembly information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Safety information for assembly work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Position of nozzles on the pipeline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 4.2 4.2.1 4.2.2 4.2.3 4.2.4 Nozzle assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Assembly information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Marking the nozzle positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Welding the nozzle on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Determining the path length and installation angle . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 4.3 4.3.1 4.3.2 4.3.3 Installing the spool piece (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Safety information for the spool piece. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Inserting the spool piece in the pipeline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Determining the pipeline diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 5 Fitting the Sender/Receiver Units in Idle Operation (Cold Tap) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 5.1 Important information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 5.2 5.2.1 5.2.2 5.2.3 Fitting the sender/receiver units in idle operation /with non-pressurized line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Drilling a hole in the pipeline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Fitting the sender/receiver unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Installing the ultrasonic sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 5.3 Leak tightness check after installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH 5 Contents 6 6 Fitting the Sender/Receiver Units in Running Operation (Hot Tap) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 6.1 6.1.1 6.1.2 6.1.3 6.1.4 Safety information for the fitting tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Work safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety of hydraulic equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Proper installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Accident risk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 78 78 78 78 6.2 6.2.1 6.2.2 6.2.3 Using the fitting tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembling the fitting tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Moving the hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setting the coupling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 79 79 80 6.3 Installing the sender/receiver unit and ball valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 6.4 Drilling the holes in the pipeline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 6.5 Fitting an ultrasonic sensor with fitting tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 7 Installing the Electronics Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 7.1 7.1.1 7.1.2 7.1.3 7.1.4 7.1.5 Fitting the electronics unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fitting information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation location requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fastening the electronics unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turning the SPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connecting the connection cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2 7.2.1 7.2.2 7.2.3 7.2.4 7.2.5 7.2.6 Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 General information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Cable specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 Checking the cable loops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 SPU terminal compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Terminal assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 Requirements for use in hazardous areas with potentially explosive atmospheres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 94 94 94 95 96 96 FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07· © SICK Engineering GmbH Contents 8 Initial Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 8.1 Information on initial start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 8.2 8.2.1 8.2.2 Connecting to a PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 Connecting to a serial interface (RS232/COM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 Connecting to a USB port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 8.3 8.3.1 8.3.2 8.3.3 8.3.4 8.3.5 Connecting to MEPAFLOW600 CBM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 Starting MEPAFLOW600 CBM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 Choosing a user access level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 Creating a new device entry in the Device database . . . . . . . . . . . . . . . . . . . . . . . . . 117 Online connection: Connect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 Online Connection: Ethernet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 8.4 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 8.5 8.5.1 8.5.2 8.5.3 8.5.4 8.5.5 8.5.6 8.5.7 8.5.8 8.5.9 8.5.10 8.5.11 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 Entering the installation parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 Field setup wizard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 Location information and unit system (Field setup page 1 of 8) . . . . . . . . . . . . . . . 124 Application data (Field setup wizard, page 2 of 8) . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 Integrated electronic volume corrector (EVC) (Field setup wizard, page 3 of 8) . 125 I/O configuration – output configurations (Field setup wizard, page 4 of 8) . . . . 126 I/O configuration – terminal assignment (Field setup wizard, page 5 of 8) . . . . . 127 LCD Display settings (Field setup wizard, page 6 of 8) . . . . . . . . . . . . . . . . . . . . . . . 130 Configuration update (Field setup wizard, page 7 of 8). . . . . . . . . . . . . . . . . . . . . . . 132 Maintenance report (Field setup wizard, page 8 of 8) . . . . . . . . . . . . . . . . . . . . . . . . 133 Separating the connection to the device and terminating the session . . . . . . . . . 134 8.6 8.6.1 8.6.2 Functional check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 Checking the operating state on a version with LCD front panel . . . . . . . . . . . . . . 135 Function test with MEPAFLOW600 CBM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136 9 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139 9.1 Protective measures when working on the pipeline . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 9.2 Components with gas contact in the pipeline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 9.3 Maintenance work overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 9.4 Checking gas tightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141 9.5 9.5.1 9.5.2 9.5.3 Functional check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142 Comparing theoretical and measured sound velocity (SOS). . . . . . . . . . . . . . . . . . . 142 Checking the device state. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143 Time synchronization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144 9.6 Maintenance reports. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 9.7 9.7.1 9.7.2 Logbook backup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146 Checking the logbook. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146 DataLogs check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148 FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH 7 Contents 8 10 Troubleshooting 10.1 General troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152 10.2 10.2.1 10.2.2 10.2.3 Displaying status alarms and warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152 Checking the device status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153 Checking user warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156 Battery service life/capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157 10.3 Starting a diagnosis session. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158 10.4 Troubleshooting when connecting devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159 11 Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161 11.1 Electronics subassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162 11.2 Sender/receiver units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163 11.3 Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163 11.4 Fitting tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163 12 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165 12.1 12.1.1 Conformities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166 CE certificate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166 12.2 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167 12.3 Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168 12.4 12.4.1 Logbooks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168 Overview of entries in logbooks and MEPAFLOW600 CBM . . . . . . . . . . . . . . . . . . . 168 12.5 SPU terminal assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172 12.6 12.6.1 12.6.2 Wiring examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173 Intrinsically safe installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173 Non intrinsically safe installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174 12.7 Type plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151 FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07· © SICK Engineering GmbH Important Information FLOWSIC300 1 Important Information Subject to change without notice About this document For your safety Intended use Restrictions of use Additional information Disposal information Responsibility of user FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH 9 Important Information 1. 1 About this document These Operating Instructions contain essential information on the function, installation, start-up and maintenance of the FLOWSIC300. 1. 2 For your Safety 1.2.1 Hazards during installation CAUTION: General risks during installation ▸ Observe applicable valid regulations, general standards and guidelines. ▸ Observe local safety regulations, operating instructions and special regulations. ▸ Observe the information on responsibility of the user (→ p. 15, §1.6). WARNING: Hazards through the gas in the system The following conditions can increase the risk: ● Toxic gas or gas dangerous to health ● Chemically aggressive gas ● Explosive gas ● High gas pressure ● High gas temperature When ultrasonic sensors are installed on the pipeline when the pipeline is in operation (hot tapping): ▸ Only allow skilled persons trained and qualified for this method to carry out the installation. [1] ▸ Only start installation work when all planned measures have been checked and expressly approved by the plant operator. When the hot tapping method is not used to install the device: ▸ Only carry out installation work when the system is out of operation and does not contain dangerous gas. [2] Otherwise escaping gas can possibly be dangerous to health and cause injuries (e.g. poisoning, burns). WARNING: Hazards during installation work ▸ Only allow skilled persons qualified for the planned work to carry out welding, drilling and assembly work ▸ Comply exactly with mandatory and approved methods. ▸ Observe and comply with regulations of the plant operator. ▸ Meticulously check completed work. Ensure leak tightness and strength. Otherwise hazards are possible and safe operation is not ensured. 10 FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH Subject to change without notice [1] The skilled persons must be trained and experienced in hot tapping installations, and know and comply with the legal, generally accepted and in-house regulations and standards. [2] Also applicable for maintenance and repair work. Important Information 1.2.2 Hazards during operation WARNING: Hazards through leaks Operation in leaky condition is not allowed and possibly dangerous. ▸ Check leak tightness of equipment regularly (→ p. 141, §9.4). NOTICE: Risk of damage in pipeline ▸ Protect the ultrasonic sensors (→ p. 22, § Fig. 2) against liquids and mechanical effects. ▸ Pay particular attention here when the pipeline is to be cleaned with a pipeline inspection gauge. ▸ If the pipeline is to be purged with liquid: First observe the information in §9.1 (→ p. 140). Otherwise the ultrasonic sensors can be damaged or made unusable. 1.3 Intended use 1.3.1 Purpose of the device The FLOWSIC300 measuring system serves to measure the flow velocity of gases in pipelines. Apart from that, the FLOWSIC300 can also be used to determine the sound velocity and the volumes in operating conditions. 1.3.2 Installation site ● The FLOWSIC300 measuring system is electrical equipment designed for use in industrial plants. ● The FLOWSIC300 complies with the essential safety requirements of Annex I of the European Pressure Equipment Directive 2014/68/EU. 1.3.3 Operation in pressure applications FLOWSIC300 sender/receiver units as well as the fitting tool are designed for operation in pipelines that retain the pressure. The following Table shows the maximum permissible pressure. Pmax 103.4 bar 103.4 bar 103 bar 100.3 bar 100 bar Subject to change without notice Temperature range -40 °C to 38°C 50°C 100°C 150°C 180°C FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH 11 Important Information 1.3.4 Operation in potentially explosive atmospheres WARNING: Risk of explosions in potentially explosive atmospheres When the measuring system is to be used in a potentially explosive atmosphere: ▸ Only use the FLOWSIC300 measuring system in potentially explosive atmospheres that correspond to the individual device specifications. Otherwise there is a risk of explosions. The inside of the pipeline does not belong to the surrounding potentially explosive atmosphere. The pipeline does not have to have the same atmospheric conditions as the surrounding Ex zone. Subject to change without notice Technical information on operation in potentially explosive atmospheres → p. 103, §7.2.6. 12 FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH Important Information 1.4 Restrictions of use 1.4.1 Customized versions All individual operating parameters specified by the customer in the associated questionnaire are considered when manufacturing a FLOWSIC300. This means every FLOWSIC300 is an individual customized measuring system. Individual features can include: ● Materials ● Sealing design ● Additional equipment (options) ● Measuring ranges ● Basic settings WARNING: Hazard through incorrect use ▸ The FLOWSIC300 may only be used for the specified application case and only within the specified limits.[1] ▸ Observe and comply with the specifications on the type plate. ▸ Give priority to individual information delivered with the system (→ p. 14, §1.5). Otherwise safe and correct operation is not ensured. [1] E.g. maximum pressure, maximum temperature, technical characteristic values relating to safety and chemical composition of the gas in the pipeline. 1.4.2 Functional restrictions through contamination ● Deposits (dust, particles, condensation) on the ultrasonic sensors of the sender/ receiver units reduce measuring precision. ● The measuring function fails when contamination on the ultrasonic sensors is too strong. 1.4.3 Voltage limitations for intrinsic safety Subject to change without notice WARNING: Hazard for intrinsic safety ▸ Ensure voltages in the safe area are not higher than rated voltage UM = 253 V AC (→ p. 103, §7.2.6). Otherwise the intrinsic safety of the ultrasonic sensors is not ensured in case of a malfunction. FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH 13 Important Information 1. 5 Additional information Individual information for each device Some device components and settings depend on individual operating conditions. The scope of delivery is specified in the individual information delivered with the system. This can include: – Order and delivery documents – Configuration specifications made at the factory (basic settings) – Approval for potentially explosive atmospheres (incl. specifications) – Specifications for additional equipment and materials Individual installation dimensions Individual path parameters (length and angle of the ultrasonic measuring path to the gas flow) resulting from nozzle installation (→ p. 58, §4.2.1) are required during the initial startup to complete the configuration. Additional information for trained skilled persons (when required) ● FLOWSIC300 Service Manual ● FLOWSIC300 Modbus Specification Document ● FLOWSIC300 HARTbus Specification Document ● FLOWSIC300 Technical Bulletin ENCODER Output Subject to change without notice These documents are available from your regional sales organization. 14 FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH Important Information 1.6 Responsibility of user Designated users These Operating Instructions are intended for skilled persons responsible for the following tasks: – Installation (setting up/assembly) – Start-up – Operating and monitoring during operation – Maintenance/service ● Skilled persons are persons in accordance with DIN VDE 0105 or IEC 364 or directly comparable standards. It is decisive that these persons can recognize and avoid possible hazards, especially hazards through gases dangerous to health, hot or under pressure. In potentially explosive atmospheres: ● Installation, start-up, maintenance and inspection must be carried out by skilled persons with knowledge on ignition protection types and installation procedures, relevant rules and regulations as well as basic principles of range setting. ● The device may only be operated by instructed persons who have been instructed on the tasks to be carried out, possible hazards and protective measures. ● Only skilled persons trained specifically by the manufacturer may carry out repair work. ● Only original spare pasts from the manufacturer may be used. Safe installation ▸ Use the device only as specified in these Operating Instructions. The manufacturer bears no responsibility for any other use. ▸ Observe safety information in these Operating Instructions (e.g. → p. 10, §1.2). ▸ Observe applicable valid regulations, standards and guidelines. ▸ Observe local safety regulations, operating instructions and regulations. Subject to change without notice The plant operator is responsible for correct and reliable performance of installation work and establishing safe operating conditions. Safe operation ▸ Carry out the prescribed maintenance work (→ p. 139, §9). ▸ Do not remove, add or modify any components to or on the device unless described and specified in the official manufacturer information. Otherwise: – The device could become dangerous – Any warranty by the manufacturer becomes void – The approval for use in potentially explosive atmospheres is no longer valid. WARNING: Risk through incorrect use ▸ Only operate the FLOWSIC300 in the specified, individual operating conditions (→ p. 13, §1.4). Otherwise safe operation is not ensured. Retention of documents ▸ Keep these Operating Instructions available for reference. ▸ Pass these Operating Instructions on to a new owner. FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH 15 Important Information 1. 7 Disposal information Materials ● The FLOWSIC300 is mainly made of steel, aluminium and plastic materials. ● It does not contain any toxic, radioactive or other environmentally harmful substances. ● Substances from the pipeline can possibly penetrate, or deposit on seals. Disposal Dispose of electronic components as electronic waste. Check whether materials that had contact with the pipeline need to be disposed of as special waste. ▸ Dispose of the hydraulic fluid of the fitting tool as waste oil. Subject to change without notice ▸ ▸ 16 FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH Product Description FLOWSIC300 2 Product Description Subject to change without notice System components Operating modes, device status and signal output MEPAFLOW600 CBM FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH 17 Product Description 2. 1 Basic system information 2.1.1 Functional principle The FLOWSIC300 measuring system works according to the principle of ultrasonic transit time difference measurement. Sender/receiver units are mounted on both sides of a pipeline at a certain angle of inclination to the gas flow (→ § Fig. 1). These sender/receiver units contain piezoelectric ultrasonic sensors that function alternately as senders and receivers. The sound pulses are emitted at angle α to the flow direction of the gas. Depending on angle α and gas flow rate v, the transit time of the respective sound direction varies as a result of certain "acceleration and braking effects" (formulas 2.1 and 2.2). The higher the gas velocity and the smaller the angle to the flow direction, the more the transit times of the sound pulses differ. Gas flow rate v is calculated from the difference between both transit times, independent of the sound velocity value. Therefore changes in the sound velocity caused by pressure or temperature fluctuations do not affect the calculated gas flow rate with this method of measurement. Fig. 1 Functional principle FLOWSIC300 v L α tAB tBA L Sender/receiver unit B v tBA tAB = = = = = Gas flow rate in m/s Measuring path in m Angle of inclination in ° Sound transit time in flow direction Sound transit time against the flow direction α Sender/receiver unit A Determining the gas velocity Measuring path L is equal to the active measuring path, that is, the area through which the gas flows. Given measuring path L, sound velocity c, and angle of inclination α between the sound and flow direction, the sound transit time in the direction of the gas flow (forward direction) when the signal is transmitted can be expressed as: tAB = L c + v · cos α (2.1) Valid against the flow is: L c - v · cos α (2.2) After the resolution to v: v= L 2 · cos α · ( t1AB 1 tBA ) (2.3) i.e. a relation in which, except for the two transit times measured, only the active measuring path and the path angle exist as constants. 18 FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH Subject to change without notice tBA = Product Description Determining the sound velocity Sound velocity c can be calculated by resolving formulas 2.1 and 2.2. c= L · 2 + tBA ( ttAB ) AB · tBA (2.4) Based on the dependencies in formula 2.5, the sound velocity can be used to determine the gas temperature and molecular weight, and for diagnosis purposes. c = c0 · 1+ θ 273°C (2.5) Calculating the gas temperature Since the sound velocity is dependent on the temperature, the gas temperature can also be calculated from the transit times (by resolving formulas 2.4 and 2.5 to derive θ). θ = 273°C · ( 4L · c · ( tt 2 0 2 ) + tBA 2 –1 AB · tBA AB ) (2.6) Formula 2.6 shows that, in addition to the measured transit times, the values of L and the sound velocity in standard conditions are also included in the calculation. ● This means precise temperature measurement is only possible when measuring path L has been measured extremely accurately and a calibration has been carried out (see Section → p. 20, §2.1.3), and the gas composition is constant. ● The gas temperature calculated using formula 2.6 cannot be used to determine the volume flow rate in the standard state (→ p. 20, §2.1.3) Calculating the volume flow rate The volume flow rate in operating state is calculated from the gas velocity and the geometric dimensions of the pipeline. Calculating the volume flow rate in the standard state is described in § 2.1.3 (→ p. 20). 2.1.2 Measured variables Measured variable Vf Vb Ef Eb Vo Qf Qb Unit Display m³ m³ m³ m³ m³ m³/h m³/h MEPAFLOW600 CBM m³ Nm³ m³ Nm³ m³ m³/h Nm³/h Subject to change without notice Volume in operating conditions Volume in standard conditions Error volume in operating conditions Error volume in standard conditions Total volume, original Volume flow rate in operating state Volume flow rate in standard state Abbreviation FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH 19 Product Description 2.1.3 Calculating and calibrating the volume flow rate Volume flow rate in operating state The FLOWSIC300 is generally used to determine the volume flow rate in closed pipelines. Here, the uncorrected volume flow rate Qac is defined by representative cross-section A and mean gas velocity vA with respect to the cross-section (surface velocity): Q ac* = vA • A Further factors, such as Reynolds number and flow profile must be considered for calculation of the actual flow rate Qac. A functional relation was introduced in FLOWSIC300 for calculation of the actual volume flow rate Qac: Qac = Qac* • (1 + f [Qac* , pabs, CC0...4, PF, K0...5]) This functional relation has been implemented in the FLOWSIC300 as a calibration function with coefficients determined at the factory through reference measurement on a test bench and regression analysis, and then stored in the control unit. The coefficients for various nominal pipe diameters are parameterized during production of the device based on the specification of the planned nominal pipe diameter in the device. An optional throughflow calibration supports improving coefficient precision and then entering in the measuring system. This can therefore further improve measuring precision. Volume flow rate in standard state The volume flow rate can be converted to the standard state as follows: p pRohr T normal 1 Q sc = Q ac ----------------------------------------- -- p normal T Rohr Q ac: Q sc: ppipe: pnormal: Tpipe: Subject to change without notice Tnormal: κ: Volume flow rate in operating state Volume flow rate in standard state Absolute pressure in pipeline, normally set as parameter as fixed/default value typical for the plant. - If an optional analog module is used as an analog input for connecting a separate pressure sensor, the volume flow rate can be scaled with the current installation values. 