Sensyflow iG Intelligent gas-mass flowmeter
PROFIBUS DPV1
PA Profile 3.0
Version 1.00
Preliminary
Operating manual
42/14-39 EN
Rev. 00
2 Sensyflow iG, Version 1.00 42/14-39 EN
Gas-mass flowmeter Sensyflow iG
PROFIBUS DPV1
PA Profile 3.0
Version 1.00
Operating manual
Document No. 42/14-39 EN
Issue date 02.02
Revision 00
Manufacturer:
ABB Automation Products GmbH
Borsigstraße 2
63755 Alzenau
Germany
Phone: +49 6023-
Fax: +49 6023-3210
© Copyright 2002 by ABB Automation Products GmbH
Subject to changes without notice.
This technical documentation is protected by copyright. Translating, photocopying and diseminating it in
any form whatsoever - even editings or excerpts thereof - especially as reprint, photomechanical or elec-
tronic reproduction or storage on data processing systems or networks is not allowed without the permis-
sion of the copyright owner and non-compliance will lead to both civil and criminal prosecution.
Contents
42/14-39 EN Sensyflow iG, Version 1.00 3
Contents
Sensyflow iG
1 Correct use, general safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1 Range of applications, proper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Equipment and functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Typical applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 General safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2.1 Safe operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2.2 Notice according to the German Hazardous Material Directive . . . . . . . . . . . . . . . . . . . . 6
2 Important information in advance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1 Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.2 In case of questions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.3 Accompanying documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.4 The calibration certificate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3 System description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.1 Pipe components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.2 Transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.3 Evaluation electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4 Mechanical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.1 Pipe component and transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.1.1 Recommended steadying run lengths for inlet run disturbances . . . . . . . . . . . . . . . . . . 11
4.1.2 Adaption of a Sensyflow iG transducer by using a weld-on adapter . . . . . . . . . . . . . . . . 12
4.2 Installating the transducer in areas with high ambient temperature . . . . . . . . . . . . . . . . 13
4.3 Aligning housing head and display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.4 Mounting the evaluation electronics (remote version) . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5 Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.1 General information about PROFIBUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.2 PROFIBUS bus design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.3 Connection, power supply, and communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.4 Connecting PROFIBUS DP via PROFIBUS M12 bus connector . . . . . . . . . . . . . . . . . . 18
5.5 PROFIBUS bus terminator and cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.5.1 PROFIBUS DP bus terminator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.5.2 PROFIBUS cable DP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.6 Cable connection between sensor and evaluation electronics (remote version) . . . . . . 19
6 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
7 Operation, configuration and communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
7.1 PROFIBUS communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
7.1.1 PROFIBUS slave addresses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
7.1.2 Module configuration for cyclic data communication (DP) . . . . . . . . . . . . . . . . . . . . . . . 22
7.1.2.1 GSD file . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
7.1.2.2 Status byte message overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
7.1.2.3 Hexadecimal status byte messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
7.1.2.4 Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
7.1.3 Acyclic data communication (DPV1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7.1.3.1 Device Management Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7.1.3.2 Physical Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7.1.3.3 Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Transducer Block Flow (TB Flow) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Function Block Flow Analog Input (AI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
7.1.3.4 Gas temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Transducer Block Gas Temperature (TB Temp.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Function Block Gas Temperature Analog Input (AI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7.1.3.5 Totalizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Function Block Totalizer (TOT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
7.2 Description of function blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
7.3 SMART VISION DTM configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4 Sensyflow iG, Version 1.00 42/14-39 EN
7.4 Display, operation, and configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
7.4.1 Operating structure overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
7.4.2 Display modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
7.4.3 Operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
7.4.4 Entering and changing data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
7.4.5 Status signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
7.5 Overview of parameterization options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
7.6 Menu structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
7.7 Parameterization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
7.7.1 Submenu level 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Submenu level 1 → PARAMETER MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Submenu level 1 → PROFIBUS MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Submenu level 1 → SERVICE MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
7.7.2 Submenu level 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Submenu level 2 → TB FLOW MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Submenu level 2 → AI FLOW MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Submenu level 2 → TB GAS TEMP MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Submenu level 2 → AI GAS TEMP MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Submenu level 2 → TOTAL MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
8 Maintenance and service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
8.1 Cleaning the transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
9 Sensyflow iG: measuring principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
9.1 Physical basics of the measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
9.2 The digital Sensyflow method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
9.3 Advantages of the digital concept . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
10 Type overview, technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
11 Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
12 Decommissioning and packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
13 Appendix: Manufacturer-specific GSD file (Device data file) . . . . . . . . . . . . . . . . . . . 57
Correct use, general safety instructions
42/14-39 EN Sensyflow iG, Version 1.00 5
1 Correct use, general safety instructions
1.1 Range of applications, proper use
Sensyflow iG has been designed for mass flow measurement of gases and gas conglomerates in closed
pipe circuits. These operating instructions describe the device version with PROFIBUS DPV1 interface
according to PA profile 3.0.
