SICK FLOWSIC60 Continuous air flow measurement for mining applications Operating instructions

OPERATING INSTRUCTIONS

FLOWSIC60

Continuous air flow measurement

for mining applications

Front page

Installation

Operation

2 FLOWSIC60 Operating Instructions 8014241/YTG9/V1-0/2016-02 © SICK Engineering GmbH

Document Information

Document ID

Title: Operating Instructions FLOWSIC60

Part No.: 8014241

Version: 1-0

Release: 2016-02

Described Product:

Product name: FLOWSIC60

Manufacturer

SICK Engineering GmbH

Bergener Ring 27 · D-01458 Ottendorf-Okrilla · Germany

Phone: +49 35 20552410

Fax: +49 35 20552450

E-mail: info.pa@sick.de

Trademarks

Windows is a Microsoft Corporation trademark.

Other product names used in this document may also be trade-

marks and are only used for identification purposes.

Original Documents

The English version 8014241 of this document is an original

document of SICK Engineering GmbH.

SICK Engineering GmbH assumes no liability for the correctness of

an unauthorized translation.

Please contact SICK Engineering GmbH or your local representa-

tive in case of doubt.

Legal Information

Subject to change without notice.

Glossary

AC Alternating current

Al Aluminium

ATEX ATEX: Atmosphères Explosifs: Abbreviation for Euro-

pean standards that govern safety in potentially

explosive atmospheres

CSA Canadian Standards Association (www.csa.ca)

DC Direct Current

IEC International Electronical Commission

IECEx IEC system for certification in accordance with stan-

dards for devices for use in potentially explosive

atmospheres

IPxy Ingress Protection: Degree of protection of a device

in accordance with IEC/DIN EN 60529; x specifies

the protection against contact and impurities, y pro-

tection against moisture.

MDR Manufacturer Data Record

NAMUR Abbreviation for "Normen-Arbeitsgemeinschaft für

Mess- und Regeltechnik in der chemischen Indust-

rie", now "Interessengemeinschaft Automatisier-

ungstechnik der Prozessindustrie" (www.namur.de)

FLOWSIC60 Operating Instructions 8014241/YTG9/V1-0/2016-02 © SICK Engineering GmbH 3

Warning Symbols

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.

Information Symbols

Hazard (general)

Hazard in potentially explosive atmospheres

Hazard by voltage

Information about the use in potentially explosive

atmospheres

Important technical information for this product

Important information on electric or electronic func-

tions

Supplementary information

Link to information at another place

Contents

4 FLOWSIC60 · Operating Instructions · 8014241/YTG9/V1-0/2016-02 · © SICK Engineering GmbH

1 Important Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1.1 About this document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

1.2 Main Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

1.3 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

1.3.1 Product identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

1.3.2 Operation in potentially explosive atmospheres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

1.3.3 Restrictions of use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

1.4 Responsibility of user. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

1.5 Safety instructions and protective measures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

2 Product description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2.1 System information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

2.1.1 System components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

2.1.2 Determinig the gas velocity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

2.1.3 Operating principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

2.1.4 FLOWSIC60 Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

2.1.5 Signal Processing unit (SPU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

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

3.1 Mechanical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

3.1.1 Project Planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

3.1.2 Mounting of sensors to tunnel wall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

3.1.3 Mounting of Signal processing Unit (SPU) and cable holder . . . . . . . . . . . . . . . . . . . 27

3.1.4 Alignment of sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

3.1.5 Determination of path length and path angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

3.2 Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

3.2.1 General information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

3.2.2 Cable specifications for power supply and analog output . . . . . . . . . . . . . . . . . . . . . 31

3.2.3 Checking the cable loops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

3.2.4 Electrical installation of Signal Processing Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

3.2.5 Operation in hazardous areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

4 Commissioning and Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

4.1 Operation and Menu structure of the SPU via LC-Display . . . . . . . . . . . . . . . . . . . . . . . . 44

4.2 Operational concept . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

4.2.1 Menu structure on the LCD display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

4.2.2 Data editing in Configuration Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

4.3 Comissioning and initial start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

4.4 Calibration / Zero-point adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

4.5 Operating Modes, Meter States and Signal Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

4.5.1 Operation Mode and Configuration Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

4.5.2 Meter States . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

5 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

5.1 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

5.2 In case of works in tunnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

6Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

6.1 General troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Contents

FLOWSIC60 · Operating Instructions · 8014241/YTG9/V1-0/2016-02 · © SICK Engineering GmbH 5

7 Annex. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

7.1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

7.2 Labelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

7.3 Wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

7.4 Ex Certificate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Contents

6 FLOWSIC60 · Operating Instructions · 8014241/YTG9/V1-0/2016-02 · © SICK Engineering GmbH

Important Information

FLOWSIC60 · Operating Instructions · 8014241/YTG9/V1-0/2016-02 · © SICK Engineering GmbH 7

Subject to change without notice

FLOWSIC60

1 Important Information

About this document

Main hazards

Intended use

Responsibility of user

Safety instructions and protective measures

8 FLOWSIC60 · Operating Instructions · 8014241/YTG9/V1-0/2016-02 · © SICK Engineering GmbH

Important Information

Subject to change without notice

1.1 About this document

These Operating Instructions contain essential information on the function, installation,

start-up and maintenance of the FLOWSIC60 ultrasonic air velocity meter.