1013 mbar Gas temperature (in K): Here in FLOWSIC300, either a permanent default temperature calculated with ultrasound measurement or read via the optional analog input (for greater accuracy) can be selected for use. Standard temperature In Europe 273 K, in the USA 293 K Compressibility (=1 for ideal gases); can be configured as a constant. 20 FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH Product Description 2.2 System configurations Configuration Description 1-path measurement Two sender/receiver units (1) are mounted on the pipeline (2). Measuring path (3) is positioned across the center of the pipeline. The 1-path configuration provides a costeffective measuring solution, especially for nominal pipe diameters up to 12 inches. An uninterrupted flow profile is the prerequisite for a good measuring result. Monitoring and diagnosis functions requiring the adjustment of several ultrasonic paths are not available for 1-path configuration. Note: Special operating conditions can make it necessary to position the path outside the pipeline center (shortens the measuring path). 2-path measurement 1 1 2 3 Two pairs of sender/receiver units are installed at the same measuring location and are connected to the electronics unit. Both measuring paths should preferably be positioned outside the center of the pipeline and run parallel to one another. A measuring result from both measuring paths is calculated in the electronics unit. Subject to change without notice The 2-path configuration provides increased measuring precision and interference immunity. In addition, advanced monitoring and diagnosis functions are available for two ultrasonic measuring paths. The 2-path configuration can be used for nominal pipe widths from 12 inches. Path compensation: The device uses an integrated algorithm for path compensation in the case of a path failure. In trouble-free function, the system learns the relation of gas velocity and sound velocity between both measuring paths. In case of a path failure, the system can calculate theoretical values on the basis of the learned path relations and can replace the invalid values against them. In this way, the path failure can be temporarily compensated and measurement is continued with slightly increased uncertainty. Under such conditions, the measurement system automatically signals "Check request". Preinstallation in piping (option) As an option, the 1- or 2-path configuration can be installed in a pipe section at the factory. Pipe sections with standardized flange connections (spools) or welding pipe sections can be realized in this configuration. This configuration provides the highest measuring precision and the lowest start-up effort due to the possible calibration in the factory and the preconfiguration of the electronics unit. Special versions are available for difficult or narrow installation locations where both sender/receiver units are installed on the same side of the pipeline (principle: Sound reflection on the pipeline walls). ▸ Observe the individual device information provided on delivery. FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH 21 Product Description 2. 3 System overview 2.3.1 System components Fig. 2 FLOWSIC300 standard configuration (1-path measurement) 6 7 8 5 4 3 2 1 Pos. Component 1 2 3 4 5 6 7 Ultrasonic sensor Nozzle Sender/receiver unit FLSE Cover Connection cable TNC-TNC (electronics unit cover) SPU (pivotable → p. 96, §7.1.4) Electronics unit 8 Plant pipeline Quantity for 1-path 2-path measurement measurement [1] 2 4 1 1 ● The nozzles are made individually for each order - tailored to the planned pipeline. An installation tool is supplied for assembly (→ p. 62, §4.2.3). ● A complete spool piece with built-in fitted nozzles is available as an option which is then fitted in the pipeline (→ p. 27, §2.5.1). Options/accessories Component Spool piece (→ p. 27, §2.5.1) [1] Fitting tool for ultrasonic sensors (→ p. 28, §2.5.2) [1] Replaces nozzles and installation accessories for nozzles. 22 FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH Subject to change without notice [1] Option. Product Description 2.3.2 Sender/receiver units Ultrasonic sensors optimally tuned to system requirements are fitted in the sender/ receiver units of FLOWSIC300. The high quality of the sensor design provides the basis for accurate and highly stable transit time measurements with nanosecond precision. The ultrasonic sensors are designed electrically intrinsically safe, category "ia". The sender/receiver units and the ultrasonic sensors are marked on delivery. Installation on the pipeline must be carried out under consideration of the main throughflow direction according to the following Table to ensure correct measuring function. 1-path installation 2.3.3 2-path installation SPU Subject to change without notice Function The Signal Processing Unit (SPU) contains all the electrical and electronic components for controlling the ultrasonic sensors. It generates transmission signals and analyzes the received signals to calculate the measuring values. The SPU also contains several interfaces for communication with a PC or standardized process control system. Current device states, errors, warnings and power failures are written to non-volatile memory (FRAM) with a timestamp (logbooks → p. 168, § 12.4.) The last device state stored is set as start value for the volume counter when the system is started. The FRAM backup provides an unlimited number of writing cycles and guarantees saved data protection for a minimum of 10 years. Design The SPU is equipped with a front panel containing a two-line LCD to display current measured values, diagnostics and logbook information (→ § Fig. 3). Selection using a magnetic pen is possible with the front cover closed. The MEPAFLOW600 CBM program supports user-friendly information displays. FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH 23 Product Description Fig. 3 LCD front panel for FLOWSIC300 FLOWSIC300 4 9 9 8 2 0m 3 / h 0 m3 / h +V - V DATA ENTER STEP Measured values C/CE Control buttons for the magnetic pen Control buttons for manual use DATA STEP C/CE ENTER Subject to change without notice The power supply and interface terminals are located on the back of the SPU in a separate terminal compartment (→ p. 100, § 7.2.4). The electronics are fitted in a pressure-proof housing certified in accordance with EN 60079-1 or IEC 60079-1 with ignition protection type "d" – 'pressurized enclosure'. Sensor power circuits are intrinsically safe (category "ia"). 24 FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH Product Description Integration in the plant (example Ex i) Compressibility factor Z Heating value Hs RS485 / MODBUS Service PC / higher level control system 12 … 24 VDC Gas volume flow rate (std.) Electronic Volume Corrector (EVC) / Flow Computer (FC) Energy content Temperature Fig. 4 Pressure Source Integration in the plant Volume flow rate act. 2.3.4 Ex-i isolating transducer (only required for intrinsically safe installation) Non Ex area Ex area Subject to change without notice FLOWSIC300 FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH 25 Product Description 2. 4 Scope of delivery Measuring system Component Nozzle [2] Ultrasonic sensor Sender/receiver unit Flat seal (sealing disc) for sender/receiver unit Electronics unit Connection cable Quantity for 1-path 2-path measurement measurement [1] 2 4 2 4 2 4 2 4 1 1 2 4 [1] Option. [2] Not necessary when a spool piece is delivered (→ "Options/accessories“"). Accessories Component Foil strips to mark nozzle positions Installation tool for nozzles [1] Hand extraction tool for ultrasonic probes Handles for locking ring of sender/receiver unit Explanation → p. 59, §4.2.2 → p. 62, §4.2.3 [1] Not necessary when a spool piece is delivered (→ "Options/accessories“"). Software Component PC software MEPAFLOW600 CBM [1] Geometry tool [2] Explanation → p. 42, §2.11 → p. 65, §4.2.4 [1] Installation file on data medium (CD-ROM). [2] Calculation Table on data medium (CD-ROM). Options/accessories Component Spool piece [1] Pressure measurement (pressure sensor, measuring line) [2] Temperature measurement (temperature sensor, measuring line) [2] Fitting tool for ultrasonic sensors Explanation → p. 27, §2.5.1 → p. 28, §2.5.2 Subject to change without notice [1] Replaces nozzles and installation tool. [2] Only for spool piece (see separate information for specifications). 26 FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH Product Description 2.5 Installation accessories 2.5.1 Spool piece Purpose A FLOWSIC300 measuring pipe is a pipe piece (spool piece) for the gas line with the nozzles for the sender/receiver units already fitted. This means the precise welding work to fit the nozzles need not be done on-site. Versions ● The following are designed according to the individual order: Nominal width, flange, material. ● The number of nozzles depends on the selected system configuration (→ p. 21, §2.2). ● The fitting length depends on the pipeline diameter (→ § Fig. 5). See the order documents or individual information provided on delivery for the spool piece version delivered. Fig. 5 Spool piece (example) Lifting points Fitting length Spool piece type plate Pipeline diameter ≤ 24" > 24" Fitting length 1000 mm 1500 mm Subject to change without notice ● The spool piece can be delivered with additional sensors fitted (→ "Options“"). ● Fitting the spool piece → p. 68, §4.3. Options All system solutions (FLOWSIC300 + spool piece) are optionally available with pressure and temperature sensors. The pressure and temperature measuring points are configured and positioned according to customer specifications Additional options for spool pieces: – 3D measurement (minimizes geometric uncertainty) – Flow-calibrated – Version without flanges for welding into the pipeline (leak tightness must be checked after installation in pipeline) FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH 27 Product Description 2.5.2 Fitting tool Purpose The following work on the FLOWSIC300 can be carried out with the fitting tool without having to interrupt operation of the pipeline (at plant pressure): ● Drill holes for ultrasonic path in pipeline (→ p. 81, §6.3) ● Checking the ultrasonic sensors for damage or contamination ● Replacing the ultrasonic sensors The fitting tool is suitable for use with all sender/receiver units. The plant operator should have at least one fitting tool available for maintenance and service work. This can be used on a whole range of FLOWSIC300 measuring systems. WARNING: Explosion hazard The fitting tool is not approved for operation in explosive atmospheres. When used on the pipeline, risk of explosion must be excluded or a possible ignition hazard signaled in time by suitable means (e.g. monitoring with gas detector). NOTICE: It is recommended to perform a technical check and maintenance on the fitting tool after 10 fitting tasks. The following tasks should be carried out at least: ● Replacing the O-ring seal on the ball valve. ● Functional check of the pressure gauge on the ball valve and on the hydraulic pump. ● Functional check of the bypass and toggle valves. ● Visula check of all welding seams on the hydraulic cylinder Subject to change without notice NOTICE: It is recommended to check the fitting tool after 100 fitting tasks or 5 years with a strength test according to Annex I Section 7.4 of Directive 2014/68/EU. 28 FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH Product Description Components Fig. 6 Fitting tool 4a 4c 4b 3 4 1a 1b 1c 2b 2a 2 1 Pos. Component 1 Ball valve 2 Hydraulic cylinder 3 4 Hydraulic hose Hydraulic pump Pos. 1a 1b 1c 2a 2b Subcomponent Toggle valve Pressure gauge for gas pressure Bypass valve Coupling Hydraulic piston 4a 4b 4c Pressure gauge for hydraulic pressure Pressure valve Oil tank cap Functional principle The ball valve is fitted on the locking ring and then the hydraulic cylinder fitted. Ball valve and hydraulic cylinder form a pressure lock. The ball valve valves serve to compensate the pressure. When the ball valve is open, the hydraulic cylinder can push or pull an ultrasonic sensor in or out of the nozzles. The hydraulic cylinder coupling can be set to "fit" or "remove". The coupling engages into the ultrasonic sensor during removal; during fitting, the ultrasonic sensor is only pushed without engaging (→ p. 80, §6.2.3). Subject to change without notice Instructions on the fitting tool → p. 77, §6 FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH 29 Product Description 2. 6 Output configurations 2.6.1 Hardware variants and signal outputs (I/O configuration) FLOWSIC300 outputs are available in various configurations. Different output configurations require different hardware variants of the electronics unit (→ p. 31, Table 1). Fig. 7 Terminals in FLOWSIC300 SPU (cover open) The following settings can be assigned to the four available physical outputs (the actual RS485 MODBUS communication port 33/34 is not considered to be an output). The settings can be configured on the "Device parameters" page and in the Field setup wizard of the MEPAFLOW600 CBM software. Digital output Output DO0 (31/32) Possible settings Warning, data invalid, flow direction, check request AO output 4 .. 20 mA or 4 .. 20 mA with serial HART® [1] Communication (33/34) Communication port RS485 MODBUS [2] (fixed) Output DO1 (51/52) Pulse, warning, data invalid, warning, flow direction, check request Output DO2 (41/42) Warning, data invalid, flow direction, check request Output DO3 (81/82) Warning, data invalid, flow direction, check request, ENCODER (NAMUR) [3] Subject to change without notice [1] See document "HARTbus Specification“ for further details on HART®. [2] See document "Short Manual MODBUS" for more details on RS485. [3] See document "Technical Bulletin ENCODER output" for more details on the encoder option. 30 FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH Product Description Table 1 Available hardware variants / output configurations Output terminal Analog board Hardware variant/Output configuration HV [1] 3 (1/3) 5 (2/4) C(6/10) EVC Without Without With 31/32 Status Analog/ HART EVC int. PS 33/34 RS485 RS485 RS485 51/52 Pulse Pulse Pulse 41/42 Status Status Status 81/82 Status Status Status Subject to change without notice [1] Hardware variants, internal key FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH 31 Product Description 2. 7 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 in accordance with "NAMUR" on delivery, unless "Open Collector" was specified in the purchase order. Fig. 8 Wiring of digital outputs Open Collector US IB = 100 mA US - 2 V 0.1 A RL RL US - 2 V 0.01 A NAMUR 1k +8.2 V DC 10 k 1k 0V Subject to change without notice NOTICE: ● An operating current range of 20 mA is recommended. ● Imax at the open collector connection must not exceed 100 mA, otherwise the output may be destroyed. ● The maximum possible frequency of the impulse output depends on RL and the cable length (cable capacitance). ● A higher frequency requires a lower RL . For this case a low capacitance cable is recommended. 32 FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH Product Description 2.7.1 Hardware variant C(6/10) with integrated electronic volume corrector (EVC) Hardware variant C(6/10) has an integrated electronic volume corrector. FLOWSIC300 supports three different algorithms for gas volume correction. Alternatively the option "Fixed values" can be used. SGERG88 MR113-3 GERG91 mod Alternative option "Fixed values" Usable up to a pressure of 100 bar (1450 psi). Algorithm developed in Russia and recommended for use in the Russian petroleum market for wet gases (flare gas) in a temperature range of –10°C .. 230°C at pressures up to 150 bar. Recommended for correction of dry natural gas in Russia. Alternatively, the user can choose to calculate the molar mass using the measured sound velocity and the gas temperature recorded as fixed or actual value. Subject to change without notice See document "FLOWSIC600 Technical Bulletin: EVC" (available from your local representative) for detailed information on the EVC. FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH 33 Product Description 2. 8 Operating modes and signal output The FLOWSIC300 has the following operating modes (→ § 2.8.1): ● Operation mode ● Configuration mode The device can have the following device status in measuring operation (→ § 2.8.2): ● Measurement valid ● Check request ● Data invalid 2.8.1 Operation mode and Configuration mode The FLOWSIC300 can be used in two modes: Operation mode or Configuration mode. Operation mode In Operation mode, the FLOWSIC300 runs in one of the three device statuses depending on the measuring conditions. Configuration mode Configuration mode serves to modify parameters that directly influence measurement and to test the system and output signals. Configuration mode forces the device to status "Data invalid". Digital output "Measurement valid" is deactivated because invalid measured values can occur in Configuration mode. The system continues operation using the current sample rate and executes all calculations as in measuring operation. Frequency output and analog output may be set to test values and do thus not necessarily indicate measured values. Apart from the parameter measuring rate and ModBus interface/device address baud rate, all parameter changes are considered immediately in running calculations. The device switches automatically to Operation mode when the device is in Configuration mode and no activities occur for longer than 15 minutes on the LCD display or via MEPAFLOW600 CBM. Subject to change without notice Check cycle Setting the associated control bit in the system control register (#3002) allows activating a check cycle on a measuring path (the setting can be made on page "Device parameters" in MEPAFLOW600 CBM). Here, the send signal is coupled into the receive amplifier of the measuring path via an electric attenuator (= sensor simulator). This function can only be activated when Configuration mode is activated. It is only useful when testing path electronics. Any existing check cycles are deleted automatically when Configuration mode is terminated. 34 FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH Product Description Device status 2.8.2.1 Status: Measurement valid Status "Measurement valid“ is the normal device status of the FLOWSIC300. Frequency output and current output are updated cyclically and deliver the volumes and actual volume flow rate. Apart from that, the analog signal can display the actual volume flow rate, the corrected volume flow rate, the sound velocity (SOS) or the gas velocity (VOG). The digital output "Direction of flow" is updated in accordance with the direction of the volume flow. The digital output "Measurement valid" (active) represents the status of the measurement. Positive (forward) and negative (reverse) volume flow rates are integrated and saved in separate internal memory sections. The ModBus interface serves to inquire all parameters and signals at any time without influencing system functions. Each measurement initiated by the system controller includes one full transit time measurement with, and one against the direction of flow on each path. The result of each measurement is written to a mean value memory to be used in further calculations. The size of this memory block and thus the device response delay can be modified through the parameter in register #3502 "AvgBlockSize". If no result can be calculated due to poor signal quality, this measurement is registered as an invalid attempt in the mean value memory. The mean value is formed in a variable averaging process including all valid measured values in the memory. The measuring system switches to status "Check request" when the number of invalid measurements in one path exceeds the prescribed threshold (parameter register #3514 "Limit%Error). 2.8.2.2 Status: Check request This status is active when one of the two measuring paths of a 2-path system has failed and the adaptive path failure compensation is activated. This failure is compensated on a FLOWSIC300 in 2-path configuration. Measurement continues with slightly lower precision. The measuring system switches to status "Data invalid" when the measuring path of a 1path system fails or path compensation of a 2-path system is deactivated. Status "Check request" is also active when system alarms 2002 ("No HART communication with temperature sensor"), 2003 ("No HART communication with pressure sensor") or 2004 ("Maximum pulse output frequency exceeded") are active (see Table → p. 168, § 12.4.1). 2.8.2.3 Status: Data invalid If the quality of the signals received from all measuring paths is insufficient, the device marks the measured value as invalid and activates device status "Data invalid". However, the SPU will cyclically attempt to reestablish valid measurements. As soon as the signal quality and the number of valid measurements allow it, the device switches automatically back to status "Measurement valid" or "Check request". Subject to change without notice 2.8.2 FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH 35 Product Description 2.8.3 Signaling pulse output and state Output signal / LCD / port Measurement Pulse output signals Signal behavior Check request Configuration mode Data invalid [1] Single pulse output "Check request" Status signal Status "active / inactive" [2] Measurement valid "Flow direction" Status signal Status "active / inactive" [2] Positive or negative direction of flow Status "active / inactive" [2] "Warning" LC-Display +V m³ 123456 Status "active / inactive" [2] Compensation of path failure Status "active / inactive" [2] Positive or negative direction of flow Status "active / inactive" [2] 1234 m³ Display blinks Serial port RS485 "Undefined" "Undefined" "Undefined" "Undefined" "Undefined" "Undefined" FLOWSIC300 Configuration +V m³ 123456 Display blinks ● Measured value, diagnosis information and parameters ● Measuring data logging, diagnosis and configuration using the MEPAFLOW600 CBM program ● Connection with external process control equipment through implemented MODBUS protocol (data polling) [1] The device can be configured so that it outputs a fixed frequency for "Data invalid". The frequency to be output in this case can be configured (0-6 kHz) in Reg. #3034 "ErrorFreq". [2] State "active" or "inactive" can be assigned to the electrical switching state "normal open" or "normal closed" using the configuration in the MEPAFLOW600 CBM program (settings for register #5101 on page "Parameters"). Subject to change without notice ● Standard setting for "Check request", "Configuration" and "Data invalid" is "normal closed". ● Measured values, parameters, messages and other information can be displayed on the LCD display. ● A blinking character in the top right corner of the LCD display indicates that a logbook contains unacknowledged logbook entries. Depending on the type of entry this will be: "I" – Information "W" – Warning "E" – Error The blinking character disappears when all new entries have been acknowledged. For details see → p. 146, § 9.7.1. 36 FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH Product Description 2.9 Self-diagnosis with user warnings During normal operation, the ratios of sound and path velocities, amplification values, performance, and signal-to-noise ratios are continuously monitored. If these values exceed set limits (customized User Warning limits), a warning signal will be generated. This allows immediate measures to be taken to address a problem which could potentially impact measurement quality. A message in the Warning Logbook documents the time of the event and the specific User Warning limit which was exceeded. ● The "Warning" signal does not affect the functionality of the meter. ● All User Warning parameters - except for the parameter ‘Min. VOG for warnings" - can be configured in the User Access Level "Operator" and without switching the meter to the Configuration Mode. A User Warning becomes active only if a User Warning limit has been continuously exceeded for a certain time (specified in the parameter "Warning duration and averaging for warnings" in the Configuration tab of User Warnings). During commissioning or operation, the User Warning limits can be adapted and activated or deactivated in the "User Warnings" window in MEPAFLOW600 CBM to suit individual application requirements. Fig. 9 Button "User" in the MEPAFLOW600 CBM main system bar, "User Warnings" window Opens the "User Warnings" window System warnings Subject to change without notice Path warnings FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH 37 Product Description 2. 