For proper use it is required to observe the Technical data section in the data sheets. You will find the
data sheets in see section 10 "Type overview, technical data" on page 53 of these operating instructions.
Any other use is considered improper.
Equipment and functions
• Graphic display 120 × 32 pixels (optional)
• Mass flow or nominal volume flow measurement
• Numeric or bar graph display indication of measured value
• Integrator function (totalizer) with Start/Stop, Reset, and Preset function
• Gas temperature measurement
• 4 characteristic curves for different gases or pipe diameters (optional)
• Max./min value storage of flow rate, gas and housing temperature
• Alarm and limit value functions
• Status and diagnostic signals
• Operating hour meter
• Simulation of measuring values and status signals
• Password-protected input menus
• 4 display languages
Typical applications
• Gas volume measurement in chemical industry and process technology
e. g. air, N
2
, O
2
, H
2
, NH
3
, natural gas, gas conglomerates.
• Compressed air balancing
• Gas burner control systems
• Sewage gas and activation air measurement in sewage plants
• Biogas measurement
• Gas balancing at air decomposers: N
2
, O
2
, Ar
• Hydrogen measurement in the process
1.2 General safety instructions
1.2.1 Safe operation
The technology of the mass flow meter is state of the art.
It is constructed and tested according to DIN VDE 0411 Part 1 "Safety Requirements for Electronic Mea-
surement Apparatus" and has left the factory in a safe condition. To maintain this state and guarantee
hazard-free operation, all safety instructions in this manual headed by "Caution" must be observed.
Otherwise, personnel might be endangered and the mass flow meter itself or other devices and equip-
ment could be damaged.
Prerequisites for
safe operation
These operating instructions contain important information about the safe and proper operation of the
equipment. Observing these instructions is mandatory for safe operation.
Failure to observe the instructions can cause hazards for life and limb of the user respectively property
damages at the devices or the entire system.
Proper and safe operation of the mass flow meter requires proper transportation and storage, installation
and commissioning by qualified personnel, operation within its design limits, and careful maintenance ob-
serving all information in these operating instructions.
Qualification of per-
sonnel
Only personnel familiar with the installation, commissioning, and maintenance of similar devices and ha-
ving the required qualifications for their tasks are allowed to work on the device.
Operator The operator of the plant is fully and solely responsible for proper and workmanlike and, thus, safe ope-
ration.
The operator must make sure that the operating instructions have been understood by the target audi-
ence.
Correct use, general safety instructions
6 Sensyflow iG, Version 1.00 42/14-39 EN
A copy of the operating instructions must be stored in a suitable place at the usage location of the device
at all times.
Read these operating instructions prior to commissioning, decommissioning, maintaining, or repairing a
device.
National
regulations
The regulations, standards, and guidelines mentioned in these operating instructions are valid for Ger-
many. When using the devices in other countries the appropriate and valid national regulations must be
observed.
Notes and
regulations to be
observed
Observe
– the contents of these operating instructions and references to other documents and their contents
– the safety instructions attached to the mass flow meter
– the application data indicated in the calibration certificate
– the appropriate and valid safety instructions for the construction and operation of electrical systems
– the appropriate and valid safety instructions for handling gases
– the regulations and directives regarding explosion protection.
During operation The operator must commission a qualified electrician to inspect and examine the system at defined inter-
vals. The examination intervals must be chosen in such a way that any damages that can be expected
can be recognised in time.
The examinations must be performed at least every three years.
The examinations can be skipped if the electrical system is continuously monitored by a responsible en-
gineer.
Duties of the operator:
– maintain the system in proper condition
– continuously monitor the system
– execute required maintenance and repair work immediately
– carry out required safety measures
If the devices are used in areas where dusts can cause explosion hazards, you must clean the devices
frequently.