1.2 Main Hazards

Hazards due to explosive or combustible gases

The FLOWSIC60 measuring system may be used in potentially explosive atmospheres

according to the respective specifications.

1.3 Intended use

The FLOWSIC60 measuring system is designed for contactless measurement of air flow

velocity in explosive atmospheres.

1.3.1 Product identification

1.3.2 Operation in potentially explosive atmospheres

WARNING:Hazards due to explosive or combustible gases



In potentially explosive atmospheres, only use the FLOWSIC60 specified for

such use.



Observe the information contained in these Operating Instructions during

installation work on running equipment.

Product name: FLOWSIC60

Manufacturer:

SICK Engineering GmbH

Bergener Ring 27

01458 Ottendorf-Okrilla

Germany

WARNING: Explosion danger in hazardous areas!

The front cover of the device electronics is sealed. Do not open the front cover!

Otherwise the explosion protection of the device expires and serious damage

and injury can occur.

The FLOWSIC60 is approved for use in Ex Zone 0. The device designation for

use in hazardous areas is:

Electronics:

– Ex ia [ia] I Ma

– Ex ia [ia] IIC/IIB/IIA T4 Ga

Transducers:

–Ex ia I Ma

– Ex ia IIC/IIB/IIA T6/T4 Ga

Compliance with the above requirements is the sole responsibility of the user.

Important Information

FLOWSIC60 · Operating Instructions · 8014241/YTG9/V1-0/2016-02 · © SICK Engineering GmbH 9

Subject to change without notice

1.3.3 Restrictions of use

Refer to the type plate for the configuration of your FLOWSIC60.

Check the FLOWSIC60 is suitably equipped for your application (e.g., gas conditions).

1.4 Responsibility of user



Only put the FLOWSIC60 into operation after reading the Operating Instructions.



Observe all safety information.



If anything is not clear: Please contact the SICK Customer Service.

Designated users

The FLOWSIC60 measuring system may only be installed and operated by skilled

technicians who, based on their technical training and knowledge as well as knowledge of

the relevant regulations, can assess the tasks given and recognize the hazards involved.

Technicians must be skilled according to DIN VDE 0105 or IEC 364 or directly comparable

standards.

The named persons must have exact knowledge of operational hazards caused by

explosive gases as well as adequate knowledge of the measuring system gained through

training.

Correct use



Use the FLOWSIC60 only as described in these Operating Instructions. The manufac-

turer bears no responsibility for any other use.



Observe all measures necessary for conservation of value, e.g. for maintenance and

inspection and/or transport and storage.

 Do not remove, add or modify any components 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

 Do not use damaged components or parts.

Specific requirements for use of devices in hazardous areas

WARNING: Explosion hazard

Restrictions as documented in the Ex certification and this manual must be

observed. This includes observing limits for correct use as specified in the

Technical Data.



Cabling /installation, device set-up, maintenance and check may be only

carried out by experienced staff which has knowledge about the rules and

regulations for hazardous areas, in particular:

–type of protection

– installation rules

– area definition



Regulations to be applied:

– IEC 60079-14

– IEC 60079-17

or comparable national regulations.

10 FLOWSIC60 · Operating Instructions · 8014241/YTG9/V1-0/2016-02 · © SICK Engineering GmbH

Important Information

Subject to change without notice

Special local conditions



Observe the valid legal regulations as well as the technical rules deriving from imple-

mentation of these regulations applicable for the respective equipment during work

preparation and performance.



Special caution and attention is required on equipment with increased hazard potential

(explosion protection zones). Comply with existing special regulations.



Carry out work according to the local conditions specific for the equipment as well as

operational hazards and regulations.



Suitable protection devices and safety equipment for persons must be available accord-

ing to the respective hazard potential and be used by the personnel.

Retention of documents

Keep the Operating Instructions belonging to the measuring system as well as equipment

documentation onsite for reference at all times. Pass the respective documentation on to

any new owner of the measuring system.

Selection of materials

The user must check whether the intended materials of the device components are

suitable for the process conditions.

1.5 Safety instructions and protective measures

Using the equipment for any purpose other than intended, or improper operation may

result in injuries and damage to the equipment. Read this section and the notes and

warnings in the individual sections of this manual carefully and observe the instructions

given therein when carrying out any work on the FLOWSIC60 measuring system.

General instructions:



Always comply with the statutory provisions and the associated technical rules and reg-

ulations relevant to the equipment when preparing for and carrying out any work on the

measuring system. Always observe the relevant regulations.



Always consider local and equipment-specific conditions and process-specific dangers

when carrying out any work on the equipment.



Operating instructions and equipment documentation shall always be available on site.