1 0 Data handling in the FLOWSIC300 2.10.1 Integrated volume counters The FLOWSIC300 is equipped with integrated volume counters which can be displayed both on the LCD display and in MEPAFLOW600 CBM. Integrated volume counters Volume counter Abbreviation Volume at flowing conditions (forward) + Vf Volume at flowing conditions (reverse) - Vf Error volume at flowing conditions (forward) + Ef Error volume at flowing conditions (reverse) - Ef Total volume at flowing conditions (forward) + Vo Total volume at flowing conditions (reverse) - Vo Total volume at flowing conditions (all) Vo Last hour/day registers Volume counter Abbreviation Forward volume of last hour Last hour forw. Reverse volume of last hour Last hour rev. Forward volume of last day Last day forw. Reverse volume of last day Last day rev. Additional counters in meters with integrated Electronic Volume Corrector (EVC) Volume counter Abbreviation Volume at base conditions (forward) + Vb Volume at base conditions (reverse) - Vb Error volume at base conditions (forward) + Eb Error volume at base conditions (reverse) - Eb 38 Mass counter Abbreviation Mass counter (forward) +M Mass counter (reverse) -M Mass total (forward) M+ Mass total (reverse) M- Error mass (forward) Me+ Error mass (reverse) Me- FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH Subject to change without notice Mass counters Product Description 2.10.2 Logbooks Important system events are stored in three logbooks in the SPU memory of the meter. Each logbook entry consists of a running index number, the event, a time stamp and the acknowledgement status. Entries in Custody logbook [1] and Warning logbook [2] also include the volume counter readings valid at that time. The events are logged continuously in order of occurrence into one of the three logbooks: ● Logbook 1 (Custody logbook [1], max. 1000 entries) ● Logbook 2 (Warning logbook [2], max. 500 entries) ● Logbook 3 (Parameter logbook [3], max. 250 entries) Every logbook has its own index counter. Logbook entries are classified on the LCD display according to the event type. Event types in logbooks Display Event type E Error W Warning I Information All logbooks of FLOWSIC300 are configured to ring buffer mode when delivered. This means the index number continues increasing, and after the logbook has reached its maximum number of entries, each new entry overwrites the oldest entry. The logbooks can also be configured so that the volume counters stop when Custody logbook [1] and/or Parameter Logbook [3] are full. In this case, meter state "Data invalid" will be activated until the corresponding logbook has been saved and deleted. Index counter overflow The index number displayed in the LCD display runs up to 9999 and then overflows. In case of an index overflow, all logbook entries are deleted and all logbook index counters reset. Subject to change without notice Acknowledging entries Each entry can be acknowledged manually on the LCD display as well as in MEPAFLOW600 CBM. It is possible to acknowledge individual entries or all entries at once. FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH 39 Product Description 2.10.3 DataLogs[1] FLOWSIC300 has two DataLogs (Hourly Log and Daily Log). They save averaged measured values and are stored in the SPU‘s non-volatile memory (FRAM). All data can be downloaded and exported to Excel files with MEPAFLOW600 CBM. The following sections describe the default configuration of the DataLogs. The DataLogs can be configured to best suit your application. 2.10.3.1 Hourly Log The Hourly Log logs hourly diagnostic values by default (dataset type "Diagnostic Values") for the forward flow. As long as the flow is valid and the VOG is above Vmin all diagnostic and flow values are averaged over one hour and saved every full hour. The Hourly Log stores these values for more than a month (38 days) by default. They are then overwritten with new values. 2.10.3.2 Daily Log The Daily Log logs the daily diagnosis values by default (dataset type "Volume Counters") for the forward flow. All flow values are averaged over one day and saved at the (configurable) Accounting Hour. The Daily Log stores these values for approximately 2 years by default (1 year and 361 days). They are then overwritten with new values. DataLog storage cycle Hourly Log and Daily Log can be configured to save entries in a storage cycle of: 3 min, 5 min, 15 min, 30 min, 1 hour, 12 hours or 24 hours. If a DataLog is set to a Storage cycle of 12 or 24 hours, the accounting hour takes effect. 2.10.3.3 DataLog storage behavior Hourly Log and Daily Log can be configured for the following storage behavior: ● Overflow (Default) ● Stopping Storage Behavior "Stopping" If a DataLog is configured with the storage behavior "Stopping", a warning will be shown in the Meter Status Table when the DataLog is full. Types of datasets stored in the DataLogs Hourly Log and Daily Log can be configured to store one of the following type of dataset: ● Diagnostic values ● Volume counter ● Standard Volume Counters ● Mass Flow Counters Subject to change without notice 2.10.3.4 [1]This feature may be deactivated. Please contact your SICK representative. 40 FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH Product Description 2.10.4 Diagnostics Comparison Log[1] The Diagnostics Comparison Log provides a comparison between current diagnostic values (current fingerprint) and those of a reference time (reference fingerprint, for example, at time of commissioning). Since the diagnostic values are velocity-dependent, it is necessary to use a velocity-adaptive comparison. Five gas velocity range classes are calculated from the velocity range of the meter. The current diagnosis values are stored in Current Classes 1 to 5, while the reference values are stored in Reference Classes 1 to 5. Reference values are collected after the meter has been commissioned or after the classes have been cleared. Reference values are stored in the Reference Classes 1 to 5. If a Reference Class is filled with an entry, the next valid entry is stored into the same velocity range but in the corresponding Current Class (e.g. if Reference Class is filled, the next value from within this velocity range will be stored in Current Class 1). During operation, the Current Classes are continually overwritten with new entries. The Reference Classes stay unchanged until they are manually cleared. Per default the Diagnostics Comparison Log operates bidirectional, saving separate data for both flow directions. The values are stored in the gas velocity classes 1 to 5, depending on the gas velocity. Diagnostics Comparison Log Subject to change without notice Fig. 10 [1]This feature may be deactivated. Please contact your SICK representative. FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH 41 Product Description 2. 1 1 MEPAFLOW600 CBM 2.11.1 Software installation System requirements ● Microsoft Windows XP/Windows 7 ● Min. 1 GHz CPU ● Min. 512 MB RAM ● USB or serial interface ● Screen resolution min. 1024 x 768 pixels (ideal display resolution 1280 x 1024 pixels) Compatibility MEPAFLOW600 CBM can be used with all firmware and hardware versions of the FLOWSIC300. Availability of software functions depends on the firmware version of the connected FLOWSIC300. Installation A product CD with the MEPAFLOW600 CBM program is delivered with the FLOWSIC300. Insert the product CD into your CD-ROM drive to install the software. Start file FLOWSIC300_R_CD.exe‘ to install the program. Subject to change without notice Download from www.sick.com/flowsic600 The MEPAFLOW600 CBM program can be downloaded free of charge from website www.sick.com/flowsic600. Select the Software tab and follow the download instructions. Access to most of the data delivered by the FLOWSIC300 (such as displays, logbook entries and parameters) can be made using the LCD display of the device. However, the MEPAFLOW600 CBM software provides a more user-friendly access to diagnostic, configuration and measurement data of the flow meter. 42 FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH Product Description 2.11.2 Overview The MEPAFLOW600 CBM program provides a menu-based user interface with many functions for diagnosis of the FLOWSIC300. It allows access to all system parameters, displays diagnostic information in diagrams and graphs, generates reports (e.g. Status reports) and data files (recordings, logs) that can be exported for data evaluation. Its device database serves to manage parameters, reports, session files and logbooks both online and offline. Fig. 11 MEPAFLOW600 CBM graphical user interface Opens page "Meter Status" Opens page "User Warnings" Menu Main system bar with displays Button navigation Software functions – (see next page) Subject to change without notice Status bar FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH 43 Product Description Software Features Main readings bar Meter Status User Warnings Button navigation Connect/Disconnect Diagnosis session Data recorder DataLogs Logbook Overview Meter values Maintenance report Meter explorer Go to Operation Mode / Go to Configuration Mode Program settings Parameters Save cache SOS Calculator Meter calibration Field setup Firmware update I/O check Path diagnosis Subject to change without notice Report manager Description Window displaying the current Meter Status. Window for the display of the User Warnings and for the configuration of the User Warning Limits and the Diagnostic Comparison Limits. Description Assistant for establishing online and offline connections between MEPAFLOW600 CBM meter database and FLOWSIC300. Quick creation of session files for diagnostic purposes. Tool for the recording and playback of current, future or cached readings. Access to Hourly Log, Daily Log and Diagnostics Comparison data saved in the meter. Data can be exported to Excel. The Diagnostics Comparison Report can be printed or exported as PDF. Access to meter logbook and logbook entries saved to meter database. Overview of higher level meter information: Counter readings, identification and location of meter and display of readings (e.g. flow rate) in graph. Detailed diagnostic page with graphs for velocity of gas, speed of sound (SOS), path performance, AGC, signal-to-noise-ratio (SNR), turbulence, profile symmetry and user selectable readings (e.g. flow rate). Summary of device status. Assistant for the creation of Maintenance reports. Overview, access and management of the meter database saved on the PC. Includes all meter data and sessions with entries for all changes of parameters, changes of the operating mode, measurement records (including diagnosis sessions) and maintenance reports. Functions for export, import, creation and deletion of meter data. Operation Mode switches: "Operation Mode" for normal operation or "Configuration Mode" for writing information (i.e. parameters) to the meter. Access to program settings for the individual adjustment of the program appearance and setup (e.g. settings for file path, memory, unit system and layout). Access to all meter parameters. Assistant for comparing current parameter settings with previous ones. Saves the historical data from the PCs memory (cache) to a record. A theoretical SOS can be calculated for a specific gas composition. The calibration wizard guides the user through the calibration procedure with automated processes to write the information to the meter and generate reports. The field setup wizard guides the user through the commissioning procedure. Assistant for installing firmware updates. The I/O check wizard guides the user through a test of all meter outputs. Access to path diagnosis and graphs of received signals. Overview, access and management of all reports stored in the meter database. The report manager enables the creation of Trend reports from saved records and maintenance reports. 44 FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH Preparing for Installation FLOWSIC300 3 Preparing for Installation Subject to change without notice Overview Project planning Installation location requirements FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH 45 Preparing for Installation 3. 1 Overview of installation work A 1 2 3 B 1 2 3 4 Preparations Work step Observe the individual device information delivered with the device Determine the measuring location (position of sender/receiver units) Determine the installation location for the electronics unit Installing sender/receiver units in running operation (hot tapping) Work step Install nozzles on pipeline Install sender/receiver units Drill holes for ultrasonic path in pipeline by means of "hot tapping" method[1] Install ultrasonic sensors using the fitting tool Information/instructions → p. 48, §3.2.2 → p. 94, §7.1.2 Information/instructions → p. 55, §4 → p. 81, §6.3 → p. 81, §6.3 → p. 85, §6.5 [1] Requires special machines (hot tapping tool) and special technical knowledge. This work is not described in these Operating Instructions and the manufacturer is not responsible for implementation. Recommendation: Have this work carried out by a specialist company. Or: B 1 or: 2 3 4 C 1 2 3 D Installing the electronics unit Work step Fit electronics units Electrical installation Install connection cable to the sender/receiver units Carrying out initial start-up Work step Connect electronics unit to a PC Connect electronics unit to MEPAFLOW CBM Perform Field setup wizard or manual start-up Information/instructions → p. 94, §7.1 → p. 97, §7.2 → p. 96, §7.1.5 Information/instructions → p. 114, §8.2 → p. 116, §8.3 → p. 122, §8.5 Subject to change without notice 1 2 3 Installing the sender/receiver units when operation idle Work step Information/instructions Install nozzles on pipeline → p. 55, §4 Install spool piece in pipeline (Option → p. 27, §2.5.1) → p. 68, §4.3 Drill holes for ultrasonic path in pipeline Install sender/receiver units → p. 71, §5 Install ultrasonic sensors (without fitting tool) → p. 71, §5 46 FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH Preparing for Installation 3.2 Project planning 3.2.1 Project planning checklist The following Table provides an overview of the project planning work to be carried out to ensure the device is correctly installed and fully functional. You can use this Table as a checklist and tick off all the steps you have carried out. Task Requirements Determine mea- Flow distribution, inlet and outlet suring location (→ p. 48, §3.2.2) paths Accessibility, accident prevention Vibration-free installation Ambient conditions Work step Lowest possible influence on measuring precision Easy and safe Accelerations < 1 g Limit values → p. 167, §12.2 Installation locations Plan the voltage supply Electronics unit accessibility Operating voltage, As shown in Techn. Data (→ p. 167, power requirements §12.2) Follow specifications for new equipment; select best possible location for existing equipment Provide platforms or pedestals when necessary Take appropriate measures to eliminate/reduce vibrations If necessary: Provide weatherproof covers / sun protection, enclose or insulate device components. Cable lengths Ensure adequate cable cross-sections and protection Subject to change without notice Select device components √ FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH 47 Preparing for Installation 3.2.2 Determining the measuring and installation location Measuring precision is influenced, among other things, by flow behavior and the position of the measuring axis. Large cross-section variations, curved pipes, fittings, air flaps or inlets can cause profile deformations or turbulence with a negative effect on the measuring result. Fig. 12 Measuring and installation location Pipeline Possible installation area Inlet section min. 20 D i Outlet section 5 Di A Homogeneous flow profile Di Criteria Measuring location Nozzle for sender/receiver unit General requirements Flow behavior Pipeline design Inlet and outlet path lengths Installation location Platform Wall and insulation thickness 48 Platform Requirements Position with essentially homogenous gas flow Balanced, uniform profiles are most likely to be expected for long inlet and outlet paths Whenever possible, no deflections, cross-section variations, curves, feed and drain lines, flaps or fittings in the area of the inlet and outlet paths The longer the inlet section (especially), the better the reproducibility of measuring results. Isometric conditions at measuring point are most important for determining the required upstream and downstream piping and should be checked carefully. ● Uncritical inlet conditions with a single 90° bend require a straight inlet pipeline > 20 x Di and outlet pipeline > 5 x Di. ● More complex inlet disturbances require longer pipings up to 30 Di/10 Di. ● For too short inlet/outlet paths: Inlet path > outlet path Pipelines with vertical, horizontal or inclined direction Installation free of vibrations, acceleration < 1 g Largest possible distance to control valves or other noisy fixtures Adequate installation space (→ p. 50, Fig. 13) Easy and safe access for installation and maintenance work of the sender/receiver units Platform secured by a railing to prevent possible accidents Clearance for assembling sender/receiver units (→ p. 50, §3.2.2.3) ● Maximum wall thickness 20 mm, maximum insulation thickness 100 mm. ● Larger wall and insulation thicknesses require customer-specific solutions (available on request only). FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH Subject to change without notice 3.2.2.1 Inhomogeneous flow profile Preparing for Installation ▸ On new systems: Comply with the specifications. ▸ On existing systems: Select the best possible location. ▸ For ideal installation: Request advice from the manufacturer. CAUTION: Accident hazards ▸ Observe local safety regulations and occupational health and safety regulations in addition to these Operating Instructions. 3.2.2.2 Additional requirements for a spool piece (option) Requirements ● Select the measuring tube in the same rated width as the pipeline ● Deviations from inner diameter of the inlet pipe and spool piece < 1%. ● No welding beads and burrs on the insides of the spool piece Assembly Pipelines with horizontal or vertical direction ● Horizontal installation: Align the spool piece so that level created by the measuring paths is horizontal. ● Vertical installation: Only possible if the measuring system is used for dry, non-condensing gases. See information → p. 51, §3.2.3 a) Gas flow Free from any foreign material, dust and liquids. Otherwise, filters and traps shall be used. Seals between meter Must not protrude into the pipeline. Any protrusion into the flowing gas stream may change the flow probody and pipeline file and thus the measuring accuracy may be adversely affected. Pressure sensor The connection on the pressure inlet nozzle can be a bushing or a flange, depending on the size of the spool piece or customer requirements. Clamping sets and Bolts, nuts and flange seals used must be suitable for the operational conditions and comply with legal seals regulations and relevant standards. Subject to change without notice Criteria Pipeline design FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH 49 Preparing for Installation Clearance next to the pipeline Fig. 13 Space required during installation B ≈ 500 A ≈ 850 3.2.2.3 = Lateral clearance required on both sides of the pipeline for using the fitting tool = Lateral clearance required on both sides of the pipeline for operation of FLOWSIC300 without using the fitting tool Subject to change without notice A B 50 FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH Preparing for Installation 3.2.3 Further notes for project planning Applications with specific conditions or installation in vertical pipelines a) Applications with wet gas Condensate can accumulate in the nozzle pipes. Following solutions can help avoiding measuring problems (malfunctions caused by solid-borne noise, see Service Manual) or damage when removing the ultrasonic sensors (condensate escaping). ▸ Use a nozzle position which prevents accumulations of condensate in nozzle pipes. ▸ Use a closed continuous or periodical condensate drain with backflow to the pipeline. Technical solutions are available on request depending on operating conditions (pressure, temperature). ▸ Obtain approval from the plant operator before installing condensate drains. ▸ Isolate the nozzle pipe to reduce dew point underflow (only for low gas temperatures < 100 °C). b) Short inlet and outlet paths (→ p. 48, § Fig. 12) ▸ Use the best possible positioning for the measuring path (consult SICK for support). Installation location for separate pressure and temperature sensors (option) ▸ Install pressure tap and immersion sleeves for separate sensors as follows: Component Pressure tap Immersion sleeve for temperature measurement Installation location – At measuring location – In the 10 - 2 o'clock area on the pipeline – After the measuring location (in flow direction) – Distance to center of measuring path = 3D Subject to change without notice Example diagram for sensor integration in the system → p. 25, §2.3.4 FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH 51 Preparing for Installation 3. 3 Preparation work 3.3.1 Checking delivery ▸ ▸ ▸ 3.3.2 Check delivery includes all ordered parts. Check delivered parts for damage. Especially: – Transducer surfaces of the ultrasonic sensors – Sealing surfaces on flanges – Inside of the spool piece (when delivered) Document any damage determined and report to the manufacturer. Checking operating conditions CAUTION: Risks from incorrect flowing conditions ▸ Ensure the conditions at the installation location and the specifications on type plates match (→ p. 175, § Fig. 69, → p. 27, § Fig. 5). Otherwise the FLOWSIC300 does not run reliably and is possibly unsafe. 3.3.3 Tools required Subject to change without notice The following tools are required for installation: ● Allen keys, 6 mm, 8 mm, 14 mm ● Torque wrench, measuring range 155 Nm ● Attachment for torque wrench 24 mm, 30 mm ● Wrenches, SW 11 mm, 24 mm, 27 mm, 30 mm 52 FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH Preparing for Installation 3.4 General safety information CAUTION: General hazards during installation ▸ Observe the safety information in these Operating Instructions. ▸ Observe legal regulations, standards and guidelines. ▸ Observe local regulations, safety regulations and company-internal operating instructions. ▸ Check whether special regulations are applicable for the respective plant. ▸ Check whether particular local hazards exist. Take suitable protective measures when necessary. ▸ Use suitable lifting equipment during transport and assembly. Observe maximum loads. ▸ Ensure personal protective equipment is used. Otherwise health risks and material damage can occur. WARNING: Hazards through electrical voltage ▸ Before working on mains connections or live components: Make sure the power supply to the device is switched off (disconnected from the mains and potential-free). ▸ Before switching the mains supply on: Ensure a safe state (e.g. fit shock protection, close housing). 3.5 Safety information on gas tightness Subject to change without notice WARNING: Hazards through leaks ▸ During installation and maintenance, ensure gas tightness is secured and will remain secured. ▸ Check condition of seals and sealing surfaces. Only fit intact, clean seals. Replace questionable seals. Only use replacement seals that match the individual specification (information → p. 13, §1.4.1). ▸ Only put the measuring system into operation when overall gas tightness is ensured. Otherwise possible risk of explosions and health hazards. FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH 53 Subject to change without notice Preparing for Installation 54 FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH Installing the Nozzles FLOWSIC300 4 Installing the Nozzles Subject to change without notice Safety information Marking and assembling on the pipeline Fitting the spool piece (alternative, option) FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH 55 Installing the Nozzles 4. 1 Assembly information 4.1.1 Safety information for assembly work CAUTION: General accident hazards Some components are heavy. Incorrect and careless handling of these components creates accident hazards. ▸ Do not work under suspended loads (suspended heavy components). ▸ Secure components and tools against dropping and unintentional movement. ▸ Wear safe working clothes (safety shoes, gloves). ▸ Warn other persons as necessary. WARNING: Hazards through gas ▸ Observe the safety information in §1.2.1 (→ p. 10). WARNING: Hazard through unstable assembly of the nozzle The maximum load torque when fitting the device with the fitting tool can be up to 300 Nm. ▸ Consider the maximum load torque during mechanical installation and when welding the welding seams. ▸ If required, support the nozzles additionally on the pipeline in a suitable manner. ▸ Carry out welding work correctly (→ p. 10, §1.2.1). Subject to change without notice All dimensions are in mm (if not specified otherwise). 