Use genuine spare parts, only.
1.2.2 Notice according to the German Hazardous Material Directive
According to the German Waste Disposal Act dated 1986-08-27 ((AbfG. §11 Special Waste) the owner
of special waste is responsible for its disposal. According to the German Hazardous Material Directive
dated 1986-10-01 ((GefStoffV, §17 General Protection Duties) the employer is also obliged to protect his
employees. Therefore, we must point out the following:
a) All flow sensors and/or flow transducers sent to ABB Automation Products GmbH for repair must be
free of any hazardous substances (acids, lyes, solutions, solids).
b) Flow sensors must be flushed and rinsed in order to neutralize hazardous substances. Flow sensors
have cavities. Therefore, the cavity must be neutralized after operation with hazardous materials (refer
to German Hazardous Material Directive, GefStoffV).
c) In case of service or repair the measures listed in a) and b) must be confirmed in writing.
d) Costs arising from increased efforts for handling of contaminated devices and the disposal of hazar-
dous substances during repair shall be invoiced to the owner of the device!
Important information in advance
42/14-39 EN Sensyflow iG, Version 1.00 7
2 Important information in advance
2.1 Symbols
To ensure optimum use of these operating instructions and a safe use of the assemblies during commis-
sioning, operation, and maintenance please observe the following explanations regarding the symbols
used.
Explanation of symbols used.
If the information contained in these operating instructions is not sufficient for an application our service
organisation will gladly be at your disposal for further information.
Please read these assembly and operating instructions carefully prior to installation.
2.2 In case of questions
If you cannot find any information concerning technical questions or malfunctions in these operating in-
struction, please apply to one of our external service points or contact our technical user assistance hot-
line directly. For all questions concerning the measuring system, please have the calibration certificate
readily at hand.
2.3 Accompanying documentation
Depending on the version the appendix contains:
• for explosion-protected devices: a copy of the Ex conformity certificate
• for devices manufactured according to DVGW: a copy of the DVGW approval
• for devices used in gaseous oxygen: security clearance in form of a manufacturer's certificate.
2.4 The calibration certificate
For every measuring system leaving our factory a file documenting the production process is kept. The
most important document in this case is the calibration certificate. It contains important information of the
respective instrument such as, for example, measuring medium, measuring range(s), fabrication num-
bers, and order number.
Warning
You will find this symbol in all safety instructions throughout these ope-
rating instructions whenever there is danger for life and limb.
Apart from the information in these operating instruction you must also
observe commonly valid safety and accident prevention directives.
Caution
The symbol "Caution" points out subject matter that – if not observed –
can cause damage to components or personal injury.
i
Note
The "Note" symbol points out subject matter that – if not observed – can
cause the loss of convenience or the impairment of functions.
Example:
"Ready-made C routines are located on the support diskette."
•
General listing.
Sensyflow Hotline
Phone.: +49 (0) 60 23 92-35 97 or -326 7
Fax: +49 (0) 60 23 92-321 0
E-mail: sensyflow.dea[email protected]om
STOP
!
Important information in advance
8 Sensyflow iG, Version 1.00 42/14-39 EN
Fig. 2-1 Calibration certificate sample
Calibration subject:
sensor data and serial
(fabrication) number
Customer data
regarding the application
Calibration data:
Data regarding test bench
and boundary conditions
Calibration result:
Tolerances determined
on the test bench in
form of tables and
diagrams
System description
42/14-39 EN Sensyflow iG, Version 1.00 9
3 System description
The mass flow meters of the Sensyflow iG family operate according to the hot-film anenometer principle.
An exact description can be found in Section 9, "Measuring principle"
The compact version of the metering system comprises a transducer (sensor with transducer electronics)
and a pipe component (in different construction types). In the remote version the sensor and the evalua-
tion electronics are separate units that can be mounted max. 25 m apart.
Sensyflow iG transducer
with display (compact version)
Fig. 3-1 Pipe component 1 in wafer flange version (intermediate flange
DN 40 to DN 200 / ANSI 1 ½" to 8")
Sensyflow iG transducer
with display (remote version)
Fig. 3-2 Pipe component 2 as partial measuring section DN 25 to DN
50 ANSI 1" to 2" (
1)
centering pin)
Fig. 3-3 Weld-on adapter from DN 150 (
1)
centering pin)
Z-18949
1)
Z-18957
1)
System description
10 Sensyflow iG, Version 1.00 42/14-39 EN
3.1 Pipe components
The pipe components and weld-on adapters guarantee the defined installation of the transducer in the
pipeline. Moreover, they allow simple installation and removal of the transducer for inspection and/or cle-
aning. By closing the pipe component with a blind flange (C 25 / PN 40 according to DIN 2527) it is pos-
sible to use the measuring section even without installed transducer.