Always observe the safety instructions and notes on the prevention of injuries and dam-

age given in these manuals.



Make sure appropriate protective accessories are available in sufficient supply. Always

use such protective accessories. Check that appropriate safety devices are fitted and

working correctly.

NOTICE:

If the FLOWSIC60 is used in conjunction with control equipment, the operator

must ensure that any failure or malfunction does not lead to damaging or

dangerous operating conditions.

In order to prevent device failure, the specified maintenance actions must be

carried out by qualified and experienced service staff at regular intervals.

Important Information

FLOWSIC60 · Operating Instructions · 8014241/YTG9/V1-0/2016-02 · © SICK Engineering GmbH 11

Subject to change without notice

Protection devices

Preventive measures for operating safety

NOTICE:

Suitable protection devices and safety equipment must be available according

to the respective hazard potential for use by personnel.

NOTICE:

The user must ensure that:



Neither failures nor erroneous measurements lead to operational states

that can cause damage or become dangerous



The specified maintenance and inspection tasks are carried out regularly

by qualified, experienced personnel.

12 FLOWSIC60 · Operating Instructions · 8014241/YTG9/V1-0/2016-02 · © SICK Engineering GmbH

Important Information

Subject to change without notice

Recognizing malfunctions

Every deviation from normal operation is to be regarded as a serious indication of a

functional impairment. These are, amongst others:



Warning displays (e.g. heavy contamination)



Large drifts in measured results



Increased power input



Higher temperatures of system parts



Monitoring device triggering



Smells or smoke emission

Avoiding damage

The operator must ensure the following to avoid malfunctions that can directly or indirectly

lead to injuries to persons or material damage:



The responsible maintenance personnel are present at any time and as quickly as pos-

sible



The maintenance personnel are adequately qualified to react correctly to malfunctions

of the measuring system and any resulting operational malfunctions (e.g. when used for

measurement and control purposes)



The malfunctioning equipment is switched off immediately in case of doubt and that

switching off does not cause collateral malfunctions.

Repairs

NOTICE:

Any repair work on FLOWSIC60 and its components will be carried out at the

manufacturer only.

In case of malfunction, the defective component can be exchanged and sent to

the manufacturer for repair.

Product description

FLOWSIC60 · Operating Instructions · 8014241/YTG9/V1-0/2016-02 · © SICK Engineering GmbH 13

Subject to change without notice

FLOWSIC60

2 Product description

System information

14 FLOWSIC60 · Operating Instructions · 8014241/YTG9/V1-0/2016-02 · © SICK Engineering GmbH

Product description

Subject to change without notice

2.1 System information

The FLOWSIC60 transducers consist of two ultrasonic sensors, sensor cables and a signal

processing unit. The transducer is mounted in the holder. Coaxial connection cables are

used for the communication with the SPU.

2.1.1 System components

The FLOWSIC60 measuring system contains of the following components:



Sensor A and B



Signal processing unit (SPU) for control, evaluation and output of data



Connection cable, 2 pcs., for connections of transducers to junction box



Mounting set 2pcs., for fastening the wall brackets on the mine wall



Cable holder 1 pc., for storage of connection cables

Fig. 1 FLOWSIC60 measuring system

Sensor A

Sensor B

Signal Processing unit

Power

supply

Direction of

Air flow

Analog

output

Product description

Subject to change without notice

2.1.2 Determinig 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:

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.

Valid against the flow is:

After the resolution to v:

v =

· ()

t

BA

=

t

AB

=

L 1 1

2 · cos α t

AB

t

BA

L

c - v · cos α

L

c + v · cos α

(2.1)

(2.3)

(2.2)

Product description

Subject to change without notice

2.1.3 Operating principle

FLOWSIC60 operates by measuring the transit time difference of ultrasonic pulses. The

sensors are mounted on both sides of the tunnel at a certain angle to the flow direction

(



Fig. 1).

The sensors alternately send ultrasonic pulses to each other. Depending on the installation

angle α and the air velocity 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 transit time

difference of the sound pulses traveling from sensor A to B and in opposite direction is

directly related to the air velocity. The air velocity v is calculated from the transit time

difference of the ultrasonic pulses, independent of the velocity of sound. Changes in the

velocity of sound caused by pressure or temperature fluctuations, therefore, do not affect

the calculated air velocity with this method of measurement.

Product description

Subject to change without notice

2.1.4 FLOWSIC60 Sensor

Fig. 2 Sensor

Fig. 3 Dimensions - Sensor

Mounting

bracket

Sensor front

Safety screw

Product description

Subject to change without notice

2.1.5 Signal Processing unit (SPU)

Fig. 4 Signal processing unit

Signal Processing Unit (SPU)

Junction box

Cable holder

Cabling from transducer units

Product description

Subject to change without notice

Fig. 5 Dimensions - Signal processing unit

Product description

Subject to change without notice

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SICK FLOWSIC60 Continuous air flow measurement for mining applications Operating instructions

SICK FLOWSIC60 Continuous air flow measurement for mining applications Operating instructions

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