56 FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH Installing the Nozzles 4.1.2 Position of nozzles on the pipeline Position to pipe center 1-path configuration 2-path configuration ▸ Weld the nozzles on so that the measuring path ▸ Weld 2 nozzles parallel to each other on each goes through the middle of the pipeline. side of the pipeline. ▸ Distance to pipe center = each 60% of the pipe inner diameter. r 0.6 r 0.6 r Fitting angle ▸ Fit the nozzles at an angle of (α) = 60° to the pipeline (when not specified otherwise in the individual information). ▸ Fit the nozzles horizontal whenever possible. ● No liquid (e.g. condensate) can collect in the nozzles when these are horizontal. ● Procedure description → p. 62, §4.2.3 Fig. 14 Nozzle fitting angle (α) Top view Subject to change without notice α FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH 57 Installing the Nozzles 4. 2 Nozzle assembly Not applicable when a spool piece is included in the scope of delivery (description → p. 27, §2.5.1, fitting → p. 68, §4.3) 4.2.1 Assembly information Pipeline dimensions The exact actual inner diameter of the pipeline must be known at the installation location. A predefined specification from a standard is not sufficient. ▸ When necessary, measure the outer diameter and wall thickness of the pipeline. Installation dimensions The nozzle installation dimensions are required for configuring the measuring system (during initial start-up). ▸ Document all geometric dimensions determined during installation (see instructions). Precision required during assembly Inexact nozzle assembly can have a negative influence on measuring precision. ▸ Fit the nozzles at the marked positions with a precision of ± 1 mm. Subject to change without notice When a spool piece (→ p. 27, §2.5.1) with the option "3D measurement" is used, the nozzle position is determined with a precision of ± 0.1 mm. 58 FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH Installing the Nozzles 4.2.2 Marking the nozzle positions Step 1: Adapt the foil strip on the nozzle installation tool to the pipeline 1) Wind the foil strip at the measuring point with an overlap of 20-30 cm around the pipeline. – Cut off the protruding rest. – Ensure exact right-angled alignment – Secure the foil strip on the pipeline (e.g. with adhesive strips) 2) Mark the foil strip when the overlap starts. 3) Take the foil strip off and lay it out on a flat surface. Overlap line U (pipe circumference) For 1-path measurement: Wrap the strip up to where the overlap starts and then fold it so that the part corresponding to the pipe circumference is halved. Subject to change without notice ● The foil strip is delivered with the installation tool. ● Foil length = 5 m ● Foil width = 0.5 m FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH 59 Installing the Nozzles Step 2: Mark the nozzle positions on the foil strips 1-path configuration 2-path configuration 4a) Roll the strip out again and mark the kink line. Overlap line U/2 90 ° 4b) Fold the strip out again and mark the kink line as follows: Kink line 90 ° 90 ° 90 ° 2.498•r 2.498•r 0.6435•r 90 ° 0.6435•r r = D/2 (→ p. 57, §4.1.2) 90 ° 5) Draw guide lines (1) for the nozzle positions in a distance as listed in the Table, mark the crossing points (2) and draw marking points (3) in distance 60 mm (x) from the crossing points. The following Tables are valid for nominal pipe widths according to ANSI B36.10. If pipeline diameters deviate, the associated nozzle clearance can be calculated using the Geometry Calculation Sheet "Calc transducer distance". U/2 x x Nominal Size inch 4 5 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 42 48 52 56 a x x 2 Outer diameter mm 114.3 141.3 168.3 219.1 273 323.8 355.6 406.4 457.2 508 558.8 609.6 660.4 711.2 762 812.8 863.6 914.4 1066.8 1219.2 1321 1422 3 x = 60 mm Nozzle distance a mm inch 66 2.6 82 3.2 97 3.8 126 5.0 158 6.2 187 7.4 205 8.1 235 9.2 264 10.4 293 11.5 323 12.7 352 13.9 381 15.0 411 16.2 440 17.3 469 18.5 499 19.6 528 20.8 616 24.2 704 27.7 763 30.0 821 32.3 Nominal Size inch 4 5 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 42 48 52 56 6a) Measure and note values a and U/2 (required for calculating path angle and path length). 60 Path 2 Path 1 a x x x = 60 mm x 2 3 Outer diameter mm 114.3 141.3 168.3 219.1 273 323.8 355.6 406.4 457.2 508 558.8 609.6 660.4 711.2 762 812.8 863.6 914.4 1066.8 1219.2 1321 1422 1 Nozzle distance a mm inch 53 2.1 65 2.6 78 3.1 101 4.0 126 5.0 150 5.9 164 6.5 188 7.4 211 8.3 235 9.2 258 10.2 282 11.1 305 12.0 328 12.9 352 13.9 375 14.8 399 15.7 422 16.6 493 19.4 563 22.2 610 24.0 657 25.9 6a) Measure and note values a and U (required for calculating path angle and path length). FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH Subject to change without notice x U 1 Installing the Nozzles Step 3: Transfer the nozzle positions onto the pipeline 1-path configuration 2-path configuration 7) Wind the foil strip around the pipeline again at the measuring location. Fix the foil strip so that the crossing points are horizontally opposite each other. 8 Use a metal center punch to mark the nozzle positions with crossing and marking positions. Path 1 Path 2 Crossing point (marking for the center of the nozzle) Marking point (aid for aligning the nozzle) Crossing point (marking for the center of the nozzle) Marking point (aid for aligning the nozzle) Path 1 Path 2 9) Take the foil strip off again. Join the additional markings with lines. Marking lines Subject to change without notice Marking lines FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH 61 Installing the Nozzles 4.2.3 Welding the nozzle on Installation tool for nozzles ▸ Use the delivered installation tool for assembling the nozzles. Fig. 15 Installation tool for the nozzles (schematic) 4 3 2 1 2 3 4 Welding aid Centering disc 1 Threaded rod Centering disc 2 1 Step 1: Ensure safe conditions WARNING: Hazards due to combustible gases or high pressure Before commencing installation work: ▸ Ensure the pipeline is free from pressure and free from combustible substances. Purge the pipeline when necessary. ▸ Only carry out welding work when it is ensured that no risk of explosions can arise. ▸ Observe the safety information in §1.2.1 (→ p. 10) and §3.4 (→ p. 53). WARNING: Hazards during welding work ▸ Only allow skilled persons qualified for work on pressure lines to carry out the welding work. ▸ Observe laws, standards and guidelines. ▸ Observe local operating regulations. Comply with regulations of the plant operator. Subject to change without notice Step 2: Attach a welding aid 1 Screw welding aid (1) to the tip of threaded rod (3). 2 Position the tip of the threaded rod onto the crossing point and weld the welding aid to the pipeline. 62 FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH Installing the Nozzles Fig. 16 Positioning the welding aid View B A 1 View A 2 Marking lines B 1 α Standard: α = 60° Observe individual information, when delivered. 3 NOTICE: The deviation from the marking lines should not exceed 0.5 mm after welding. ▸ Check the welding aid for correct positioning after welding. ▸ If the deviation is larger than the nominal position: Loosen the welding aid and position again. Step 3: Fasten the nozzle 1 Push small centering disc (4) into the cone of welding aid (1) and fasten with nut (5). Fig. 17 Fitting the nozzle Subject to change without notice 4 5 6 7 8 9 1 Marking lines 2 Slide nozzle (6) over threaded rod and centering plate. 3 Position large centering disc (7) on the nozzle. FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH 63 Installing the Nozzles 4 Screw counternuts (8), (9) onto the threaded rod and secure the nozzle on the pipeline. Make sure the gap between the pipeline and the nozzle is sufficient to ensure the formation of a correct welding root. An uncoated wire with approx. 2 mm diameter, for example, can serve as spacer. 5 Align the nozzle so that the marking lines on the nozzle and pipe wall (→ § Fig. 17) are flush and tighten the screws until the nozzle is pressed against the wire and pipeline surface. Make sure the nozzle remains aligned correctly. 6 Attach the nozzle circumferential to the pipe wall. 7 Remove the wire. 8 Remove threaded rod with nuts and centering by turning the counternut (8) against fastening direction. Step 4: Finish the welding seam 1 Apply the welding heat as evenly as possible and keep it low to minimize warpage. Observe the maximum intermediate layer temperature according to the welding instructions. 2 Determine the distance between pipe outer wall and centering (D1; see also → p. 67, § Fig. 22). Fig. 18 Determine the nozzle length when welded (Nozzle) Centering Dx Step 5: Weld the second nozzle on ▸ Weld the second nozzle on the opposite side of the pipeline in the same manner. ▸ Determine the distance between pipeline outer wall and centering again (D2). Subject to change without notice WARNING: Risk of explosion/health hazard A faulty welding seam can allow gas to escape from the pipeline. This can immediately lead to a dangerous situation. ▸ Ensure welding seams are gas-tight. ▸ Check strength and durable tightness of the welding seams. 64 FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH Installing the Nozzles 4.2.4 Determining the path length and installation angle Purpose The path length (length of ultrasonic path) and the path angle must be determined as exact as possible to obtain optimum measuring precision. These values must be entered during initial start-up (→ p. 122, §8.5). Variant 1 (with "open" pipeline) 1 Determine the distance of the sealing surfaces of both nozzles R and angles ß1, ß2 as exact as possible (→ Fig. 19). Fig. 19 Installation parameters L R NL S = = = = Path length Distance of nozzle sealing surfaces Nominal length of probe (standard = 206 mm) Seal thickness (standard = 4 mm) Path angle α = 60° (nominal value) 2 Calculate the path length L Fig. 20 Formula for the calculation of path length L Subject to change without notice L = R + 2 S – 2 NL FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH 65 Installing the Nozzles Variant 2 (alternative, when R cannot be determined exactly) 1 Determine dimensions a, D1, D2, β1, β2 as exact as possible (→ § Fig. 22). 2 Use the FLOWSIC300 geometry tool provided to calculate path angle α and path length L (formulas → p. 67, § Fig. 23) or calculate manually. Note calculation results and make these available for initial start-up. ● The geometry tool is a calculation Table for Microsoft Excel (→ Fig. 21). ● Geometric dimension precision influences the overall measurement uncertainty. Geometry tool Subject to change without notice Fig. 21 66 FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH Installing the Nozzles Fig. 22 Determining the path length and installation angle L NL D1, D2 α β1, β2 U S f = = = = = = = = Path length Nominal length of probe (standard = 206 mm) Nozzle lengths when welded (→ p. 64, § Fig. 18) Path angle Assembly angles of nozzles [1] Pipeline circumference at installation location Seal thickness = 4 mm 1.0 [2] [1] Standard: 60° [2] Value valid for 1-path measurement. For 2-path measurement (option): f = 0.8. Fig. 23 Formulas for geometric parameters b = a – NL – D1 – S cos 1 – NL – D2 – S cos 2 U k = ---- f – NL – D1 – S sin 1 – NL – D2 – S sin 2 L= 2 b +k 2 Subject to change without notice k = atan --- b FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH 67 Installing the Nozzles 4. 3 Installing the spool piece (optional) This information is only valid when the scope of delivery includes a spool piece (→ p. 27, §2.5.1). 4.3.1 Safety information for the spool piece 4.3.1.1 Transport safely ▸ Ensure the spool piece is always fixed and secured. ▸ Handle with care - avoid damage. ▸ Lift correctly (→ § Fig. 24). Fig. 24 Lifting requirements Max. 45° Lifting lugs 4.3.1.2 Store properly ▸ Comply with permissible storage conditions (→ p. 167, §12.2). ▸ Protect sealing surfaces and the inside of the spool piece against corrosion during storage (e.g. with Anticorit-Spray). Spool pieces made of stainless steel may not need corrosion protection. 68 FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH Subject to change without notice CAUTION: Hazard through improper lifting Improper lifting leads to accident and injury risks, and the spool piece could be damaged. ▸ Only use the planned lifting lugs as lifting points. ▸ Consider the weight and size of the spool piece. ▸ Only use lifting equipment and load attachments (e.g. lifting belts) suitable for the spool piece weight. Compare the type plates of the lifting equipment and spool piece. ▸ Do not work under suspended loads. ▸ Also fasten any devices mounted to the lifting equipment and brace these during transport. Installing the Nozzles 4.3.2 Inserting the spool piece in the pipeline ▸ ▸ ▸ ▸ Insert the spool piece in the pipeline at the measuring location (→ p. 48, §3.2.2). Fit the spool piece so that the following conditions are met: – The spool piece arrow markings point in pipeline flow direction. – The side nozzles are horizontal. – The spool piece is centered as exactly as possible in the pipeline. Fit flange seals carefully. – Check condition of sealing surfaces. – Only use seals in perfect condition. Tighten flange screws correctly: – Crosswise, alternately and in small steps – Finally tighten all screws with the specified tightening torque. NOTICE: ▸ Fit the ultrasonic sensors before pipeline start-up (→ p. 71, §5 or → p. 77, §6). 4.3.3 Determining the pipeline diameter Pipeline inner diameter Di is used for configuring the geometric data (). It can be calculated as follows: U Di = ---- – 2 W U = Pipeline circumference at installation location W = Wall thickness Recommendations: ▸ Determine the wall thickness by measuring (e.g. with ultrasonic measurement technology). ▸ Measure the wall thickness at four different points and use the mean value. Subject to change without notice The actual wall thickness can vary by up to 13% of the wall thickness specified in corresponding standard. FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH 69 Subject to change without notice Installing the Nozzles 70 FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH Fitting the Sender/Receiver Units in Idle Operation (Cold Tap) FLOWSIC300 5 Fitting the Sender/Receiver Units in Idle Operation (Cold Tap) Subject to change without notice Safety information Fitting the sender/receiver units Removing the sender/receiver units FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH 71 Fitting the Sender/Receiver Units in Idle Operation (Cold Tap) 5. 1 Important information DANGER: Accident and health risks The information concerning the installation of the sender/receiver units and the ultrasonic sensors in this Chapter applies exclusively for work on a pipeline not in operation, does not contain hazardous or explosive gas or gas dangerous to health and is not under pressure. ▸ Before starting work, the planned measures must be explicitly approved by the plant operator and the following must be ensured by suitable measures for the complete duration of the work: – There is atmospheric pressure in the pipeline. – The pipeline does not contain gases which are dangerous, explosive or dangerous to health. – There is no risk of explosion in the vicinity of the pipeline. – The work will be monitored by a safety representative of the plant operator. ▸ The plant operator is responsible for ensuring and checking the safe state of the pipeline without dangerous gas. Fitting the sender/receiver units with hot tapping → p. 77, §6 5. 2 Fitting the sender/receiver units in idle operation /with non-pressurized line ▸ Carry out this procedure once for each nozzle. 5.2.1 Drilling a hole in the pipeline ▸ Holes for the ultrasonic path (example: 1-path measurement) Subject to change without notice Fig. 25 Drill a hole in the pipeline in the center of the nozzle position. – Fasten a suitable drilling tool on the nozzle. – Hole diameter: Dmin = 30 mm, Dmax = 35 mm 72 FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH Fitting the Sender/Receiver Units in Idle Operation (Cold Tap) 5.2.2 Fitting the sender/receiver unit ▸ Fitting the sender/receiver unit on the nozzle: – The safety pin on the sender/ receiver unit (marked red) must be aligned upwards to enable convenient working with the fitting tool. – Check/clean sealing surfaces – Flat seal – 4 M20 x 55 screws – Tightening torque: 155 Nm (use a torque wrench) 5.2.3 Installing the ultrasonic sensor 1 Remove the screw plugs on the locking ring of the sender/receiver unit. 2 Screw the handles in the locking ring Subject to change without notice 3 Loosen the release lock by pressing the safety pin down with a suitable tool FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH 73 Fitting the Sender/Receiver Units in Idle Operation (Cold Tap) 4 Unlock the sender/receiver unit: - Grip both handles. - Turn the locking ring towards marking "UNLOCK" to the stop (75°). 5 Prepare the sender/receiver unit and ultrasonic sensor: ▸ Check/clean sealing surfaces ▸ Check the sealing ring (O-ring) of the ultrasonic sensor and clean/replace when necessary. Subject to change without notice 6 Let the ultrasonic sensor slide into the sender/receiver unit (to the stop). For better handling, the delivered extraction tool (T-handle) can be screwed into the ultrasonic probe. 74 FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH Fitting the Sender/Receiver Units in Idle Operation (Cold Tap) 7 Lock the sender/receiver unit: - Turn the locking ring handles towards marking "LOCK" to the stop. - Unscrew the handles. 8 Refit the screw plugs. 9 Pull the probe cable out of the ultrasonic sensor (remove the plastic screw beforehand when necessary). Subject to change without notice 10 Connect the probe cable on the inside of the housing cover. 11 Check the housing cover seal for damage. 12 Fit the housing cover with the 4 screws. FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH 75 Fitting the Sender/Receiver Units in Idle Operation (Cold Tap) 5. 3 Leak tightness check after installation ▸ Recommendation: Carry out a leak tightness check after fitting the sender/ receiver units according to valid regulations and standards. Subject to change without notice 1 Fill the pipeline with gas and create the test pressure. 2 Check the installation for leak tightness. 76 FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH Fitting the Sender/Receiver Units in Running Operation (Hot Tap) FLOWSIC300 6 Fitting the Sender/Receiver Units in Running Operation (Hot Tap) Subject to change without notice Safety information Handling Fitting the sender/receiver units FLOWSIC300 · Operating Instructions · 8014244/YZF6/V1-1/2016-07 · © SICK Engineering GmbH 77 Fitting the Sender/Receiver Units in Running Operation (Hot Tap) 6. 1 Safety information for the fitting tool ● Fitting tool description → p. 28, §2.5.2 ● Fitting the sender/receiver units without fitting tool → p. 71, §5 6.1.1 Work safety ▸ ▸ ▸ ▸ ▸ ▸ 6.1.2 Safety of hydraulic equipment ▸ ▸ ▸ ▸ ▸ ▸ ▸ 6.1.3 Only use the fitting tool for the described purposes and not for other purposes (e.g. not as lifting equipment) Do not overload the equipment (observe operation displays). Wear suitable protective clothing (gloves, safety shoes). Do not work under suspended loads. Protect equipment against intense heat (over 65 °C). Do not use equipment or tools that are damaged or in a questionable condition. Observe the hydraulic pump Operating Instructions. Only work on a level, safe base. Check hydraulic couplings before use, clean when necessary. Do not bend hose lines and protect against damage. Avoid friction on edges and crimping. Before pumping, ensure mechanical and hydraulic connections are secure. Do not extend the pump lever of the hydraulic pump (e.g. with auxiliary means). Clean and store the equipment safely after use. Proper installation WARNING: Hazards through improper installation work See → p. 56, §4.1 Accident risk DANGER: Danger to life through careless handling If a sender/receiver unit is unlocked without the fitting tool fitted, the sender/ receiver unit can shoot out driven by the pressure in the gas line. The locking mechanism is blocked as long as the fitting tool is not mounted completely to prevent faulty operation. ▸ Unlock a sender/receiver unit only when the fitting tool is mounted and ready. Otherwise there is an immediate danger to life and the risk of severe injuries for persons in the flight path of the fitting tool shot out. Note: This also applies when the cover is fitted on the sender/receiver unit. A sender/receiver unit shot out can smash through the cover. ▸ Safety recommendation: Always remove the handles from the locking ring of the sender/receiver unit after locking. The handles on the locking ring of the sender/receiver unit can only be removed when locked. 78 FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH Subject to change without notice 6.1.4 Fitting the Sender/Receiver Units in Running Operation (Hot Tap) 6.2 Using the fitting tool WARNING: Explosion Hazard The fitting tool is not approved for operation in explosive atmosphere. When used on the pipeline, risk of explosion must be excluded or a possible ignition hazard signaled in time by suitable means, e.g. monitoring with a gas detector. 6.2.1 Assembling the fitting tool 1 Check hydraulic couplings before use, clean when necessary. 2 Connect the hydraulic cylinder and hydraulic pump with the hydraulic hose (plug-in connections). The hydraulic pump and hydraulic hose are filled with hydraulic oil and ready for operation when delivered. 6.2.2 Moving the hydraulic ▸ Observe the hydraulic pump Operating Instructions. Extending the hydraulic piston: 1 Close the pressure valve of the hydraulic pump (turn handwheel clockwise to stop). 2 Activate the pump lever of the hydraulic pump. ▸ Watch the pressure gauge on the hydraulic pump. The movement range of the hydraulic piston is limited by the oil level in the hydraulic pump. Subject to change without notice Retracting the hydraulic piston: ▸ Slowly open the pressure valve of the hydraulic pump. ▸ When removing an ultrasonic sensor during running pipeline operation: Only open the pressure valve slightly and listen to the sound of the retracting hydraulic piston. First open the pressure valve fully when the hydraulic piston is in the end position. ▸ If the hydraulic cylinder is not fitted: Open the pressure valve and push the hydraulic piston manually into the hydraulic cylinder (use the wooden rod provided as aid). FLOWSIC300 · Operating Instructions · 8014244/YZF6/V1-1/2016-07 · © SICK Engineering GmbH 79 Fitting the Sender/Receiver Units in Running Operation (Hot Tap) 6.2.3 Setting the coupling ▸ Set the coupling appropriately before using the fitting tool: 1 Extend the coupling: - Close the pressure valve of the hydraulic pump. - Pump until the coupling appears. 2 Set the coupling as required: To fit: Unlocked To remove: Engaged 4 Press the hydraulic piston back into the hydraulic cylinder: - Open the pressure valve of the hydraulic pump. - Press the hydraulic cylinder manually into the hydraulic cylinder. 80 FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH Subject to change without notice 3 Checking the movement range of the hydraulic cylinder: - Carefully push out the hydraulic cylinder by pumping with the hydraulic pump. - Check whether the minimum dimension L = 120 mm is reached. - Do not push out the hydraulic cylinder more than L = 130 mm! - If the hydraulic cylinder cannot be pushed out at least L = 120 mm, check the oil level in the hydraulic pump. Replenish oil as required. Fitting the Sender/Receiver Units in Running Operation (Hot Tap) 6.3 Installing the sender/receiver unit and ball valve ▸ Carry out once on each nozzle. Subject to change without notice Information ● Fit the sender/receiver unit directly on the nozzle flange. It fastens the ultrasonic sensor. The sender/receiver unit is closed pressure-tight when an ultrasonic sensor is installed. ● When the ultrasonic sensors are to be installed with the pipeline in operation (hot tapping), the ball valve must be positioned and the fitting tool used. Fitting tool and ball valve form a pressure lock. Only use the fitting tool together with the ball valve. ● An ultrasonic sensor must be fitted before the ball valve can be removed again. FLOWSIC300 · Operating Instructions · 8014244/YZF6/V1-1/2016-07 · © SICK Engineering GmbH 81 Fitting the Sender/Receiver Units in Running Operation (Hot Tap) Prerequisites ● Nozzles on the pipeline (→ p. 58, §4.2) ● SW 11 Wrench [1] ● SW 8 Allen key [2] [1] For the toggle valve of the ball valve; alternative: metal rod or punch ø 4.0 … 4.5 mm. [2] For the bypass valve of the ball valve. Procedure 1 Fitting the sender/receiver unit on the nozzle: – The safety pin on the locking ring (marked red) must be aligned upwards to enable convenient working with the fitting tool. – Check/clean sealing surfaces – Flat seal (pre-assembled) – 4 M20 x 55 screws – Tightening torque: 220 Nm (use a torque wrench) 2 Remove the screw plugs on the locking ring of the sender/receiver unit. 3 Screw the handles in the locking ring of the sender/receiver unit. Subject to change without notice 4 Loosen the release lock by pressing the safety pin down with a suitable tool 82 FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH Fitting the Sender/Receiver Units in Running Operation (Hot Tap) 5 Unlock the sender/receiver unit: - Grip both handles. - Turn the locking ring towards marking "UNLOCK" to the stop (75°). 