For larger nominal widths (≥ DN 150) or non-round pipe cross-sections the transducer is installed in the
pipeline in a defined position by means of the weld-on adapter. Depending on the respective nominal
width and the desired adaption type, the versions available as standard are displayed in see section 10
"Type overview, technical data" on page 53.
3.2 Transducer
The transducer is constructed as push-in sensor and contains in the compact version – apart from the
sensor unit – also the complete transducer circuitry (power supply, display, measuring circuitry) located
in the connection head.
The remote version transducer consists merely of the sensor unit and the connection housing with termi-
nal block.
Dimensions and technical data of the transducers are shown in see section 10 "Type overview, technical
data" on page 53.
3.3 Evaluation electronics
The flame-proof encapsulated housing of the evaluation electronics contains - apart from power supply,
display (optional), and sensor control - also the entire bus interface for PROFIBUS DPV1 communication.
The electronic circuitry regulates the heating power of the sensor unit, processes flow, temperature, and
diagnostic signals and provides linearized output signals and status messages at the PROFIBUS.
You can select from the following measuring value display types:
• gas temperature and mass flow value
• mass flow value numerically and as bar graph
• integrator value and mass flow value
• gas temperature
• integrator value and time
Via the SERVICE MENU you can call up current status and diagnostic signals. Internally, the maximum
and minimum mass flow and gas temperature values are recorded together with the accumulated opera-
ting hours (which can also be displayed in the SERVICE MENU).
A multitude of configurations allow the adaption of the device to different measuring tasks. A complete
listing of all parameterization possibilities can be found in see section 7.7 "Parameterization" on page 43.
.
Mechanical installation
42/14-39 EN Sensyflow iG, Version 1.00 11
4 Mechanical installation
4.1 Pipe component and transducer
Inlet and outlet runs must be provided to avoid negative effects on the measuring accuracy, These
steadying run lengths make sure that disturbances of the flow profile are eliminated before they can reach
the actual measuring point at the transducer. Straight, undisturbed pipe lengths are used as steadying
run lengths, their length depends on the type of the inlet run disturbance.
4.1.1 Recommended steadying run lengths for inlet run disturbances
The inlet and outlet run lengths are stated as multiples of the pipe diameter D.
Recommended insatallation requirements according to DIN EN ISO 5167-1
Expansion
X = 15
Reducer
X = 15
90° elbow
X = 20
Two 90° elbows
in one level
X = 25
Two 90° elbows
in two levels
X = 40
Valve/ slide
X = 50
XD
×
5D
×
Z-18938
Z-18939
Z-18940
Z-18941
Z-18942
Z-18943
Z-18944
Mechanical installation
12 Sensyflow iG, Version 1.00 42/14-39 EN
• Components that influence the flow (e. g. valves, shut-off fittings and similar components) should pos-
sibly be mounted at the outlet run length, i. e. behind the measuring point .
• The sealings used must not change the cross-section of the pipeline opening and must guarantee the
absolute tightness after installing the transducer and pipe component.
• Centric installation must be especially observed when using pipe component 1. The inside diameter of
pipes and flanges must match exactly. Every step, edge, or untidy weld disturbs the flow profile forma-
tion, thus reducing the achievable measuring accuracy.
• The flow direction must be in line with the arrow indicated on the pipe component. The positioning pin
at the pipe component respectively weld-on adapter must be at the outlet run length (behind the measu-
ring point).
To achieve the stated measuring accuracy, the steadying run lengths shown above are absolutely requi-
red. For combinations of several inlet run disturbances, e. g. valve and reducer, you must always consider
the longer inlet run length.
In confined spaces at the mounting location the outlet run length can be reduced to 3× D. The reduction
of the minimum inlet run length, however, will take it's tall on the achievable accuracy. High repeatability
of the measuring value is still provided.
Under certain circumstances, special calibration can be performed for insufficient steadying run lengths.
For this purpose and in individual cases, consult ABB's DKD Calibration Department at Alzenau.
