FLOWSIC300 Ultrasonic Gas Flow Meter

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FLOWSIC300 Ultrasonic Gas Flow Meter | Manualzz
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").
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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).
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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.
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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.
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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.
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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.
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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).
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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
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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.
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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
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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.
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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.
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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.
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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
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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
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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
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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.
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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.
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Subject to change without notice
Installing the Nozzles
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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
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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
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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
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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.
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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.
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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.
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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
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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.
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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).
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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.
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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.
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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
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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).
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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.
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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
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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.
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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.
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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
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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°).
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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.
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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.
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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.
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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
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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).
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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.
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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.
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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.
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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
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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.
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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).
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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.
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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
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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.
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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.
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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).
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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.
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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.
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Subject to change without notice
Installing the Electronics Unit
110
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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
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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.
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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.
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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
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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–
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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
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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.
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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
▸
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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.
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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.
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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.
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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
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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
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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
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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.
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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
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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).
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Initial Start-up
Meter factor calculator
Subject to change without notice
Fig. 49
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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.
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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.
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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.
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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.
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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.
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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
▸
▸
▸
▸
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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.
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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
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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
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Subject to change without notice
Initial Start-up
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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
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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.
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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.
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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.
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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
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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.
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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.
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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
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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.
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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
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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
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Subject to change without notice
Maintenance
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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.
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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.
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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.
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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.
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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
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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.
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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).
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159
Subject to change without notice
Troubleshooting
160
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Spare Parts
FLOWSIC300
11
Spare Parts
Subject to change without notice
Electronics subassembly
Sender/receiver units
Cables
Fitting tool
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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
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163
Subject to change without notice
Spare Parts
164
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Appendix
FLOWSIC300
12
Appendix
Subject to change without notice
Conformities
Technical Data
Logbooks
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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
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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
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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
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