6 Fit the ball valve of the fitting tool on the locking ring. – Check/clean sealing surfaces – Flat seal between ball valve and locking ring – Screws: M16 x 120 – Tightening torque: 140 Nm (use a torque wrench) 1 2 Subject to change without notice 7 Prepare the ball valve: ▸ Close bypass valve (1). ▸ Close toggle valve (2). ▸ Check function (move lever). FLOWSIC300 · Operating Instructions · 8014244/YZF6/V1-1/2016-07 · © SICK Engineering GmbH 83 Fitting the Sender/Receiver Units in Running Operation (Hot Tap) 6. 4 Drilling the holes in the pipeline WARNING: Hazards during hot tapping When sender/receiver units are installed on the pipeline when the pipeline is in operation (hot tapping): ▸ Only have this work done by skilled persons qualified for hot tapping. ▸ Comply with all legal, general and company-internal regulations. ▸ Only start installation work when all planned measures have been checked and approved by the plant operator. Only once on each nozzle. ▸ Drill a hole in the pipeline in the center of the nozzle position. – Fasten a suitable drilling tool on the ball valve. – Hole diameter: Dmin = 30 mm, Dmax = 35 mm This work requires special tools (hot tapping tool) and special technical knowledge. Fig. 26 Hot tapping illustration (Example) Subject to change without notice WARNING: Accident risk When the hole is ready: Gas flows through the pipeline when the ball valve is opened. ▸ Keep the ball valve closed and fitted until an ultrasonic sensor has been fitted (procedure → p. 85, §6.5). ▸ Secure the ball valve against unintentional activation (use lever lock on ball valve). ▸ Instruct other persons accordingly. 84 FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH Fitting the Sender/Receiver Units in Running Operation (Hot Tap) 6.5 Fitting an ultrasonic sensor with fitting tool Only valid for hot tapping installation (normal procedure → p. 73, §5.2.3). ▸ Carry out once on each nozzle. → p. 28, §2.5.2 → p. 58, §4.2 → p. 81, §6.3 → p. 81, §6.3 → p. 81, §6.3 Subject to change without notice Prerequisites ● FLOWSIC300 fitting tool available and ready for use ● Nozzle installed gas-tight on pipeline ● Hole for ultrasonic path in pipeline drilled correctly ● Sender/receiver unit fitted on nozzle and locked ● Ball valve of fitting tool fitted on sender/receiver unit and locked FLOWSIC300 · Operating Instructions · 8014244/YZF6/V1-1/2016-07 · © SICK Engineering GmbH 85 Fitting the Sender/Receiver Units in Running Operation (Hot Tap) Step 1: Preparations CAUTION: Accident risk As long as an ultrasonic sensor is not installed: Gas flows through the pipeline when the ball valve is opened. ▸ Keep the ball valve closed and fitted until an ultransonic sensor has been fitted. ▸ Secure the ball valve against unintentional activation (use lever lock on ball valve). ▸ Instruct other persons accordingly. 1 Switch the hydraulic cylinder coupling to "Fit" (procedure → p. 80, §6.2.3). ▸ The ultrasonic probe must not engage on the hydraulic piston during installation. ▸ When applicable, check with the ultrasonic probe that it does not engage. 2 Inspect the sealing ring (O-ring on ultrasonic sensor): - If the sealing ring is damaged: Replace the sealing ring. - If the sealing ring is not greased: Clean the O-ring and apply a greasy film. Subject to change without notice 3 Place the ultrasonic sensor in the hydraulic cylinder: - Open the pressure valve of the hydraulic pump. - Push the hydraulic piston in the hydraulic cylinder (use the plastic or wooden rod provided on delivery). - Let the ultrasonic sensor slide into the hydraulic cylinder to the stop as shown below. 86 FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH Fitting the Sender/Receiver Units in Running Operation (Hot Tap) Step 2: Position the hydraulic cylinder 1 Position the hydraulic cylinder (with ultrasonic sensor inside) onto the ball valve. - Check/clean sealing surfaces and sealing ring (O-ring) of the hydraulic cylinder. Replace the sealing ring when necessary. - Tighten 8 screws M16 x 45, tightening torque approx. 20 Nm (O-ring ensures leak tightness). Note: One of the fastening screws releases the locking mechanism of the sender/receiver unit. Subject to change without notice 2 Compensate the pressure: - Slowly open the bypass valve of the ball valve. - Wait until the pressure display on the ball valve remains constant (pipeline pressure). - If the pressure on the pressure gauge is implausible, check for correct installation and function of all components. - Close the bypass valve. FLOWSIC300 · Operating Instructions · 8014244/YZF6/V1-1/2016-07 · © SICK Engineering GmbH 87 Fitting the Sender/Receiver Units in Running Operation (Hot Tap) Subject to change without notice 3 Slowly open the ball valve to the stop. 88 FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH Fitting the Sender/Receiver Units in Running Operation (Hot Tap) Step 3: Fit the ultrasonic sensor 1 Remove the screw plugs of the locking ring of the sender/receiver unit. 2 Screw the handles in the locking ring. Subject to change without notice 3 Unlock the sender/receiver unit (if not already done so): - Grip both handles. - Turn the locking ring of the sender/receiver unit towards marking “UNLOCK” to the stop (75°). FLOWSIC300 · Operating Instructions · 8014244/YZF6/V1-1/2016-07 · © SICK Engineering GmbH 89 Fitting the Sender/Receiver Units in Running Operation (Hot Tap) 4 Push the ultrasonic sensor into the sender/receiver unit: - Close pressure valve (P) of the hydraulic pump. - Watch the hydraulic pressure on the pressure gauge of the hydraulic pump. Pump carefully until the hydraulic pressure rises above the pressure displayed on the ball valve (= pressure in pipeline). P ● The hydraulic pressure must overcome the pipeline pressure. ● The ultrasonic sensor is in the end position (hydraulic piston can no longer be moved) when the hydraulic pressure rises clearly above the pipeline pressure. ● The hydraulic pump has a safety valve against overpressure. ● The pipeline is sealed by the sender/receiver unit when the ultrasonic sensor is fitted and locked. - 90 Refit the screw plugs. FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH Subject to change without notice 5 Lock the sender/receiver unit: - Grip both handles. - Turn the locking ring handles towards marking "LOCK" to the stop. - Unscrew the handles. Fitting the Sender/Receiver Units in Running Operation (Hot Tap) Step 4: Remove the fitting tool 1 Let the hydraulic piston slide back: - Slowly open pressure valve (P) of the hydraulic pump slightly. Listen to the sound of the retracting hydraulic piston. - When the hydraulic piston is in the end position: Open the pressure valve of the hydraulic pump completely. P WARNING: Hazardous gas (possibly explosive or toxic) When the ultrasonic sensors are removed and fitted, a significant volume of process gas (up to 120 dm³ with 100 bar/up to 12 dm³ with 10 bar) escapes via the toggle valve when the fitting tool is vented. The escaping process gas must be channeled off safely via the toggle valve (e.g. into a suitable container). ▸ On plants with toxic gases or gases otherwise harmful to health: Take appropriate protective measures to avoid health damage. ▸ On plants with explosive gases: Take appropriate protective measures to exclude risk of explosion. Subject to change without notice 2 Relieve the pressure: - Slowly open the toggle valve of the ball valve. - Wait until the pressure display on the ball valve remains constant (ambient pressure). - Close the toggle valve again. FLOWSIC300 · Operating Instructions · 8014244/YZF6/V1-1/2016-07 · © SICK Engineering GmbH 91 Fitting the Sender/Receiver Units in Running Operation (Hot Tap) 3 Remove the hydraulic cylinder. ▸ Separate the hydraulic pump from the hydraulic cylinder as required. 4 Remove the ball valve. 5 Check that the sender/receiver unit is gas-tight. WARNING: Hazards through leaks Operation in leaky condition is not allowed and possibly dangerous. If gas escapes from the sender/receiver unit: 1 Remove the ultrasonic sensor again (see Service Manual); 2 Check the sealing ring on the ultrasonic sensor and renew as required. 3 Then carefully refit the ultrasonic sensor. Step 5: Fit the cover Pull the probe connection cable from the ultrasonic sensor. Connect the probe connection cable on the inside of the housing cover. Check the housing cover seal for damage. Fit the housing cover with the 4 screws. Subject to change without notice 1 2 3 4 5 If present: Connect the connection cable to the SPU to the outside of the housing cover. 92 FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH Installing the Electronics Unit FLOWSIC300 7 Installing the Electronics Unit Subject to change without notice Fitting the electronics unit Cable specifications Electrical installation Information on safe operation FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH 93 Installing the Electronics Unit 7. 1 Fitting the electronics unit 7.1.1 Fitting information ● The connection cables between the electronics unit and sender/receiver unit are maximum 15 m long. ● Voltage supply, signal lines and interfaces are connected to the rear side of the SPU (→ p. 100, §7.2.4). ● The SPU can be turned (→ p. 96, §7.1.4). ● The junction box below the signal processing unit need not be opened. NOTICE: Risk of damage ▸ Fasten load handling equipment (when used) to the assembly lugs of the electronics unit. Otherwise the SPU can be damaged. 7.1.2 Installation location requirements ▸ ▸ ▸ ▸ ▸ Subject to change without notice ▸ Install the electronics unit in a protected location that is easily accessible. Consider space requirements for plugs and cables. Select an installation location free from vibrations. Comply with the permissible ambient temperature (→ p. 167, §12.2). Shield against heat radiation from other objects. Protect against direct sunlight. Recommendation: Fit weather protection when installing outdoors (e.g. metal plate roof). Select an installation location free of chemical influence (especially for use in Ex Zone 2). 94 FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH Installing the Electronics Unit 7.1.3 Fastening the electronics unit Fig. 27 Electronics unit mm (inch) 348 (13.7) 400 (15.75) [1] 60.3 (2.0) A B 211 (8.31) 255 (10.04) 150 (5.91) 182 (7.17) A Pipe clip (in scope of delivery) B Fastening clip (optional) Table 2 [1] For connection cables with protective metal hose: 470 (18.50) Fastening methods for the electronics units Fastening method Pipe clips Threaded bushes Subject to change without notice Assembly lugs Procedure ▸ Fasten the rear side of the electronics unit to a vertical 2 inch pipe with the pipe clips (→ § Fig. 27). 1 Remove the pipe clips. 2 Use the threaded bushes (M8) on the rear side (→ p. 96, § Fig. 28). 1 Remove the pipe clips. 2 Fit the optional fastening clips to the rear side and use for fastening. FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH 95 Installing the Electronics Unit Fig. 28 Threaded bushes on the rear side of the electronics unit 7.1.4 Turning the SPU After loosening the locating screw, the SPU can be turned for better access (→ § Fig. 29). Fig. 29 Turning the SPU. Fixing screw 3 mm Allen key Max. 330° NOTICE: ▸ Secure the selected position. 7.1.5 Connecting the connection cable Subject to change without notice Carry out once for each sender/receiver unit: ▸ Lay the connection cable between the sender/receiver unit and electronics unit (→ p. 22, § Fig. 2). ▸ Connect the cable at both ends. Use the lock of the plug system. 96 FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH Installing the Electronics Unit 7.2 Electrical installation Work required for the electrical installation of the FLOWSIC300 (laying and connecting the power supply cable and signal lines) is not part of the scope of delivery. 7.2.1 General information Prerequisites ▸ Fully complete installation work of the sender/receiver units (see as from p. 56, § 4.1). ▸ Comply with cable specifications (→ p. 98, §7.2.2). External mains switch ▸ Install a switch close to the device to be able to switch the auxiliary voltage of the FLOWSIC300 on and off. The FLOWSIC300 does not have an own mains switch. European standard EN 61010 specifies that any fix-mounted devices not having an own mains switch must be equipped with an external mains switch. Laying cables ▸ Protect cables against mechanical damage (install in cable ducts or tubes). ▸ Observe permissible bending radii for cables (standard for multilead cables: 6x cable diameter). ▸ Keep connections to cable harnesses or shields as short as possible. ▸ Lay the sensor connection cables separate from cables carrying voltage. ▸ Lay the sensor connection cables separately to prevent electromagnetic interference. ▸ Lay all cables so that no hazard exists for the intrinsic safety of FLOWSIC300. Subject to change without notice WARNING: Hazard ▸ Always 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. ▸ Take all necessary precautions to avoid local or plant-specific dangers. FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH 97 Installing the Electronics Unit 7.2.2 Cable specifications WARNING: Hazards through wrong cables Cables must meet the requirements for potentially explosive atmospheres (see e.g. EN 60079-14 and other relevant standards). ▸ Only use cables suitable for use in the respective potentially explosive atmosphere. Power supply Specification Two leads Cable type Remark Ground the shielding (if present) on one side. Min./ max. cross-section 0.5 mm2 / 2.5 mm2 (20 to 12 AWG) Maximum cable length Depending on loop resistance; Max. current 150 mA (peaks) Minimum input voltage on FLOWSIC300 12 V Cable diameter 6 … 12 mm Fixing range of cable glands Auxiliary voltage specification → p. 167, §12.2 Digital output / current output Specification Twisted pair, shielded Cable type Min./ max. cross-section 2 x 0.5 mm2 (2 x 20 AWG) / 1 mm2 (2x 20-18 AWG) Maximum cable length Cable diameter Remark Connect shielding at other end to ground terminal Do not connect unused conductor pairs and prevent them from accidental short-circuit Loop resistance including load ≤ 200 Ω 6 … 12 mm Fixing range of cable glands Serial port (RS485) Specification Twisted pair, shielded, cable impedance approx. 100 … 150 W, low cable capacitance: ≤ 100 pF/m Min./ max. cross-section 2 x 0.5 mm2 (2 x 20 AWG) / 1 mm2 (2x 20-18 AWG) Maximum cable length – 300 m at 0.5 mm2 (20 AWG) – 750 m at 0.75 mm2 (18 AWG) Cable type 6 … 12 mm Do not connect unused conductor pairs and prevent them from accidental short-circuit Fixing range of the cable glands Subject to change without notice Cable diameter Remark Connect shielding at other end to ground terminal 98 FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH Installing the Electronics Unit 7.2.3 Checking the cable loops Check the cable loops to verify that the cables are connected correctly. Proceed as follows: ▸ Disconnect both ends of the cable of the loop to be tested. This is to prevent connected devices from interfering with the measurement. ▸ Test the entire cable loop between electronics unit and terminal device by measuring the loop resistance. ▸ When the insulation resistance of the cable loops is to be checked: Disconnect the cables from the electronics unit before using the insulation test device. Reconnect cables after the test. WARNING: Risk of explosions in potentially explosive atmospheres Before opening the rear housing cover (Exe terminal compartment) and before connecting or disconnecting lines: ▸ Establish a state disconnected from the mains and potential-free. [1] [1] Not applicable for intrinsically safe installations. WARNING: Risk of explosions in potentially explosive atmospheres Before opening the front housing cover (with front window) of the SPU: ▸ Establish a state disconnected from the mains and potential-free. ▸ Switch the FLOWSIC300 off (interrupt auxiliary voltage) and then wait at least 10 minutes. Subject to change without notice NOTICE: Incorrect cabling may cause failure of the FLOWSIC300! This will invalidate warranty claims. The manufacturer assumes no liability for consequential damage. FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH 99 Installing the Electronics Unit 7.2.4 SPU terminal compartment Opening the rear housing cover ▸ Loosen the securing clip using a 3 mm Allen key. ▸ Turn the rear housing cover counterclockwise and take it off. NOTICE: ▸ Only use "LOCTITE 8156" as lubricant for the housing cover. The connection plan is shown on the inside of the cover (schematic). Fig. 30 SPU housing Open the cover Cover Securing clip Terminal compartment at the rear of the SPU (see Section → §7.2.2 for North American wiring specification equivalents) Cable gland HSK-K, M 20 x 1.5, plastic (EU) or ½ in NPT (North America) Power supply 2 x 1.5 mm2 (LiYCY or equivalent) Digital output / current output 4 x 2 x 0.5 mm2 (Li2YCY [TP] or equivalent) MODBUS 4 x 2 x 0.5 mm2 (Li2YCY [TP] or equivalent) 100 Bridge 2 Cover for power supply terminals 1 Cable duct for internal 10-pole cable 10-pole terminal block for signal inputs and outputs FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH Subject to change without notice Fig. 31 Installing the Electronics Unit Fig. 32 Terminal assignment in terminal compartment of the FLOWSIC300 SPU Connection compartment Power supply Field connections (10-pole terminal block) PE Subject to change without notice Terminals 2 and PE are bridged internally, i.e. there is no galvanic separation between PE and negative potential (see → § Fig. 31). FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH 101 Installing the Electronics Unit 7.2.5 Terminal assignment Assign the terminals in the SPU connection compartment (→ § Fig. 32) as shown in the following Table. No. Connection for 1 Power supply 2 Analog output Function Terminal 1+, 231, 32 Value → p. 167, §12.2 4...20 mA, RL < 250 Ω HART bus Modbus (RS485) Passive 33, 34 1200 baud, 8 data bits, odd parity, 1 stop bit 9600 baud, 8 data bits, no parity, 1 stop bit Active 3 Serial port 4 Digital output DO 1 (HF 1) 5 Digital output DO 2 Passive 41, 42 6 Digital output DO 3 Passive 81, 82 51, 52 fmax = 6 kHz, pulse width 0.05 s – 1 s Range: Variable number of pulses per volume unit “closed": 0 V ≤ UCE L ≤ 2 V, 2 mA ≤ ICE L ≤ 20 mA (L=Low) “open": 16 V ≤ UCE H ≤ 30 V, 0 mA ≤ ICE H ≤ 0.2 mA (H=High) “closed": 0 V ≤ UCE L ≤ 2 V, 2 mA ≤ ICE L ≤ 20 mA (L=Low) “open": 16 V ≤ UCE H ≤ 30 V, 0 mA ≤ ICE H ≤ 0.2 mA (H=High) “Check request" (standard) “closed": 0 V ≤ UCE L ≤ 2 V, 2 mA ≤ ICE L ≤ 20 mA (L=Low) “open": 16 V ≤ UCE H ≤ 30 V, 0 mA ≤ ICE H ≤ 0.2 mA (H=High) “Flow direction" (standard) (alternative “Warning") Remark Baud rate to be set through software With NAMUR contact for connection to switching amplifier (to DIN 19234) NOTICE: The connections of the ultrasonic sensors are electrically intrinsically safe and are safely separated from one another and from other non-intrinsically safe circuits. The sensors may be connected and disconnected during operation as long as the safe separation of circuits has been preserved in every respect. ▸ In order to ensure this, the respective sensor connection cable should be disconnected at both ends (disconnect the electronics side first, and then if necessary, the sensor side unless the TNC connector is suitably fixed to prevent any uncontrolled movement). ▸ Operation using sensors or cables not part of the original delivery or with sensors/components from other manufacturers is not permitted. 102 FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH Subject to change without notice NOTICE: Within explosion-protected areas, the FLOWSIC300 must be connected via ground terminals with the equipotential bonding system. ▸ For measurement reasons, the equipotential bonding must, as far as possible, be identical to the pipeline potential or protective ground. ▸ Additional grounding with the protective conductor via the terminals is not permitted! Installing the Electronics Unit 7.2.6 Requirements for use in hazardous areas with potentially explosive atmospheres Intended use The FLOWSIC300 is suitable for use in hazardous areas classified as Zone 1 and Zone 2. Certification in accordance with ATEX II 1/2 G Ex de ib [ia] IIC T4 II 1/2 G Ex de ib [ia] IIA T4 Permitted ambient temperature range -40°C to +60°C EC Type Examination Certificate_ TÜV 10 ATEX 556259 X IECEx Certification (in preparation) Gb/Ga Ex de ib [ia Ga] IIC T4 Gb/Ga Ex de ib [ia Ga] IIA T4 Permitted ambient temperature range -40°C to +60°C IECEx Certificate of Conformity: see type plate FLOWSIC300 FLOWSIC300 components and their type of protection Aux. power Power supply 1+ 2- PE Digital output RS485 Digital output Field connections Digital output Digital output 31 32 33 34 51 52 41 42 81 82 Connection compartment “e”, “i”,according to EN/IEC 60079-7 and EN/IEC60069-11 Fig. 33 Signal Processing Unit (SPU) Pressure-tight compartment "d" Compliant with EN/IEC 60079-1 PE Subject to change without notice Junction box Ultrasonic sensors "ia" Compliant with EN /IEC 60079-11 and EN /IEC 60079-26 FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH 103 Installing the Electronics Unit Operating conditions for the ultrasonic sensors The FLOWSIC300 is designed for use in hazardous areas with potentially explosive atmospheres only under normal atmospheric conditions. The atmospheric conditions must be within the following ranges: – Ambient pressure range 80 kPa (0.8 bar) to 110 kPa (1.1 bar) – Air with normal oxygen content, typically 21 % v/v The ambient temperature must be within the range specified at the SPU type plate, e.g -40°C to +60°C. Once the FLOWSIC300 is installed in the pipeline, the SPU becomes a part of the pipeline. The wall of the pipeline and the meter body is then deemed a zone-separating barrier. The figure below helps in understanding the different situations for a possible application and shows what operating conditions apply. Ex-Zones Case 1: Case 2: Case 3: 104 Zone 1 or 2 Zone 1 or 2 Zone 1 or 2 Non-Ex atmosphere Zone 1 or 2 Zone 0 ● The pipeline contains a nonexplosive mixture. The gas mixture may be combustible. ● Gas pressure and gas temperature may be within the range specified by the tag on the meter body. ● The area inside the pipeline is classified as hazardous area Zone 1 or 2. ● Gas pressure must be in the range from 80 kPa to 110 kPa (normal atmospheric condition) ● Gas temperature must be within the permitted ambient temperature range specified by the type plate on the SPU ● The area inside the pipeline is classified as hazardous area Zone 0. ● Gas pressure must be in the range from 80 kPa to 110 kPa (normal atmospheric condition) ● Gas temperature must in the range from -20°C to 60°C. FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH Subject to change without notice Fig. 34 Installing the Electronics Unit Additional requirements for operation of ultrasonic sensor in Zone 0 classified areas The FLOWSIC300 is marked with a minimum rating of II1/2 G Ex [ia] or Gb/Ga Ex [ia Ga]. Operation of ultrasonic sensors in Zone 0 The ultrasonic sensors are suitable for operation in Zone 0 at atmospheric conditions, i.e. ambient temperature -20 °C to 60 °C and ambient pressure 0.8 bar to 1.1 bar(a). Using ultrasonic sensors with housings made of titanium is only allowed in Zone 0 when it is ensured that solid parts transported by the medium (dust, other particles) could not create ignition hazards through impacts or friction. Otherwise, sensors made of stainless steel must be used. After installation and following every de-installation and reinstallation of the ultrasonic sensors, the seal effect must be appropriately checked. During operation, the leaktightness must be periodically checked and the seals replaced if necessary. After deinstallation and before every reinstallation the seals must be replaced according to the original assembly. Seals can be ordered from SICK (part number and serial number from type plate at SPU). Subject to change without notice NOTICE: The rise in the ambient temperature outside the pipeline due to a hot pipeline must be taken into account. The user must ensure that the ambient temperature around the electronics housing does not exceed the maximum permitted ambient temperature marked on the type plate of the FLOWSIC300. FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH 105 Installing the Electronics Unit Requirements regarding cabling – Cables must fulfill the requirements set forth in EN/IEC60079-14. – Cables that are subject to exceptional thermal, mechanical or chemical stress must be specially protected, e.g. by laying them in conduits. – Cables that are not installed fire proof must be flame retardant according to IEC 60332-1. – Cables for Ex e must comply with EN/IEC 60079-14 section 11. – Observe the clamping range of the cable glands for cable selection. – Use Ex e II or Ex i II certified cable glands with adequate ingress protection rating as alternate replacement only. – For intrinsically safe wiring and an ambient temperature range between -20°C to +60°C, the existing metal cable glands may be replaced with light-blue plastic cable glands (available on request). – Replace the existing cable glands with suitable cable glands if installation with armored cables is intended. – When delivered, the cable glands are secured by default with a sealing plug. If the cable glands are not used, only sealing plugs with EX e II approval must be used. – Conduit systems must comply with EN/IEC 60079-14, section 9.4 and 10.5. In addition, compliance with national and other relevant regulations is required – "Conduits" according to IEC 60614-2-1 and IEC60614-2-5 are not suitable. – Conduits must be protected against vibration. – Use a suitable thread sealant, as detailed in EN/IEC60079-14, section 9.4. – Protect stranded wires against fraying with ferrules. – Keep clearance and creepage distances for the connected wires in accordance with EN/IEC60079 and EN/IEC 60079-11 respectively. – Connect unused wires to ground or safeguard so that a short circuit with other conductive parts is excluded. – Carry out potential equalization in accordance with EN/IEC6079-14 – The meter body and the electronic housing must be connected to the potential equalization. – Where the FLOWSIC300 is installed in a grounded metal duct, no additional grounding is required for the meter body. The electronics housing must nevertheless be separately grounded. 