For gases with extremely low density (hydrogen, helium) the stated steadying run lengths must be dou-
bled.
4.1.2 Adaption of a Sensyflow iG transducer by using a weld-on adapter
When installing the transducer in pipes with larger nominal width or non-round cross-section, the weld-
on adapter must be welded to the pipeline under consideration of the following information:*
1. The weld-on adapter must be shortened to length L according to following formula:
L = L
1
- ½ × ∅ D
outside
with L1 = 263, 425 or 775 mm (transducer lengths)
– Observe the pipeline wall thickness and amount of shrinkage when welding!
– The distance L1 from the flange top edge of the adapter to the pipe center line must be within
a tolerance of ±2 mm.
2. Rectangularity to the pipe axis must be absolutely kept (max. tolerance 2°).
3. The positioning pin of the adapter must be aligned in flow direction to the pipe axis (at outlet run
length, behind measuring point).
4. After welding the free passage for inserting the transducer must be at least 28 mm (if required, use
drill to clear).
5. Transducer installation:
– For the standard version, insert the supplied O-ring (55 × 3 mm) into the provided groove.
– For special version with groove and tongue system you must use a suitable flat sealing!
– Push the transducer into the adapter and screw together.
Mechanical installation
42/14-39 EN Sensyflow iG, Version 1.00 13
Fig. 4-1 Adaption by using a weld-on adapter
Note Deviations from the stated dimension and position tolerances cause additional measuring uncertainty.
4.2 Installating the transducer in areas with high ambient temperature
The permissible ambient temperatures for the electronic components are between -25 and +65 °C for de-
vice versions without display. Versions with display can only be used up to an ambient temperature of
max. +50 °C. In case of high temperatures of the medium, sufficient thermal isolation of the measuring
lead must be provided in order to prevent the temperature at the electronics unit to exceed the permissible
ambient temperature.
Usually there are no problems for devices of the remote version, as the electronics unit can normally be
mounted at a sufficient distance to the hot pipelines.
If a compact version device must be mounted directly to a hot pipeline, the lateral installation is recom-
mended. In such cases you should avoid mounting the device in 12 o'clock position, since otherwise the
rising warm air causes additional heating up of the electronic circuitry.
Weld-on adapter
(upon delivery)
Required accuracy of mounting
Centric mounting < ±2 mm
Twist < ± 2°
(1) Centering pin
on outlet run side
∅
33,7
450 mm
Z-189342
(1)
Anschlussflansch DN 25
∅ d
∅
D
min. 28 mm
h
Z-189341
(1)
O-Ring Nut
Durchflussrichtung
Fig. 4-2 Recommended mounting of the device in case
of hot pipelines, display rotated by 90°
Fig. 4-3 Sensor mounting in 12 o'clock position for uncri-
tical ambient temperatures
Mechanical installation
14 Sensyflow iG, Version 1.00 42/14-39 EN
4.3 Aligning housing head and display
In the compact and remote version the housing of the evaluation electronics has been pivot-mounted for
enhanced readability. From the center position it can be rotated by approximately 170° to the right or left
until the limit stop. For fixation the three grub screws can be tightened see Fig. 4-4.
The display alignment can be changed in steps of 90°. For this purpose you must screw off the front lid
and pull off the display cover.
Caution
For devices with long-range power supply unit it is mandatory to remove all power from the device before
opening the front lid!
Regardless of the device type you must take ESD precautions before touching the components!
After loosening the four fastening screws you can pull out the board and plug it in again in the desired
position. Subsequently tighten the fastening screws again, attach the display cover and screw on the hou-
sing lid.
Fig. 4-4 The display can be rotated in steps of 90°.
!
STOP
Mechanical installation
42/14-39 EN Sensyflow iG, Version 1.00 15
4.4 Mounting the evaluation electronics (remote version)
In the remote version you can use cables with a length up to 25 m between sensor (transducer) and eva-
luation electronics. The transducer is installed as described before in the pipe component or weld-on ad-
apter. The evaluation electronics is then mounted with the mounting plate – observing the maximum
permissible ambient temperature – to an even wall surface (see Fig. 4-5 for dimensions).
Fig. 4-5 Dimensions of the Sensyflow iG mounting plate ( Remote-Version)
Due to the rotating housing head the rear terminal box is still accessible.
The connection between sensor and evaluation electronics is made via 10-pole, numbered terminal
blocks that can be accessed after removing the covers at the sensor connection housing and the terminal
box of the electronics unit.
(dimensions in mm)
Mounting plate
Sensor
connection housing
100
Z-20275
07
112
Electrical installation
16 Sensyflow iG, Version 1.00 42/14-39 EN
5 Electrical installation
5.1 General information about PROFIBUS
PROFIBUS is a vendor-independent, standardized field bus for applications in manufacturing, process,
and building automation. The PROFIBUS technology has been defined as an international standard in
EN50170. Thus, every manufacturer of products can use the PROFIBUS standard.
The PROFIBUS family is made up by three protocol types, which are applied depending on the respective
application. Of course it is possible to interconnect all three protocol types in a single PROFIBUS network
in more complex systems. The base for this possibility is the compatibility of the protocol types.
The three protocol types are called PROFIBUS-DP, -PA and -FMS. For process automation the protocol
type DP and PA are of importance.
• PROFIBUS-DP (Decentral Periphery)
• PROFIBUS-PA (Process Automation)
• PROFIBUS-FMS (Field Message Specification)
5.2 PROFIBUS bus design
Fig. 5-1 PROFIBUS, bus design
5.3 Connection, power supply, and communication
In the device version described in this section the PROFIBUS cable is directly connected. The description
of the devices with PROFIBUS M12 bus connector can be found in see section 5.4 "Connecting PROFI-
BUS DP via PROFIBUS M12 bus connector" on page 18.
Caution
Remove all power from the device before opening the rear device cover and the cover of the supply ter-
minal block!
PROFIBUS-PAPROFIBUS-DP
31.25 kBit/s
IEC 1158-2 = H1-Bus
DP/PA-
coupler
Trans-
mitter
Posi-
tioner
Field
device
Power
unit
Ex i Ex i Ex i
Trans-
mitter
Field
Field
non-Ex
Repeater
9.6 ... 93.75 ... 12 000 kBit/s
RS 485 = H2-Bus
Contr.
room
device
DP/PA-
coupler
PROFIBUS-PA
Trans-
mitter
Posi-
tioner
Trans-
mitter
Class 1 and Class 2
master
!
STOP
Electrical installation
42/14-39 EN Sensyflow iG, Version 1.00 17
Fig. 5-2 Sensyflow iG terminal box with direct PROFIBUS connection
Caution
Before connecting the power supply lines make sure that the device is operated with the correct supply
voltage (see device rating plate)!
First you connect the grounding cable to the PE terminal, then the actual supply lines at the power supply
terminal block.
Incoming and outgoing PROFIBUS cables are connected to terminal A (green wire) and B (red wire) re-
spectively.
Terminals L and H must not be connected (CAN bus, for internal use only).
Note To ensure safe operation of the assembly and to reduce EMC interference to a minimum, the cable shield
of the PROFIBUS lines should be connected to the corresponding terminals in the connection box.
For additional EMC interference suppression the housing grounding screw (M6 thread) should be used
to establish a low-resistance connection (wire cross-section 4 mm²).
Note When disconnecting the PROFIBUS cable from the unit, the entire bus connection is interrupted!
Device versions with interruption-free disconnection capability: see next section.
!
P
E
-
+
B
B
D
P
D
P
A
C
A
N
L
A
L
H
C
A
N
H
O
N
O
F
F
T
E
R
M
I
N
A
T
I
O
N
Z-20276
Additional terminal block
cover
Power supply
Terminal block
Power supply
+ Terminals/phase
– Terminal/neutral
PE protective earth
CAN bus
Terminals L, H
(internal use only)
PROFIBUS DPV1
terminals A, B
Jumper for PROFIBUS
termination resistor
Terminals for cable shield
PROFIBUS lines
Electrical installation
18 Sensyflow iG, Version 1.00 42/14-39 EN
5.4 Connecting PROFIBUS DP via PROFIBUS M12 bus connector
Fig. 5-3 PROFIBUS DP M12 bus connector
For this device version a PROFIBUS DP M12 bus connector with complete internal wiring is supplied in-
stead of the central screw terminals (see Fig. 5-2). The bus connection is made via a T-plug that connects
the incoming and outgoing PROFIBUS cable. This version allows pulling the T-plug and disconnecting
the device from PROFIBUS DP without interfering with the bus operation.
Note Suitable T-plugs and cable sockets/plugs are available as accessories.