106 FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH Subject to change without notice General requirements for installation – The documentation for hazardous area classification (zone classification) according to EN/IEC60079-10 must be available. – The equipment must be verified as suitable for use in the classified area. – Additional requirements must be observed for use of sensors in Zone 0 as described above. – After installation an initial test run of the complete equipment and the plant according to EN/IEC60079-17 must be performed before regular operation is started. Installing the Electronics Unit Connection of the FLOWSIC300 with associated equipment The terminal compartment of the FLOWSIC300 complies with the requirements of EN/IEC60079-7 or EN/IEC 60079-11. The FLOWSIC300 provides non-intrinsically safe wiring as well as intrinsically safe wiring with the interconnected associated equipment in the following manner: 1 Power supply connection and all other field connections as non-intrinsically safe wiring 2 Power supply connection and all other field connection as intrinsically safe wiring to Exi certified equipment in a Zone 1 or Zone 2 classified hazardous area or to [Exi] certified associated equipment in the safe area. 3 Power supply connection as non-intrinsically safe wiring and all other filed connection as intrinsically safe wiring. A combination of intrinsically safe and non-intrinsically safe wiring for the field connections is not permitted. Maximum voltage in the safe area must not exceed 253 V (Um = 253V). For intrinsically safe wiring: – The safety-relevant data in the EC Type Examination Certificate and the IECEx Certificate of Conformity must be observed. – Intrinsic safety for each circuit must be assessed in accordance with EN/IEC60079-14 section 12. – The safety-relevant parameters of interconnected equipment must comply with the following values: Uo < Ui, Io < Ii, Po < Pi, Ci + Ccable < Co, Li + Lcable < Lo The interconnection of two or more intrinsically safe outputs may require an additional assessment of intrinsic safety in accordance with EN /IEC60079-11. Ensure that the cover on the power supply connection is properly sealed for regular operation. For intrinsically safe wiring, rear cover can be removed and connecting and disconnecting is permitted while the circuits are live and as long as the safe separation between the circuits has been kept. Subject to change without notice WARNING: Explosion Hazard ● Do not open the enclosure while energized. ● Wait 10 minutes after power has been removed before opening the window cover. ● Do not open the cover of the terminal compartment while energized unless wiring is intrinsically safe. ● Do not remove the cover of the power supply while energized unless wiring is intrinsically safe. ● Do not connect or disconnect while circuits are live unless the area is known to be non-hazardous or wiring is intrinsically safe. ● Do not use the equipment if damaged (includes cables or terminals). FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH 107 Installing the Electronics Unit Information on safe operation in hazardous areas Approval of the ultrasonic sensors in Zone 0 is only valid for operation under atmospheric conditions. ● Explosion protection: II 1/2G Ex de ib [ia] IIC T4 or II 2G Ex de ib [ia] IIA T4 ● Ambient temperature range is from -40°C to +60°C. ● If terminals are assigned with intrinsically safe circuits, it is recommended that the metal cable glands be replaced with the light-blue plastic ones NOTICE: The lower ambient temperature is limited to -20°C when using the light blue plastic cable glands. Please observe manufacturers specification. ● The type of protection for the field connections and power supply connection is determined by the external circuits that are connected (→ p. 107 „Connection of the FLOWSIC300 with associated equipment“). ● Safety-relevant data for intrinsically safe circuits is provided in the EC Type Examination Certificate and the IEC Certificate of Conformity. ● Ensure the cover on the power supply connection is properly sealed. In intrinsically safe installations, the terminal compartment can be opened and cables connected and disconnected while the system is energized. In this case the safe separation of the circuits from each other must be observed. ● When heat insulation measures are taken, the SPU of the FLOWSIC300 may not be insulated as well. Subject to change without notice WARNING: Always observe the temperature specifications for use in hazardous areas. 108 FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH Installing the Electronics Unit Safety relevant input and output data Ignition protection type intrinsically safe Ex ia/ib IIA/IIB/ IIC UI = 20 V, PI = 2.6 W UO = 22.1 V IO PO Ex ia/ib IIA Ex ia/ib IIB Ex ia/ib IIC [mA] [mW] CO [nF] LO [mH] CO [nF] LO [mH] CO [nF] LO [mH] Hardware variants 87 481 2 7 0.5 4 77 1 Characteristic curve: Linear or with the following maximum values for connection to certified intrinsically safe power circuits: UI = 30 V II = 100 mA PI = 750 mW Effective internal capacity: CI = 4 nF Effective internal inductance: Negligible For connection to certified intrinsically safe circuits with the following maximum values: Digital output UI = 30 V Terminals 51/52 Terminals 41/42 II = 100 mA Terminals 81/82 PI = 750 mW Effective internal capacity: CI = 4 nF Effective internal inductance: Negligible RS485 Characteristic curve: Linear Terminals 33/34 Uo = 5.88 V Io = 313 mA Po = 460 mW Co = 1000 μF for IIA resp. 43 μF for IIC Lo = 1.5mH for IIA resp. 0.2 mH for IIC or with the following maximum values for connection to certified intrinsically safe power circuits: UI = 10 V II = 275 mA PI = 1420 mW Effective internal capacity: CI = 4 nF Effective internal inductance: Negligible Ultrasonic sensor connec- Ex ia/ib IIA Ex ia/ib IIB Ex ia/ib IIC tions Characteristic curve: Linear (for connecting SICK ultra- Max. transmission voltage: U = ±60.8 V Uo = ±38.9 V Uo = ±51.2 V o sonic sensors only) Short-circuit current: Io = ±92 mA Io = ±77 mA Io = ±59 mA Po = 1399 mW Po = 556 mW Po = 556 mW Effective internal capacity Ci = v.k. negligible negligible Li = 15.5 mH Li = 6.7 mH (negligible) Effective internal inductance: Li = 20.6 mH Subject to change without notice Power supply Current output Terminals 31/32 Non-intrinsically safe 12 … 24 V DC UB = 18 V UB = 35 mA UB = 30 V IB = 100 mA UB = 5 V IB = 175 mA WARNING: Maximum voltage in the safe area must not exceed 253 V. FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH 109 Subject to change without notice Installing the Electronics Unit 110 FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH Initial Start-up FLOWSIC300 8 Initial Start-up Subject to change without notice General information Connecting to a PC Connecting to MEPAFLOW600 CBM Identification Functional check FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH 111 Initial Start-up 8. 1 Information on initial start-up General information ▸ The FLOWSIC300 is a measuring system which is normally fitted to a pipeline during installation. When delivered, the FLOWSIC300 has been preconfigured according to the information concerning the measuring location and has passed all tests for ensuring measuring precision and quality in the factory. ▸ The individual device settings resulting from the quality assurance tests as well as application-specific data are saved in non-volatile memory of the FLOWSIC300 and should not be changed during start-up. ▸ The geometric path parameters of path length and path angle must be determined during installation and entered in MEPAFLOW600 during start-up. ▸ As an option, the FLOWSIC300 can be pre-installed in a pipe section. In this case, the geometric path parameters are determined very exactly in the factory during 3D measurement and parameterized in the device. Changing the parameters is not required in this case. If the FLOWSIC300 is to be used at a different measuring location to the one specified in your order, please contact your regional sales organization. It may be necessary to adapt various device parameters in this case. Preparations for initial start-up ▸ Complete all mechanical and electrical installation work before start-up. ▸ Provide a PC with MEPAFLOW600 CBM installed (→ p. 114, §8.2). Work sequence during initial start-up 1 Connect FLOWSIC300 and MEPAFLOW-PC (→ p. 114, §8.2). 2 Start the MEPAFLOW600 CBM program and connect to the FLOWSIC300 (→ p. 116, §8.3). 3 Carry out the start-up procedure (→ p. 122, §8.5). 4 Carry out a functional check (→ p. 135, §8.6). The start-up procedure essentially comprises: ▸ Entering individual plant parameters (e.g. active measuring path installation angle). ▸ Setting desired output variables and reaction times. ▸ As required: Configuring additional functions (e.g. data storage, graphic display). Adjustment/calibration ● A zero point adjustment is not required. ● Velocity measurement calibration is only required when the velocity profile on the measuring axis of the ultrasonic sensors is not representative for the overall crosssection of the pipeline. – Reference measurements with a reference measuring system are required for calibration. The correction data (regression coefficients) determined are entered manually. 112 FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH Subject to change without notice Settings can be protected with a password. Initial Start-up Individual optimization If measurements in certain operating states of the pipeline are not satisfactory (e.g. because measuring conditions are temporarily outside the specified technical data for the measuring system), the measurements could possibly be improved by setting device-internal parameters to special, individually optimized values. The options are described in the Service Manual. Subject to change without notice NOTICE: The manufacturer assumes no liability for incorrect settings. ▸ Only allow SICK Service, or persons especially trained for this purpose, to make individually optimized settings. FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH 113 Initial Start-up 8. 2 Connecting to a PC The FLOWSIC300 has an RS485 serial interface. An interface adapter serves to connect to a computer. 8.2.1 Connecting to a serial interface (RS232/COM) Prerequisites ● RS485/RS232 cable ● RS232 interface cable "1:1" (pin 2 – pin 2 and pin 3 – pin 3) (→ § Fig. 35). ● RS485/RS232 adapter ▸ Use an adapter that can automatically differentiate between send and receive modes. ▸ To create a connection in a potentially explosive atmosphere: Use an isolating repeater as adapter. MEPAFLOW600 CBM does not support RTS/CTS data transfers. Therefore the RS485/RS232 adapter must be able to toggle automatically itself. Wiring example Fig. 35 Wiring example for "MEPA interface set RS485/RS232 intrinsically safe" Safe area (non-Ex area) Ex area Terminals 33+ 34– Field bus isolating repeater RS485 Data+ Data– V+ GND– Serial interface: RS232 STAHL Type 9185 1:1 Connection cable Subject to change without notice 18 … 31 VDC 114 FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH Initial Start-up 8.2.2 Connecting to a USB port Prerequisites ● PC with USB interface ● RS485/USB converter ● Software driver of the USB converter The USB interface set includes a CD-ROM with a software driver for the USB converter. The drive must be installed in order to be able to create an interface connection between FLOWSIC300 and MEPAFLOW600 CBM. Wiring example ▸ Install the software driver of the USB converter on the PC. Fig. 36 Wiring example for "MEPA interface set RS485/USB" (converter, cable, plug, CD-ROM with software driver), non-intrinsically safe Safe area Field bus isolating repeater RS485 A / RxD B / TxD RS232 USB 1:1 USB Connection cable Subject to change without notice Terminals 33+ 34– FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH 115 Initial Start-up 8. 3 Connecting to MEPAFLOW600 CBM 8.3.1 Starting MEPAFLOW600 CBM The MEPAFLOW600 CBM program is on the product CD delivered with the device. It can also be downloaded from www.sick.com/flowsic600. See → p. 42, § 2.11.1 for further details on installation. ▸ After completing installation, start the MEPAFLOW600 CBM program by selecting the entry "MEPAFLOW600 CBM" in the program group created during installation or by double-clicking the desktop icon. Fig. 37 MEPAFLOW600 CBM program group and desktop icon Desktop Icon Subject to change without notice Program Group 116 FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH Initial Start-up 8.3.2 Choosing a user access level ▸ ▸ Page "Connect/Disconnect to meter" is displayed with the password dialog window when MEPAFLOW600 CBM is started. (→ § Fig. 38) Select a user level by activating the corresponding radio button, enter the password and click "OK". User access level Password Operator No password required Authorized operator "sickoptic" Service "expert" User level "Service" is mandatory for initial start-up. Fig. 38 MEPAFLOW600 CBM, page "Connect/Disconnect" with password dialog window ▸ Subject to change without notice 8.3.3 The password dialog window fades and the "Connect/Disconnect" page appears with a list of all devices in the Device database. Creating a new device entry in the Device database New device entries can be made whether the respective device is connected to the PC or not. If the device is connected, MEPAFLOW600 CBM loads all the available parameters from the device. If the device is not connected, an initial master data record is created with the data entered by the user. ▸ Click "New" to create a new device entry in the Device database. Then follow the instructions on the screen. FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH 117 Initial Start-up 8.3.4 Online connection: Connect ▸ ▸ Fig. 39 Select a device and click "Connect" to establish a serial connection to a device connected to the PC. Enter the respective connection settings in the Connection settings window (→ § Fig. 39) and click "Connect" to establish an online connection to the device. If the connection fails, see → p. 159, § 10.4 for troubleshooting. Connection settings Parameters shown in → § Fig. 39 are standard values - apart from the serial port that requires individual configuration. After the connection has been established, MEPAFLOW600 CBM displays the start page (can be specified in the program settings) and the current device states. Subject to change without notice ▸ 118 FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH Initial Start-up 8.3.5 Online Connection: Ethernet The FLOWSIC300 can be connected to a network via Ethernet using a suitable adapter. This adapter converts the communication between device and MODBUS (ASCII or RTU) to MODBUS TCP. MEPAFLOW600 CBM supports the MODBUS TCP protocol. Requirements ● Firmware V3.3.05 or higher is required for the Ethernet connection. It provides the required generic MODBUS protocol via the interface for the MODBUS TCP adapter. ● The FLOWSIC300 must be connected to a "MODBUS ASCII/ MODBUS RTU to MODBUS TCP“ adapter that is connected to a network via Ethernet and has a - preferably permanent - IP address. ● The PC with MEPAFLOW600 CBM V1.0.46 or higher installed must be connected to the network and have uninhibited access to this IP address. Preparations for online connections via Ethernet ▸ Ensure the serial port (terminals 33/34 or 81/82) of the FLOWSIC300 is configured so that generic MODBUS RTU or generic MODBUS ASCII is used (NOT SICK MODBUS protocol). ▸ Connect a MODBUS RTU/MODBUS ASCII to MODBUS TCP adapter to the serial port according to the manual of the adapter. ▸ Connect the adapter cable to your network. ▸ Make sure the network assigns a permanent IP address to the adapter. ▸ Configure the adapter to the network settings (IP address / protocol / baudrate / gateway etc.) that you want to use (refer to adapter manual). ▸ Make sure the PC with MEPAFLOW600 CBM has access to the adapter‘s IP address. ▸ Ensure the MODBUS bus address of the device is known. ▸ In case of problems with the network setup, refer to your network administrator. ▸ ▸ Subject to change without notice ▸ Select a device and click "Ethernet" to establish an online connection to the device. Enter the IP address of the MODBUS TCP adapter and the bus address of the device in the "MODBUS TCP - MODBUS RTU/ASCII gateway settings" dialog window (→ § Fig. 39). Click "OK" to establish an online connection to the device. FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH 119 Initial Start-up Fig. 40 Dialog window "MODBUS TCP - MODBUS RTU/ASCII gateway settings" for online connections via Ethernet Subject to change without notice Tested "MODBUS TCP to MODBUS ASCII/RTU Adapter" The connection between FLOWSIC300 and MEPAFLOW600 CBM was tested with the "MODBUS TCP to MODBUS ASCII/RTU Converter", model MES1b from B&B Electronics. This adapter is delivered with a program that searches the network for connectable devices and provides the user with the corresponding IP addresses. 120 FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH Initial Start-up 8.4 Identification Before start-up, cross-check the data representing the flow meter with the data in the test protocols contained in the Manufacturer Data Report (MDR). This can be done on the LCD display (see "Technical Information") or - much easier – with the MEPAFLOW600 CBM program. Comparing the data with MEPAFLOW600 CBM: ▸ Open the page "Meter information" and compare the data in Section "Identification" (→ § Fig. 41) with the data in the MDER Test reports or, if the device has been calibrated, with the Calibration report and Parameter report. Fig. 41 Page "Meter information" "Identification" section Subject to change without notice Firmware The FLOWSIC300 firmware is stored in non-volatile memory (FLASH PROM). Program codes of the signal processor and the system microcontroller are identified with a common valid version number (register #5002) and checksums (register #5005) and can be verified as described above. FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH 121 Initial Start-up 8. 5 Start-up 8.5.1 Entering the installation parameters ▸ ▸ ▸ If not already done in menu item "Password", activate Service access and enter the Service password → p. 117, §8.3.2. Switch to directory "Device parameters / Meter body". Enter the values determined for the installation angle in §4.2.4 (→ p. 65) as radian measure (rad): – Register #7101 - Angle1: β1 – Register #7102 - Angle2: β2 (only for 2-path configuration) The geometry tool outputs the installation angle in degrees (°). rad = (°) --------180 ▸ ▸ Enter the path length determined in §4.2.4 (→ p. 65). – Register #7105 - Length1: L – Register #7106 - Length2: L (only for 2-path configuration) Check the settings of inner diameter (register #7100 - InnerDiameter) and pipe diameter (register #7119 - PipeDiameter) and adapt these exactly to the local situation. – Inner diameter: Diameter at measuring location – Pipe diameter: Diameter of pipeline The pipe diameter is preconfigured according to the nominal pipe width which was specified during the order process. ▸ Adapt the settings to the actual pipe diameter at the measuring location to ensure representative measuring results. Inner diameter and pipe diameter are normally equal. When the pipe diameter differs from the inner diameter at the measuring location (e.g. when a narrower pipe piece is used), enter the correct values accordingly. Device parameters / Meter body Subject to change without notice Fig. 42 122 FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH Initial Start-up Field setup wizard 8.5.2 The Field setup wizard of the MEPAFLOW600 CBM program guides the user through the parameter configuration during FLOWSIC300 start-up. The wizard consists of 8 pages. Information on checking and configuring can be found in the FLOWSIC300 "Instrument Data Sheet" contained in the device documentation (Manufacturer Data Record, MDR) (see → § Fig. 43 for an example). User level "Service" is required to change parameters using the Field setup wizard. ▸ ▸ Fig. 43 Select "Tools / Field setup wizard" in the menu to start the wizard. Follow the instructions on screen step by step. Example of an "Instrument Data Sheet" as contained in MDR 1 GENERAL 2 Meter-No.: 3889 56 * Power supply / Power consumption 12 .. 28,8 V DC FL600 57 * Enclosure classification IP 67 58 * Cable entry M20 x 1,5 (3x) ° 59 Hazardous Area Class. 3 Type 4 Meter size 5* Article number 6* TAG number 06'' / DN150 TRANSMITTER (Integral) 54 < 1W II 1/2G Eex de ib [ia] IIA T4 7* 8* 01/11-2 Order number METER BODY 9 Aluminium 60 SPU housing material ° 61 Ambient temperature (range) -40 ... 60 °C 10 Inner pipe diameter mm 147,00 62 Display 11 Overal length (A) mm 450,00 63 Display language Russian 12 Overal height (B) mm 490,00 64 Engineering units Metric 130 65 m³/h 32 ... 2500 66 Output and Signal Configuration - Signal processing unit 13 Weight 14 Flow range 15 Number of meas. paths 4 67 16 Linearity +/- 0.5% of MV 0.1 .. 1 Qmax 68 17 * Repeatability < 0,1% 69 18 Flange design code DIN/EN 1092-1 70 19 Flange class PN100 71 20 Flange face Form B2 72 MOD Terminals 33/34 (RS 485) 21 Body material 1.0566 / ASTM A350 Gr. LF2 73 DO1 Terminals 51/52 (HF-Pulse) 22 Transducers exchangeable under pressure No 74 23 * Transducer cover ° 24 Design temperature ° 25 Design pressure kg LCD °C DO0/AO0 Terminals 31/32 (HF-Pulse) Signal configuration meter factor Aluminium 75 Signal configuration -46 ... 100 76 max. Output bar (g) 94 77 DO2 Terminals 41/42 (Status) 26 Material certificate 3.1 EN 10204 78 Signal configuration 27 * Enclosure classification IP 67 79 max. Output 28 * Surface coating / painting two layers: Epoxy + Acrylic RAL9002 80 29 * Pressure tapping 1/4" NPT female 81 Sensors 30 31 Titan 3.7165 SICK Modbus ASCII Volume a.c. 1/m³ 2.880 NAMUR / normally open 8,2 V / 0,8...6,5 mA Status Warning NAMUR / normally open 8,2 V / 0,8...6,5 mA SICK Modbus ASCII 82 COMMUNICATION 83 Sensor material NAMUR / normally open 84 Interface 2x RS 485 Subject to change without notice 32 * DO3 Terminals 81/82 (RS 485) Volume a.c., no pulses when data invalid FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH 123 Initial Start-up 8.5.3 Location information and unit system (Field setup page 1 of 8) These data serve to identify a device in the MEPAFLOW600 CBM Device database. Fig. 44 Field setup wizard, page 1 of 8: Location information Subject to change without notice Start Field setup wizard 124 FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH Initial Start-up 8.5.4 Application data (Field setup wizard, page 2 of 8) The pressure and temperature values to be entered on this page are stored as parameters PressureFix and TemperatureFix. Fig. 45 Field setup wizard, page 2 of 8: Application data These values are used when the FLOWSIC300 with integrated volume corrector works using constant volume temperature and pressure correction. The "Low flow cut off" is usually set to 25% of Qmin. Option HART® When the option HART® protocol was ordered, checkbox "Optional P and T reading via HARTBUS“ can be activated. In this case, the FLOWSIC300 works with HART® communication in Master mode. Subject to change without notice 8.5.5 Integrated electronic volume corrector (EVC) (Field setup wizard, page 3 of 8) EVC option When the device was ordered with the "Integrated electronic volume corrector (EVC)" option, the integrated electronic volume corrector must be activated in accordance with the description in "Technical Bulletin: Electronic Volume Correction (EVC)" Only the necessary EVC parameters for the GERG88 correction algorithm are available in the Field setup wizard. FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH 125 Initial Start-up Fig. 46 Field setup page 3 of 8: Integrated electronic volume corrector 8.5.6 I/O configuration – output configurations (Field setup wizard, page 4 of 8) The output configuration has to be set based on the information provided in the Instrument Data Sheet. Field setup wizard, page 4 of 8: I / O configuration Subject to change without notice Fig. 47 126 FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH Initial Start-up 8.5.7 I/O configuration – terminal assignment (Field setup wizard, page 5 of 8) The terminal assignment contains five tabs for the individual terminals and one for the overview. The outputs can be specifically configured in these tabs. Use the information buttons (when displayed) for detailed information on the output signal and support functions. Use the built in Meter Factor calculator for the pulse output. Fig. 48 Field setup page 5 of 8: I / O configuration - Terminal assignment, tab for terminals 31/32 Impulse factor The meter factor is set at the factory in accordance with customer specifications. If these are not available, the meter factor is set to a standard value so that the maximum pulse output frequency is approx. 