(see Sensyflow iG data sheets and PROFIBUS accessories)
DP M12 connecting socket
DP M12
1
2
3
4
5
Plug
T-piece
Socket
Pin Signal Description
1 VP Supply voltage, positive (P 5 V)
2 RxD/TxD-N Receive/transmit data, –N, line A (green wire)
3 DGND Data transmission potential (reference potential for VP)
4 RxD/TxD-P Receive/transmit data, positive, line B (red wire)
5 Shield Shield/protective earth
Thread Shield Shield/protective earth
Electrical installation
42/14-39 EN Sensyflow iG, Version 1.00 19
5.5 PROFIBUS bus terminator and cable
To minimize line reflections and to ensure a defined steady level on the transmission line, the transmis-
sion line must be fitted with the following termination resistor combination at both ends.
5.5.1 PROFIBUS DP bus terminator
Fig. 5-4 PROFIBUS DP bus terminator
The number in parenthesis correspond to the pin assignment at the 9-pole D-Sub connector.
5.5.2 PROFIBUS cable DP
The cables for the PROFIBUS connection must comply with the following parameters according to PRO-
FIBUS Specification EN50170 part 8-2:
Note For safe functioning or to minimize line reflections and to establish a defined steady level, the PROFIBUS
network must be terminated (see PROFIBUS Termination Specification according to EN50170 Volume).
Stub lines should be avoided, as they may cause line reflections and malfunctions.
Note To ensure safe operation of the PROFIBUS communication you must take the PROFIBUS DP/FMS gui-
deline/installation into consideration.
5.6 Cable connection between sensor and evaluation electronics (remote version)
With the remote version you can use cables with a length up to 25 m between sensor and evaluation elec-
tronics. The connection is made via 10-pole, numbered terminal blocks that can be accessed after remo-
ving the covers at the sensor connection housing and the terminal box of the electronics unit. The
individual wires are wired 1:1 to the 10-pole terminal blocks in the sensor connection housing and at the
terminal box.
You can use a round data cable LIYCY 10 × 0.5 mm² with braided copper shield.
Note Ready-made cables can be ordered in lengths of 5, 15, and 25 m as accessories (see data sheet).
Parameter DP, line type A, shielded
Surge impedance in Ω 135...165 at a frequency of 3...20 MHz
Operating capacitance (pF/m) 30
Loop impedance (Ω/km) ≤ 110
Solid wire AWG 22/1
Stranded wire > 0.32 mm²
390 ohms
220 ohms
390 ohms
VP (6)
Line type B (3)
Line type A (8)
DGND (5)
Commissioning
20 Sensyflow iG, Version 1.00 42/14-39 EN
6 Commissioning
After completion of the installation procedure (see previous section) Sensyflow iG can be commissioned.
Follow the instructions below:
Caution
Before connecting the power lines make sure that the device is operated with the correct supply voltage
(see device rating plate)!
The power supply may only be switched on when the connection box cover is closed. Danger of electric
shock!
Note
• Switch on the power supply
The system is automatically booted, and the Sensyflow iG is initialized; subsequently the system chan-
ges over to the pre-set display screen and starts normal measuring operation.
In case of error, a simple troubleshooting display pops up automatically.
• Configure the PROFIBUS slave address (see next section) through either
– local configuration by using the device display (Sensyflow iG is in SERVICE/SPECIALIST mode)
or
– remote configuration, from the Class 1 master of the process control system, or a Class 2 master
with the appropriate parameterizing and configuration tool (via the SET SLAVE address telegram)
• Set up PROFIBUS DP configuration for cyclic data communication with the Class 1 master of the pro-
cess control system (see section 7) :
– Load the device data (GSD) file into the process control system, and save it in the appropriate sub-
directory (for GSD file see Appendix)
• Set the parameters and configure the system through either
– local parameterization at the display by using a magnetic pen (see section 7.4 "Display, operation,
and configuration" on page 35).
or
– DTM parameterization and configuration by using SMART VISION or FDT
( see section 7.3 "SMART VISION DTM configuration" on page 35).
After successful configuration or if there are no further user actions for 2 minutes, the system automati-
cally displays the default mask and changes over to STANDARD mode.
Note In the individual display masks the connect symbol -||- indicates whether or not a PROFIBUS connection
is established to the Class 1 or Class 2 master. If there is no connection, the symbol -| |- is displayed.
In case of error the display shows the error symbol "E" (see section 7.4 "Display, operation, and
configuration" on page 35).
!
STOP
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