2 kHz for maximum throughflow. The new meter factor can be calculated according to the following formula Subject to change without notice : fmax : max. pulse frequency [Hz] Qmax : max. volume flow [m³/h], [ft³/h] Meter factor = fmax • 3600 Qmax Pulse Volume unit ● In North America "K-Factor" is used. The K-factor is the inversion of the device value and can be set by clicking "Inverse" in "Meter factor calculator". For assistance in calculating the meter factor, use the integrated "Meter factor calculator" (→ § Fig. 49). ▸ Click the button "Meter factor calculator" ( → § Fig. 48). FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH 127 Initial Start-up Meter factor calculator Subject to change without notice Fig. 49 128 FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH Initial Start-up Warning limits If a status output has been configured as "Warning" output in step 4 (→ p. 126, § 8.5.6), the settings for this output can be displayed by clicking a register for this output. The user warning limits can be configured and activated after completion of the Field setup wizard (→ p. 122, § 8.5). Fig. 50 Status output configured for "Warning" Output configured as warning output Analog output The analog output must be configured for adapting the FLOWSIC300 to the various application conditions. Several parameters need to be changed. Output current Iout is calculated as follows: Subject to change without notice Iout = 4 mA + Q – AORangeLow (AORangeHigh - AORangeLow) • 16 mA Q: Actual volume flow rate (other possible sources: normalized volume flow rate, mass flow rate, molar mass) AORangeHigh: Upper range limit (has to be set) AORangeLow: Lower range limit (has to be set) Alarm value Enter a value outside the usual measuring range (< 4 mA or > 20 mA) which is to be output during a device malfunction. If the alarm value is configured with 0 mA, output of the current measured value continues during a malfunction. FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH 129 Initial Start-up NOTICE: In the device configuration with active analog output and use of HART bus communication, an alarm value < 4mA must be configured. When an alarm value > 20 mA is used, HART communication errors could occur. 8.5.8 LCD Display settings (Field setup wizard, page 6 of 8) ▸ ▸ Field setup wizard, page 6 of 8: LCD display setup with dropdown menu Subject to change without notice Fig. 51 Assign the language to be used in the menu of the LCD display. Choose from the dropdown menu, which measured variables and displays are to be displayed on the two page standard display. 130 FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH Initial Start-up Table 3 Possible sources for lines on LCD Reg. # Measured value output 7002 7001 5010 5012 5011 5013 7004 7003 7022 7021 3029 7035 3020 5016 5018 5041 5043 5042 5044 Volume flow rate in standard state [1] Volume flow rate in operating state[1] Volume counter forward[1] Volume counter reverse[1] Error volume counter forward[1] Error volume counter reverse[1] Gas velocity Sound velocity Pressure (from external source) Temperature (from external source) Frequency Analog output Input voltage Forward volume total [1] Reverse volume total [1] Standard volume flow rate forward[1] Standard volume flow rate reverse[1] Error volume in standard state forward[1] Error volume in standard state reverse[1] Total volume, original (plus forward, minus reverse volume)[1] Total mass counter forward[1] Total mass counter reverse[1] Mass flow Total volume in standard state forward[1] Total volume in standard state reverse[1] Volume flow rate in standard state as m3/d None 5045 5079 5081 7047 5085 5047 7065 - Abbreviation in MEPAFLOW600 CBM Qb Qf V forward V reverse E forward E reverse VOG SOS p T FO AO Uin V forward V reverse Vb forward Vb reverse Eb forward Eb reverse +/- Qb +/- Qf + Vf - Vf + Ef - Ef VOG SOS p T FO AO Uin + Vo - Vo +Vn - Vn + Eb - Eb Vo Vo M forward M reverse M flow Vo forward Vo reverse Qb (m3/d) Empty row +M -M +/- Mf +Vn - Vn +/- Qb - Abbreviations on LCD Subject to change without notice [1] The 18 digit total volume device values are stored in two word registers each with 9 positions. The first 9 digits are stored in the "low"digit register, and the last 9 digits in the "high" digit register. The LCD displays only the"low" bits of the total volume counters. FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH 131 Initial Start-up 8.5.9 Configuration update (Field setup wizard, page 7 of 8) User access level: "Authorized Operator" or "Service" ▸ ▸ ▸ ▸ ▸ ▸ Field setup wizard, page 7 of 8: Configuration update Subject to change without notice Fig. 52 Set the device to Configuration mode. Use "Write to flow meter" to write the configuration and parameter settings from pages 2 to 6 of the Field setup wizard to the device. The summary field displays information about the actions just carried out (successful or unsuccessful writing of parameters). Use "Reset at flow meter" to reset the error volume counter and the logbooks - recommended after device start-up. The time synchronization function serves to write the PC timestamp to the device and therefore synchronize the device to your local time settings. Be careful with this function. Read → p. 144, § 9.5.3 before using it. Set the device back to measuring operation. Print a parameter report to document any changes made. 132 FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH Initial Start-up 8.5.10 Maintenance report (Field setup wizard, page 8 of 8) Create the Maintenance report. ▸ Enter the information (Description, Technician) in the fields provided. ▸ Specify the collection duration (e.g. 3 minutes). This is the time in which the current device data are to be recorded to document the device status after the field has been set. (Live data collection starts after clicking "Start".) ▸ Enter the current pressure, temperature and SOS. If the SOS is unknown, use the SOS Calculator to calculate the sound velocity the gas composition. The gas composition must be current and representative (more details → p. 142, § 9.5.1). ▸ Click "Start" to start live data collection. Diagnosis data, measured values and status information will be collected over the specified time span. ▸ Once the data collection has been completed and "Create report" becomes available, click on it. This creates and displays the Maintenance report. ▸ Print the Maintenance report and file a copy in the Manufacturer Data Report (MDR) delivered with the device. ▸ Close the preview window. ▸ Click "Close" in the Field setup wizard The Field setup wizard is now complete. Subject to change without notice Fig. 53 Field setup wizard, page 8 of 8: Maintenance report The Maintenance report is stored automatically in the MEPAFLOW600 CBM database after creation. It is accessible via the "Meter explorer" and the "Report manager". The Maintenance report can also be exported to Excel using the direct link provided when the Maintenance report is displayed. FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH 133 Initial Start-up 8.5.11 Separating the connection to the device and terminating the session A session is stored in the MEPAFLOW600 CBM device database when the connection to the device is separated. It contains the following data: ● A complete set of device parameters at the time of separation ● All parameter changes made during Field setup (entries can be viewed in the "Meter Explorer") ● All logbook data downloaded on page 7 of the Field setup wizard ● The Maintenance report created on page 8 of the Field setup wizard These data can be retrieved later with the "Meter explorer" even when there is no direct connection to the device. Proceed as follows to separate the connection to the device and terminate the session: Select "File / Connect / Disconnect" to switch to the "Connect / Disconnect" page. Click "Disconnect". The "Session description" window opens. Describe the activities carried out during the session (e.g. "Field Setup"). Click "OK". Subject to change without notice ▸ ▸ ▸ ▸ 134 FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH Initial Start-up 8.6 Functional check The major system parameters are configured at the factory. The standard settings should allow FLOWSIC300 operation without errors. However, correct measuring operation should be checked when the measuring system is installed and running under the planned operating conditions. Recommendation: Carry out a plausibility check on the measured and diagnosis values - even when the device appears to functioning correctly. 8.6.1 Checking the operating state on a version with LCD front panel State Normal operating state: Current error/current warning: Logbooks contain errors, warnings or information that have not been acknowledged yet: Logbooks contain errors, warnings or information that have been acknowledged: Display Measured values/current displays. alternating (time interval: approx. 5 seconds). A message is shown every 2 seconds. A code letter blinks in the top right corner of the display.[1] The code letter is shown permanently. [2] Subject to change without notice [1] Retrieve the logbook to view detailed information (→ p. 146, § 9.7.1). Troubleshooting → p. 151, §10. [2] To delete this display: Delete the entries in the logbook. FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH 135 Initial Start-up 8.6.2 Function test with MEPAFLOW600 CBM Checking the device function 1 As soon as the plant is running with the start volume flow rates: Call up the "Meter values" page and check the performance. – Measurement performance should be at least 75%. – Exception: Performance could be considerably lower when the gas velocity is faster than 30 m/s. 2 Check the displays in the main system bar (→ § Fig. 54): – The icons under "System" and "User" must be green. – If one of these icons is yellow or red: → p. 152, §10.1. Checking the zero phases setting Call up the Path diagnosis wizard and check the "Zero Phase" parameter for each two sensors for each measuring path (paths 1, 2). Criteria for correct zero phase values (→ § Fig. 54): – The green cursor is positioned symmetric between both red dashed limit lines. – The red star-shaped marking is exactly on the third positive zero crossing of the ultrasonic signal curve. – If this is not the case: Adapt the zero phase. ▸ The correct setting of the zero phases serves as basis for precise run-time measurement of ultrasonic signals. Fig. 54 Path diagnosis wizard in MEPAFLOW600 CBM Subject to change without notice Main system bar 136 FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH Initial Start-up Checking the validity of the zero phases 1 Call up the "Meter Status" window (→ p. 155, § Fig. 63). Open the register "Advanced or Path Status". 2 Check display "Adapt": – If the LED icon for "Adapt" is on: The zero phase setting is incorrect. Checking the sound velocity (only for 2-path configuration) 1 Call up the "Meter values" page. 2 Call up the context menu of the sound velocity diagram (click in the diagram with the right mouse button). 3 Call up the display of the absolute sound velocities and deviation from mean value (→ p. 137, § Fig. 56), and check the sound velocities displayed. Criteria for correct sound velocities: – The absolute sound velocity is more or less equal for all measuring paths. – The deviation from the mean value is less than 0.1 % for all measuring paths. – The absolute sound velocities deviate maximum 0.3% from the calculated theoretical sound velocity (→ p. 142, § 9.5.1). Subject to change without notice Sound velocity differences can be very high when the gas velocity in the pipeline is very low (< 1 m/s) (effect of thermal stratification). In this case, sound velocities in the top measuring path are higher than those in the bottom measuring path. Fig. 55 Signal window displaying the ultrasonic signal on page "Path diagnosis" Fig. 56 Sound velocity per measuring path on page "Meter values" Absolute sound velocities Deviation from mean value FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH 137 Subject to change without notice Initial Start-up 138 FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH Maintenance FLOWSIC300 9 Maintenance Subject to change without notice Protective measures when working on the pipeline Maintenance work overview Checking gas tightness Functional check Documentation/data backup FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH 139 Maintenance 9. 1 Protective measures when working on the pipeline NOTICE: Risk of damage in pipeline ▸ Protect the ultrasonic sensors against liquids and mechanical effects. Otherwise the ultrasonic sensors can be damaged or made unusable. Before carrying out repair or cleaning work in the pipeline: ▸ Remove the ultrasonic sensors and replace them by the optional dummy plugs. If the pipeline is to be purged with liquid: ▸ Obtain safety information from the FLOWSIC300 manufacturer. Observe this safety information. 9. 2 Components with gas contact in the pipeline During operation: During installation/maintenance work on sender/receiver units: 9. 3 – – – – – Nozzle Ultrasonic sensors Sender/receiver units Ball valve Hydraulic cylinder of the fitting tool Maintenance work overview Checks during operation ● Check gas tightness (→ p. 141) ● Functional check – Comparing theoretical and measured sound velocity (SOS) (→ p. 142) – Checking the device state (→ p. 143) – Time synchronization (→ p. 144) – Maintenance reports (→ p. 145) Operation documentation ● Maintenance reports (→ p. 145) ● Checking the logbook (→ p. 146) ▸ Recommendation: Create and file regular Maintenance reports (→ p. 145, §9.6). To do this, document current operating conditions (gas composition, pressure, temperature, flow velocity). – Maintenance reports can be useful during troubleshooting. ▸ Observe the documented operating conditions when comparing Maintenance reports. 140 FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH Subject to change without notice ● The FLOWSIC300 has no mechanical moving parts. ● Internal threshold values can be configured to trigger a warning when contamination starts. Maintenance 9.4 Checking gas tightness ▸ Regularly check installations on the pipeline are gas-tight. ▸ Should a leak occur: – Check the installation – Remove and check seals concerned – Replace seals concerned when damaged Additionally in potentially explosive atmospheres: Check the housing of the electronics unit corresponds to the degree of protection (condition of door and cover seals, cable inlets) WARNING: Hazards through leaks Operation in leaky condition is not allowed and possibly dangerous. If the installation is not gas-tight: 1 If necessary, take protective measures against the escaping gas (e.g. alarm, breathing protection, shutdown). 2 Establish leak tightness again (replace seals) Subject to change without notice WARNING: Hazard through wrong spare parts Seals must be made of materials suitable for the individual operating conditions (pressure, temperature, chemical influences). ▸ Observe information provided on delivery on individual device versions (compare → p. 13, §1.4.1). ▸ Only use specified seal versions. Recommendation: Only use original spare parts from the manufacturer. ▸ Observe the installation information in these Operating Instructions. FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH 141 Maintenance 9. 5 Functional check Proper device function can be determined directly on the LC display of the FLOWSIC300. The MEPAFLOW600 CBM program provides a user-friendly option for carrying out routine checks. 9.5.1 Comparing theoretical and measured sound velocity (SOS) One of the main criteria for correct operation of an ultrasonic gas flow meter is conformity between the theoretical sound velocity calculated for the actual gas composition, temperature and pressure, and the sound velocity measured by the ultrasonic gas flow meter. The SOS Calculator provided by the MEPAFLOW600 CBM program calculates a theoretical sound velocity for a specific gas composition at specified temperature and pressure values (→ § Fig. 57). Calculating thermodynamic characteristics is based on the "GERG-2004 WideRange method for natural gas and other mixtures". The algorithms implemented in the SOS Calculator were developed by the Ruhr-University Bochum (Germany). Fig. 57 SOS Calculator with loaded gas composition file Checkbox for detailed options Use the MEPAFLOW600 CBM program to connect to a device (→ p. 116, § 8.3). Start the SOS Calculator in the Maintenance report or select "Tools / SOS Calculator" in the menu. ▸ Enter the gas composition and temperature and pressure for your application. ▸ Activate "Details" for additional settings. ▸ Click the "Calculate" button. ● If you have started the SOS Calculator in the Maintenance report, the calculated value is copied automatically to the corresponding field in the wizard and in the report. ● Compare the theoretical sound velocity with the sound velocity measured with the FLOWSIC300 (see Fig. 58, main system bar). ● If the deviation exceeds 0.3%, check the plausibility of temperature, pressure and gas composition. 142 FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH Subject to change without notice ▸ ▸ Maintenance 9.5.2 Checking the device state The FLOWSIC300 checks its own state with a system of user warnings and alarms. The device state need not be checked manually when the outputs are configured so that they display alarms and / or user warnings. The "Main system bar" in MEPAFLOW600 CBM provides a compact overview when visual feedback on the state of your FLOWSIC300 is desired: ▸ Use the MEPAFLOW600 CBM program to connect to your FLOWSIC300 (→ p. 116, § 8.3). ▸ Check the main system bar for any yellow or red icons (→ § Fig. 58). A red or yellow icon signals a potential problem with the FLOWSIC300. Continue checking the "Meter state" (→ p. 153, § 10.2.1) and "User warnings" (→ p. 156, § 10.2.2) should icons in the main status bar be yellow or red. Fig. 58 Main system bar Measured sound velocity Icons for system alarms, User Warnings and performance Subject to change without notice Main system bar FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH 143 Maintenance 9.5.3 Time synchronization Internal clock ● Entries in logbooks and DataLogs are stored with the date and time of the internal clock ("timestamp“). ● The internal clock can be read out with a main clock (e.g. PC clock) via MODBUS or with MEPAFLOW600 CBM. Synchronizing via MODBUS The date and time of the FLOWSIC300 can be set separately with an external write operation. Each operation for date and time triggers a separate entry in the Custody logbook [1]. Alternatively the synchronization function can be used. To use this method, the date register (#5007) and the time register (#5008) must be written within two seconds of each other. The date register (#5007) must be written first. The write operation can be done via MODBUS without setting the FLOWSIC300 to Configuration mode. : Synchronizing via MEPAFLOW600 CBM MEPAFLOW600 CBM offers a synchronization function via a button in the "Meter Information" screen (→ § Fig. 59). The icon is marked with a yellow character to indicate synchronization when the time difference between internal and PC clock is more than 30 seconds. Fig. 59 Synchronization button and clock synchronization window Subject to change without notice Synchronization only triggers an entry in the calibration regulation logbook [1] when the time change is more than 3% of the time since the last synchronization. 144 FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH Maintenance 9.6 Maintenance reports We recommend creating and filing Maintenance reports on a regular basis. Over a period of time, this provides a comparison data base useful when diagnosing problems. Operating conditions (gas composition, pressure, temperature, flow velocity) in the Maintenance reports should be similar or documented each time and then considered when evaluating the comparison. Fig. 60 Maintenance report wizard Subject to change without notice Click to open the "SOS Calculator" To create a Maintenance report, follow the described procedure: ▸ Select "Tools / Maintenance report" to open the wizard (→ § Fig. 60). ▸ Enter the information (Description, Technician) in the fields provided. ▸ Enter the collection duration. This is the time in which the current device data are to be recorded to document the device status (default: 1 minute). ▸ Enter the current pressure, temperature and sound velocity (SOS). Use the SOS Calculator to calculate the sound velocity for the gas composition (→ p. 142, § 9.5.1). The gas composition must be current and representative. ▸ Click "Start" to start recording current data. Diagnosis data, measured values and status information will be collected over the specified time span and will be saved in the meter database. ▸ Click "Create report". This creates and displays the Maintenance report. ▸ Print the Maintenance report and file it together with the Manufacturer Data Report (MDR, in scope of delivery). Apart from that, the data are stored in the MEPAFLOW600 CBM Device database and can be retrieved using "Meter explorer" and "Report manager". The Maintenance report can also be exported to Excel using the direct link provided when the Maintenance report is displayed. FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH 145 Maintenance 9. 7 Logbook backup 9.7.1 Checking the logbook To prevent a data overflow in the logbook and possible data losses, logbook entries (events) can be stored in a Device database using the MEPAFLOW600 CBM program. The entries can then be deleted in the device. The "Meter logbook" page displays all logbook entries on the device and in the MEPAFLOW600 CBM database. It provides details on each entry and information on the number of registered events and the remaining memory space. "Meter logbook" page in MEPAFLOW600 CBM 9.7.1.1 Downloading and storing the logbook entries in the MEPAFLOW database Proceed as follows to download and save the logbook entries in the MEPAFLOW600 CBM database: ▸ Use the MEPAFLOW600 CBM program to connect to a device (→ p. 116, § 8.3). ▸ Select "Meter / Logbook" in the menu to open the Logbook page. ▸ Select the logbooks to be downloaded in the "Logbook selection" dialog box and click "OK". The logbook entries are now loaded to your MEPAFLOW600 CBM database. The entries can then be viewed offline without connecting to the device or can be used with other users (export device or session). Subject to change without notice Fig. 61 146 FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH Maintenance 9.7.1.2 Confirming logbook entries on the device Proceed as follows to confirm logbook entries: ▸ Download and store the logbook entries as described in → § 9.7.1.1. ▸ Select the logbook in which entries are to be acknowledged or select "All logbooks" to acknowledge entries in all logbooks at once. ▸ Mark the entries to be acknowledged. ▸ Click "Acknowledge selection" when only selected entries are to be confirmed or "Acknowledge all" to confirm all entries in the selected logbook or selected logbooks. 9.7.1.3 Deleting logbooks on the device Logbooks need not be deleted on the device when the logbooks are configured as "rolling". When the logbook is full, new entries will overwrite the oldest entries. If a logbook is configured as "blocking" (e.g. with calibration regulation configuration), a full Custody logbook [1] activates device status "Data invalid". In this case, it is recommended to clear the logbooks. NOTICE: The following conditions must be fulfilled to clear logbooks on the device: ● The Parameter write lock must be in the "UNLOCKED" position. ● The user must be in the "Service" user level (see Service manual for password). ● The device must be in Configuration mode. Subject to change without notice Proceed as follows to clear logbooks on the device: 1 Select user access level "Service" (→ p. 117, § 8.3.2) 2 Download and store the logbook entries → § 9.7.1.1. 3 Select the logbook to be deleted on the device. Or select "All Logbooks" to empty all logbooks at the same time. 4 Set the device to Configuration mode. 5 Click "Clear meter logbook" and confirm the warning with "OK". 6 Set the device to measuring operation. 7 If the parameter write lock was released to clear the logbooks: Reset to the original state. FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH 147 Maintenance 9.7.2 DataLogs check FLOWSIC300 has two DataLogs (Hourly Log and Daily Log). They save averaged measured values and are stored in the SPU‘s non-volatile memory (FRAM). All data can be downloaded and exported to Excel files with MEPAFLOW600 CBM. Full support for the DataLogs is provided by MEPAFLOW600 CBM V1.1.00 or higher. Fig. 62 DataLogs page with opened tab for Hourly Logs „Meter Status“ section for export Subject to change without notice for update 148 FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH Maintenance 9.7.2.1 Downloading and exporting of DataLog data To download and export the data from your FLOWSIC300, complete the following steps: ▸ Use MEPAFLOW600 CBM to connect to the meter. ▸ Go to the DataLogs page (choose "Meter / DataLogs" from the menu). ▸ In the dialog "DataLog selection", select those DataLogs that you want to view and/or export and click "OK". ▸ Now the DataLogs page is displayed with the data from the meter. ▸ If you select a DataLog entry, its time stamp and the meter status (see below) is shown in the middle section. ▸ To update the data from the meter, use the button "Read DataLogs". ▸ To export DataLog data to an Excel file (.xls), use the button "Export DataLogs". Meter status In every DataLog entry, a condensed meter status information is saved. It shows all meter status information that became active during the storage cycle - even if it was for the shortest period of time. If a meter status information bit is shown active in a DataLog entry, the logbooks will contain a corresponding entry with more information. ▸ Always check the logbooks, if you require more information about the meter status information in the DataLogs. Flow weighted diagnostic information in DataLog data The datasets do not contain any diagnostic information for gas velocities below the value for the parameter Vmin (Reg. #7036 "LowFlowCutOff"). The "Flow time" value shows, for what percentage of the duration of the storage cycle the flow was above Vmin and in the flow direction specified for the DataLog. All diagnostic information is flow-weighted. Clearing entries from DataLogs If the DataLogs are configured with the storage behavior "rolling", it is not necessary to clear the entries from the DataLogs on the meter. When the DataLog is full, new entries will overwrite the oldest entries. If a DataLog is configured with the storage behavior "blocking", the DataLog will stop saving new entries when it is full and a yellow light will indicate the full DataLog on the meter status table. In this case it is recommended to clear the entries from the DataLogs. To clear all entries from a DataLog, complete the following steps: ▸ Go to the DataLogs page (choose "Meter / DataLogs" from the menu). ▸ Choose the "Configuration" tab. ▸ Switch the meter into Configuration Mode (choose "File / Configuration Mode" from the menu). ▸ Click the "Clear" button for the DataLogs from which you want to clear entries. ▸ Switch the meter into Operation Mode. Subject to change without notice 9.7.2.2 FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH 149 Subject to change without notice Maintenance 150 FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH Troubleshooting FLOWSIC300 10 Troubleshooting Subject to change without notice General troubleshooting Displaying status alarms and warnings Starting a diagnosis session Troubleshooting when connecting devices This Section helps locating the cause of a problem when routine tests during maintenance (→ p. 142, § 9.5) or function checks after start-up (→ p. 135, § 8.6) show that a measuring problem could possibly exist. If the cause of the problem cannot be localized, it is recommended to use the MEPAFLOW600 CBM software to record the current parameter set and diagnosis values in a diagnosis session file (→ p. 158, §10.3) and send this to a local SICK representative. FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH 151 Troubleshooting 10 . 1 General troubleshooting Problem ● No display ● No pulse frequency ● No active status signal Possible causes Faulty power supply Device defective 10 . 2 Actions ▸ Check input voltage on terminals 1 and 2. ▸ Check cables and terminal connections. Caution Take the relevant safety precautions! ▸ If possible, start a diagnosis session (→ p. 158, §10.3) and contact your local SICK representative. Displaying status alarms and warnings The FLOWSIC300 signals alarms and warnings as follows: ● The LCD display shows active device status alarms or warnings. If a current error or warning is active, the display will flash and a message will be displayed with a message number in the upper right corner (→ p. 168, § 12.4.1 for more details on LCD error messages). ● A status output can be configured to signal whether device status "Data invalid", "Check request" or "Warning" will be active. ● Device status registers can be read out via MODBUS (see document "FLOWSIC600 Modbus Specification“) ● The MEPAFLOW600 CBM program can be used to test the device state. Device status alarms and warnings are displayed in the main system bar. ▸ ▸ Subject to change without notice ▸ Recommendation: Use MEPAFLOW600 CBM to receive further information on the device state. If "Data invalid" or "Check request" is displayed on the device: Proceed as shown in → p. 153, § 10.2.1. If "Warning" is displayed on the device: Proceed as shown in → p. 156, § 10.2.2. 152 FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH Troubleshooting 10.2.1 Checking the device status The "Meter Status" window in MEPAFLOW600 CBM shows an overview on the status and operation of the device. ▸ Use the MEPAFLOW600 CBM program to connect to a device (→ p. 116, § 8.3). ▸ Click "System" in the main system bar to open the "Meter Status" window (→ p. 155, § Fig. 63). ▸ Check the "Meter Status" section (→ p. 155, § Fig. 63) for yellow or red lamps. Device status lamp Green lamp for "Measurement valid" Red lamp for "Data invalid" Possible causes Correct operating state. The measured values are valid. Device does not output valid measurements. Measuring volumes are counted in the error volume counter [1]. Yellow lamp for "Check request" Actions – Measurement is invalid and/or the device is in Configuration mode. ▸ If the device is in Configuration mode: Select "File / Operation mode“ in the menu to switch the device to measuring operation. ▸ Otherwise: Process as shown in §10.3 (→ p. 158). ▸ Proceed according to §10.3 (→ p. 158). – For 1-path measurement: A malfunction is affecting measuring precision.[1] – For 2-path measurement (option): A measuring path has failed or another malfunction is affecting measuring precision.[1] Yellow lamp for "User A user warning limit has been ▸ Check the user warning as shown in Warning Limit exceeded. §10.2.2 (→ p. 156). exceeded“. Red lamp for – For 1-path measurement: The ▸ Proceed according to §10.3 (→ p. 158). "Path failure" measuring path has failed. – For 2-path measurement (option): Both measuring paths have failed. Subject to change without notice [1] See p. 35, §2.8.2 for further details on device status. FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH 153 Troubleshooting ▸ If none of the lamps are yellow or red in the general section "Meter Status", the other sections can be checked for yellow or red lamps. Device status lamp Yellow lamp "Logbook(s) contain unack. entries" Red lamp when a logbook has status "full" Possible causes Logbook contains unconfirmed entries. Actions ▸ Download, check and confirm all logbook entries (→ p. 146, § 9.7.1.1.). ● The corresponding logbook is ▸ Download, check and confirm all logbook configured as "blocking“. ● This logbook is full. entries (→ p. 146, § 9.7.1.1.). ▸ Clear the device logbook (→ p. 147, § 9.7.1.3). ▸ Check whether the logbook should be con▸ ▸ Red lamp when a DataLog has status "full" ● The corresponding DataLog is ▸ Yellow light "Battery Lifespan (change battery)" Automatically activated after 8.5 ▸ years to prompt replacing the battery. ● ● configured as "blocking“. ▸ ▸ Subject to change without notice ● This DataLog is full. figured as "rolling“ (see Parameters). Download, check and confirm all logbook entries (→ p. 146, § 9.7.1.1.). Clear the device logbook (→ p. 147, § 9.7.1.3). Download and check the DataLog. Clear the DataLog. Consider reconfiguring the DataLog to "rolling". Inform SICK Service technicians to have the internal battery replaced. Information on battery → p. 157, § 10.2.3. See the Service Manual for instructions on replacing the battery. 154 FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH Troubleshooting Fig. 63 Main system bar with "System" button and open window "Meter Status" Opens the "Meter Status" window Main system bar General section "Meter Status" Displays whether logbook(s) contains unacknowledged entries Battery change "Logbooks" section Subject to change without notice "DataLogs" section FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH 155 Troubleshooting 10.2.2 Checking user warnings The "User Warnings" window displays an overview of the user warning status. ▸ Use the MEPAFLOW600 CBM program to connect to a device (→ p. 116, § 8.3). ▸ Click "User" in the main system bar in the MEPAFLOW600 CBM screen to open the "User Warnings" window (→ § Fig. 64). ▸ Check the window for yellow lights and proceed according to → p. 158, §10.3. Fig. 64 Main system bar with "User" button and open window "User Warnings" Subject to change without notice Opens the "User Warnings" window 156 FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH Troubleshooting 10.2.3 Battery service life/capacity The real-time clock (RTC) in the FLOWSIC300 is buffered by a battery. The battery service life specified by the manufacturer is at least 10 years. The remaining battery capacity can be inquired on the display in the first menu level (see "Technical Information"). Fig. 65 Display of remaining battery capacity on the LCD display Battery Charge 100% Subject to change without notice Because the FLOWSIC300 has no regular maintenance cycle, a user warning will be automatically generated if the remaining battery life is less than 15%. After 8.5 years, a warning is generated which forces the operator to change the battery. The battery may only be changed by trained staff. The procedure for changing the battery is described in the Service Manual. FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH 157 Troubleshooting 10 . 3 Starting a diagnosis session If it becomes necessary to generate a diagnosis session for remote support, follow the procedure described below: ▸ Start the MEPAFLOW600 CBM program and establish an online connection to the device (see → p. 116, § 8.3 for all preparations required). ▸ Select "Tools / Diagnosis session" in the menu or click menu item "Diagnosis session" in the button navigation (see → § Fig. 66) Fig. 66 Starting a "Diagnosis session" Menu item "Diagnosis session" ▸ ▸ ▸ Subject to change without notice ▸ Specify a file name. (The file path is set according to the program settings. If desired, specify a different path.) Click "Save". MEPAFLOW600 CBM now loads the logbooks from the device and starts a diagnosis session with all the relevant data. The entire process usually takes about three minutes. If the logbooks contain a lot of entries, the process may take longer. E-mail the Diagnosis session file to your SICK representative for support. 158 FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH Troubleshooting 1 0. 4 Troubleshooting when connecting devices Device not found during first connection ▸ Check all cables and the hardware. Also check that the adapters have been installed correctly (see → §8.2.1 and → §8.2.2). ▸ Use the options in the windows displayed to allow MEPAFLOW600 CBM to search with advanced options (see → § Fig. 67). Fig. 67 Dialog window "Meter not found" to specify advanced search options Subject to change without notice Connection lost during session ▸ Check all cables and the hardware. ▸ Use the options in the windows displayed to allow MEPAFLOW600 CBM to search with advanced options (see → § Fig. 67), especially when parameters have possibly been changed (e.g baudrate). FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH 159 Subject to change without notice Troubleshooting 160 FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH Spare Parts FLOWSIC300 11 Spare Parts Subject to change without notice Electronics subassembly Sender/receiver units Cables Fitting tool FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH 161 Spare Parts 11 . 1 Electronics subassembly Junction box Description Junction box 1-path, with connection for cable conduit Junction box 1-path, without connection for cable conduit Junction box 2-path, with connection for cable conduit Junction box 2-path, without connection for cable conduit Part No. 2 066 967 2 066 964 2 066 965 2 066 968 Electronics subassemblies Description LC-Display Fuse board with assembly parts Buffer battery Part No. 2 066 184 2 041 502 7 048 533 Connection block Description Part No. Connection block for hardware variants 1, 2, 4, 5, 7, 8, 9, A Rev2 (EMC circuit board, 2 062 870 master board) Connection block for hardware variants 6 and B Rev2 (EMC circuit board, master 2 056 878 board) Electronics block I/O config. 3, cable length 5 m Description Electronics block IIC/BCD 200 kHz (power, SPU, I/O, analog) (for I/O config. 1/1, 1/2, 1/3, 7/1, 7/2, 7/3) Part No. 2 040 387 Electronics block I/O config. 3, cable length 15 m Description Electronics block IIC/BCD 300 kHz (power, SPU, I/O, analog) Part No. 2 046 540 Electronics block I/O config. 5, cable length 5 m Description Electronics block IIC/BCD H 200 kHz (power, SPU, I/O, analog) (for I/O config. 2/4, 2/5, 3/6, 8/4, 8/5) Part No. 2 040 389 Electronics block I/O config. 5, cable length 15 m Description Electronics block IIC/BCD 300 kHz (power, SPU, I/O, analog) with analog output / HART Part No. 2 046 542 Description Electronics block IIC/BCD for I/O variant C, cable length 5m, FL300-NNCNNNNSN Part No. 2 067 051 Electronics block I/O config. C, cable length 15 m Description Electronics block IIC/BCD for I/O variant C, cable length 15 m, FL300-NNCNNNNLN 162 Part No. 2 067 053 FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH Subject to change without notice Electronics block I/O config. C, cable length 5 m Spare Parts 1 1. 2 Sender/receiver units Description Sender/receiver unit assembly set O-ring 36.0 * 2.5, VITON LT170-TT for probe holder Sealing cover for S/R unit FLSE300 with seal, without connection for cable conduit Sealing cover for S/R unit FLSE300 with seal, with connection for cable conduit Extraction tool for probe holder, T-handle 1 pair of spare probes X8 including probe holder and O-ring 1 pair of handles for adjusting ring S/R unit FLSE300 1 1. 3 2 067 032 2 066 972 2 067 809 2 067 515 Cables Description Sensor cable 5m, without cable conduit Sensor cable 5m, with cable conduit Sensor cable 15 m, with cable conduit 1 1. 4 Part No. 2 066 974 2 067 525 2 067 031 Part No. 2 066 955 2 066 956 2 066 954 Fitting tool Part No. 2 067 522 2 066 951 2 066 952 2 066 953 2 066 174 Subject to change without notice Description Hydraulic hose for hand pump for FLOWSIC300 fitting tool with hydraulic coupling Compact ball valve 2" for FL300 fitting tool Hydraulic cylinder 2" for FLOWSIC300 fitting tool Hand pump for FLOWSIC300 fitting tool Sealing set for probe change, including 1x flat seal, 1x fitting tool O-ring, 1x probe holder O-ring FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH 163 Subject to change without notice Spare Parts 164 FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH Appendix FLOWSIC300 12 Appendix Subject to change without notice Conformities Technical Data Logbooks FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH 165 Appendix 12 . 1 Conformities 12.1.1 CE certificate Subject to change without notice The FLOWSIC300 has been developed, manufactured and tested in accordance with the following EU Directives: ● ATEX Directive 2014/34/EU ● EMC Directive 2014/30/EU Conformity with the above Directives has been determined and the CE label attached to the device. 166 FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH Appendix 1 2. 2 Technical Data Meter characteristics and measuring parameters Measured variables Number of measuring paths Measuring principle Measured medium Measuring ranges Measurement span Repeatability Measurement uncertainty Gas temperature Operating pressure Nominal pipe size Actual flow rate, actual volume, gas velocity, speed of sound 1, 2 Ultrasonic transit time difference measurement Natural gas, process gases, high-pressure flare gases, air Gas velocity: 0.3 … 60 m/s, depending on the nominal pipe width Max. 1:130 < 0.5 % of measured value 1% … 5% of measured value (depending on device configuration) -40 °C … +180 °C 0 bar (g) ... 100 bar (g) 4" … 56" Ambient temperature Storage temperature Ambient humidity -40 °C … +60 °C -40 °C … +70 °C ≤ 95% relative humidity; non-condensing Ex certification ATEX: II 1/2G Ex de ib [ia] IIC Ta IECEx Gb/Ga Ex de ib [ia Ga] IIC T4 Ultrasonic sensors are intrinsically safe “ia“. CE Sender/receiver units IP68 Control unit SPU IP65/IP67 Ambient conditions Approvals Electrical safety IP classification Outputs and interfaces Analog output Digital outputs Interfaces Bus protocol 1 output: 4 … 20 mA; 200 Ω Active/passive, electrically isolated 3 outputs: Passive, electrically isolated, open collector or acc. to NAMUR (EN 50227), fmax = 6 kHz (scalable) 1 RS-485 (for configuration, measured value output and diagnosis) MODBUS ASCII/RTU HART Installation Dimensions (W x H x D) Weight Assembly See dimension drawings Sender/receiver unit: ± 15 kg Control unit SPU: ± 6 kg Fitting tool in case: ± 45 kg Nozzle 1.5" Cl.600: ± 5 kg Connection 1.5" CI.600 according to ANSI B16.5 for welding to pipeline Sensor cable length: 5 m or 15 m Installation of control unit SPU to 2" tube or wall fitting Subject to change without notice Electrical connection Voltage Power input 12 V … 28.8 V DC (with active analog output: 15 ... 28.8 V) <1W FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH 167 Appendix 12 . 3 Dimensions Clearance required next to the pipeline Electronics unit dimensions 12 . 4 → p. 50, § Fig. 13 → p. 95, § Fig. 27 Logbooks Classification of logbook entries Entries are split into three classes and identified by the initial character in the first line. Significance Information Warning Error / malfunction Identification I W E Type of occurrence Identification + – 12.4.1 Significance Event timepoint marking the start of a state Event timepoint marking the end of a state Overview of entries in logbooks and MEPAFLOW600 CBM Message No. on LCD Logbook message in MEPAFLOW600 CBM 3002 No DSP communication Logbook LCD text 1 E+System 0001 NO DSP-Communic. Custody logbook [1] E-System 0001 NO DSP-Communic. 3003 Data invalid 1 E+DSP 0001 Reading invalid E-DSP 0001 Reading invalid 3004 Firmware CRC invalid 1 E+Firmware 0001 CRC invalid E-Firmware 0001 CRC invalid 3005 Parameter CRC invalid 1 E+Parameter 0001 CRC invalid E-Parameter 0001 CRC invalid Parameter out of range 1 E+Parameter 0001 #XXXX range error E-Parameter 0001 #XXXX range error 3007 Failure during storage of path compensation 1 parameter E+PathComp. 0001 Storage error E+PathComp. 0001 Storage error 3008 Meter clock time invalid 1 E+System 0001 ClockTime inval. E-System 0001 ClockTime inval. 168 FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH Subject to change without notice 3006 Appendix Message No. on LCD Logbook message in MEPAFLOW600 CBM Logbook LCD text 3011 CRC volume counter (a.c) invalid 1 E+Count.ac 0001 CRC invalid E-Count.ac 0001 CRC invalid 3012 CRC volume counter (n.c) invalid 1 E+Count.sc 0001 CRC invalid E-Count.sc 0001 CRC invalid 3013 Transit time mode activated 1 E+System 0001 TransitTimeMode E-System 0001 TransitTimeMode 3014 No signature key 1 E+System 0001 No signature key E-System 0001 No signature key 2001 Path failure 1 W+PathError 0001 Path 1 2 W-PathError 0001 All paths OK 2002 No HART communication to temperature transmitter 1 W+HART T 0001 No communication W-HART T 0001 No communication 2003 No HART communication to pressure transmitter 1 W+HART P 0001 No communication W-HART P 0001 No communication 2004 Maximum pulse output frequency exceeded 1 (6kHz) W+PulseOut 0001 6000 Hz exceeded W-PulseOut 0001 6000 Hz exceeded 2005 EVC parameter invalid 1 W+EVC 0001 EVC para.invalid W+EVC 0001 EVC para.invalid 2006 EVC hardware error 1 W+EVC 0001 EVC module error Subject to change without notice W+EVC 0001 EVC module error 1001 Flow meter power ON 1 I Power ON 0001 dd/mm/yy mm:ss 1002 Meter clock adjusted 1 I Set Time 0001 dd/mm/yy mm:ss 1003 Configuration Mode active 1 I+Meas.Mode 0001 Maintenance ON 1 I-Meas.Mode 0001 Measurement ON 1 1004 Firmware changed 1 FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH I Update FW 0001 3104 -> 3200 169 Appendix Message No. on LCD Logbook message in MEPAFLOW600 CBM Logbook LCD text 1014 Overflow volume counter (a.c.) 1 I Count.ac Overflow 0001 1015 Overflow volume counter (s.c.) 1 I Count.sc Overflow 0001 1016 Error volume counter cleared 1 I Reset E 01/01/07 0001 10:47 1017 All volume counters cleared 1 I Reset V 01/01/07 0001 10:47 1027 Parameter error → factory parameters have been loaded 1 I+InitError 0001 DefaultParaLoad I-InitError 0001 DefaultParaLoad 1029 Air test mode activated 1 I+Airtest Active 0001 I-Airtest Not active 0001 Warning logbook [2] 1008 Warning logbook [2] erased and initialized 2 I Logbook 2 0001 Reset and Init 1010 Warning logbook [2] overflow 2 I+Logbook 2 0001 Overflow I-Logbook 2 0001 Overflow 1018 DataLog 1 cleared 2 I DataLog 1 0001 Reset 1019 DataLog 2 cleared 2 I DataLog 2 0001 Reset 1020 DataLog 3 cleared 2 I DataLog 3 0001 Reset 1021 DataLog 1 overflow 2 I+DataLog 1 0001 Overflow I-DataLog 1 0001 Overflow 1022 DataLog 2 overflow 2 I+DataLog 2 0001 Overflow I-DataLog 2 0001 Overflow DataLog 3 overflow 2 I+DataLog 3 0001 Overflow I-DataLog 3 0001 Overflow 1024 DatenLog 1 CRC error 2 I+DataLog 1 0001 CRC invalid I-DataLog 1 0001 CRC invalid 1025 DatenLog 2 CRC error 2 I+DataLog 2 0001 CRC invalid I-DataLog 2 0001 CRC invalid 170 FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH Subject to change without notice 1023 Appendix Message No. on LCD Logbook message in MEPAFLOW600 CBM Logbook LCD text 1026 DataLog 3 CRC error 2 I+DataLog 3 0001 CRC invalid I-DataLog 3 0001 CRC invalid 1028 Customer limit exceeded Limit value mask 0xXXXXXXXXXX (specifies limit value exceeded) 2 I+Userlimit 0001 Limit XXXXXXXXXX I-Userlimit 0001 Limits OK Parameter logbook [3] 1005 Parameter changed 3 I Parameter 0001 Parameter changed Reg3001 1006 All parameters to default (Reset) 3 I Parameter 0001 Reset all 1009 Parameter logbook [3] erased and initialized 3 I-Logbook 3 0001 Reset and Init 1011 Parameter logbook [3] overflow I+Logbook 3 0001 Overflow 3 Subject to change without notice I-Logbook 3 0001 Overflow FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH 171 Appendix 12 . 5 SPU terminal assignment Connection in accordance with ATEX IIC Terminal assignment in accordance with ATEX IIC Subject to change without notice Fig. 68 172 FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH Appendix Wiring examples 12.6.1 Intrinsically safe installation Subject to change without notice 1 2. 6 FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH 173 Appendix Non intrinsically safe installation Subject to change without notice 12.6.2 174 FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH Appendix 1 2. 7 Type plates Fig. 69 FLOWSIC300 type plate Pos. 00 01 02 03 04 05 06 07 08 09 10 11 12 13 14 Pos. 15 16 17 18 19 20 21 22 23 24 25 26 27 28 Significance – – – – Phys. unit for Pos. 04 Phys. unit for Pos. 05 – – –v – – – – Type plate of a spool piece (→ p. 27, §2.5.1) (Schema) Subject to change without notice Fig. 70 Significance Type key (→ p. 176, § Fig. 71) Item number Serial number Year of manufacturer Min. ambient temperature Max. ambient temperature – – – – – – Gas group Ex (→ p. 167, §12.2) – – FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH 175 Appendix Type key Subject to change without notice Fig. 71 176 FLOWSIC300 · Operating Instructions · 8014244/YZF6/V 1-1/2016-07 · © SICK Engineering GmbH 8014244/YZF6/V1-1/2016-07 Australia 3KRQH ²WROOIUHH E-Mail [email protected] India 3KRQH²² (0DLOLQIR#VLFNLQGLDFRP South Korea 3KRQH (0DLOLQIR#VLFNNRUHDQHW Israel 3KRQH (0DLOLQIR#VLFNVHQVRUVFRP Spain 3KRQH (0DLOLQIR#VLFNHV Italy 3KRQH (0DLOLQIR#VLFNLW Sweden 3KRQH (0DLOLQIR#VLFNVH Japan 3KRQH (0DLOVXSSRUW#VLFNMS Switzerland 3KRQH (0DLOFRQWDFW#VLFNFK Malaysia 3KRQH E-Mail [email protected] Taiwan 3KRQH (0DLOVDOHV#VLFNFRPWZ Netherlands 3KRQH (0DLOLQIR#VLFNQO Thailand 3KRQH (0DLOWDZLZDW#VLFNVJSFRPVJ Chile 3KRQH (0DLO LQIR#VFKDGOHUFRP New Zealand 3KRQH ²WROOIUHH E-Mail [email protected] Turkey 3KRQH (0DLOLQIR#VLFNFRPWU China 3KRQH (0DLO LQIRFKLQD#VLFNQHWFQ Norway 3KRQH E-Mail [email protected] Denmark 3KRQH E-Mail [email protected] Poland 3KRQH (0DLOLQIR#VLFNSO USA/Mexico 3KRQH ²WROOIUHH (0DLOLQIR#VLFNFRP Finland 3KRQH (0DLOVLFN#VLFNIL Romania 3KRQH (0DLO RIILFH#VLFNUR Vietnam 3KRQH (0DLO1JR'X\/LQK#VLFNVJSFRPVJ France 3KRQH (0DLOLQIR#VLFNIU Russia 3KRQH (0DLOLQIR#VLFNUX Gemany 3KRQH (0DLOLQIR#VLFNGH Singapore 3KRQH (0DLOVDOHVJVJ#VLFNFRP Great Britain 3KRQH (0DLOLQIR#VLFNFRXN Slovakia 3KRQH E-Mail [email protected] Hong Kong 3KRQH (0DLO JKN#VLFNFRPKN Slovenia 3KRQH (0DLORIILFH#VLFNVL Hungary 3KRQH (0DLORIILFH#VLFNKX South Africa 3KRQH (0DLOLQIR#VLFNDXWRPDWLRQFR]D Austria 3KRQH (0DLORIILFH#VLFNDW Belgium/Luxembourg 3KRQH (0DLOLQIR#VLFNEH Brazil 3KRQH (0DLOPDUNHWLQJ#VLFNFRPEU Canada 3KRQH (0DLOLQIRUPDWLRQ#VLFNFRP Czech Republic 3KRQH E-Mail [email protected] SICK AG | Waldkirch | Germany | www.sick.com United Arab Emirates 3KRQH (0DLOLQIR#VLFNDH 0RUHUHSUHVHQWDWLYHVDQGDJHQFLHV DWwww.sick.com
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