SICK FLOWSIC600 BIO Ultrasonic Gas Flow Meter for Biogas Operating instructions

Brand: SICK

Model: FLOWSIC600 BIO Ultrasonic Gas Flow Meter for Biogas

Category: Temperature & humidity sensors

Type: Operating instructions

OPERATING INSTRUCTIONS

Installation

Operation

Maintenance

Title Page

FLOWSIC600 BIO

Ultrasonic Gas Flow Meter for

Biogas

2 FLOWSIC600 BIO · Operating Instructions · 8014158/YZO8/V1-0/2016-07 · © SICK Engineering GmbH

Document Information

Product

Product name: FLOWSIC600 BIO

Document ID

Title: Operating Instructions FLOWSIC600 BIO

Part No.: 8014158

Version: 1-0

Release: 2016-07

Manufacturer

SICK Engineering GmbH

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

Phone: +49 35 20552410

Fax: +49 35 20552450

E-Mail: [email protected]

Original documents

The English version 8014158 of this document is an original docu-

ment 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

Abbreviations used in this manual

act. actual (under operating/flowing conditions)

AGC Automatic Gain Control

ASCII American Standard Code for Information

Interchange

ANSI American National Standards Institute

ASME American Society of Mechanical Engineers

AWG American Wire Gage

CBM Condition Based Maintenance

CSA Canadian Standards Association

DC Direct Current

DIN Deutsches Institut für Normung

DN Nominal Diameter (internal)

DSP Digital Signal Processor

EC European Community

EN Euro Norm (European Standard)

EVC Electronic Volume Corrector

Ex Potentially ex

plosive atmosphere

HART

 Communication interface

IEC International Electrotechnical Commission

LCD Liquid Crystal Display

LED Light Emitting Diode

MEPAFLOW Menu-assisted Parameterization and Diagno-

sis for FLOWSIC600

MDR Manufacturer Datal Record

NAMUR Normenarbeitsgemeinschaft für Mess- und

Regeltechnik in der chemischen Industrie

(now "Interessengemeinschaft Prozessleit-

technik der chemischen und pharmazeuti-

schen Industrie"; ~ Association for Instrumen-

tation and Control Standards in the Chemical

Industry)

norm. normalized/corrected (under standard condi-

tions)

OI Operating Instructions (this document)

OIML Organisation Internationale de Metrologie

Legale

PC Personal Computer

PTB Physikalisch Technische Bundesanstalt

(~ Federal Metrology Office in Germany)

RTU Remote Terminal Unit

SPU Signal Processing Unit

VDE Verband der

Elektrotechnik Elektronik Infor-

mationstechnik

(~Association of German Electrical Engineers)

FLOWSIC600 BIO · Operating Instructions · 8014158/YZO8/V1-0/2016-07 · © 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 by voltage

Hazard in potentially explosive atmospheres

Information on product characteristics related to Euro-

pean Directive ATEX

Important technical information for this product

Important information on electric or electronic func-

tions

Supplementary information

Link to information at another place

Contents

4 FLOWSIC600 BIO · Operating Instructions · 8014158/YZO8/V1-0/2016-07 · © SICK Engineering GmbH

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

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

1.2 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

1.2.1 Intended use of the equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

1.3 Authorized staff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

1.4 General safety instructions and protective measures . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

1.5 Dangers due to hot, corrosive and explosive gases and high pressure . . . . . . . . . . . . 10

1.6 Electrostatic charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1.7 Environmental information and instructions for disposal . . . . . . . . . . . . . . . . . . . . . . . . 11

1.8 Specified service life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2 Product Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2.1 System components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

2.1.1 Meter body. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

2.1.2 Ultrasonic transducers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

2.1.3 SPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

2.2 Terminal assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

2.3 Operating modes and signal output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

2.3.1 Operation mode and Configuration mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

2.3.2 Meter states . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

2.3.2.1 Status: Measurement valid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

2.3.2.2 Status: Check request. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

2.3.2.3 Status: Data invalid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

2.3.3 Output of pulse signals and status information . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

2.4 MEPAFLOW600 CBM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

2.4.1 Software installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

2.4.2 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

3 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

3.1 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

3.1.1 Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

3.1.2 Product identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

3.1.3 Transport and storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

3.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

3.2.1 Measuring location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

3.2.2 Recommendations for installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

3.3 Mechanical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

3.3.1 Choosing flanges, seals and other parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

3.3.2 Mounting the FLOWSIC600 BIO in the piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

3.3.3 Installation in stainless steel piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

3.3.4 SPU alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

3.4 Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

3.4.1 General information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

3.4.2 Cable specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

3.4.3 Checking the cable loops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

3.4.4 Terminal enclosure on the SPU. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

3.4.5 Operating the FLOWSIC600 BIO in non-hazardous areas. . . . . . . . . . . . . . . . . . . . . . 40

3.4.6 Operating the FLOWSIC600 BIO with ATEX approval . . . . . . . . . . . . . . . . . . . . . . . . . 41

Contents

FLOWSIC600 BIO · Operating Instructions · 8014158/YZO8/V1-0/2016-07 · © SICK Engineering GmbH 5

4 Commissioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

4.1 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

4.2 Connecting the FLOWSIC600 BIO to a PC or laptop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

4.2.1 Connecting the FLOWSIC600 BIO via RS485 / RS232 cable. . . . . . . . . . . . . . . . . . . 47

4.2.2 Connecting the FLOWSIC600 BIO via RS485/USB converter . . . . . . . . . . . . . . . . . . 48

4.3 Connecting the FLOWSIC600 BIO with MEPAFLOW600 CBM . . . . . . . . . . . . . . . . . . . . . 49

4.3.1 Starting MEPAFLOW600 CBM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

4.3.2 Choosing a user access level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

4.3.3 Creating a new meter entry in the meter database . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

4.3.4 Online connection: Direct serial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

4.3.5 Online connection: Ethernet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

4.4 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

4.4.1 Checking identification, operation / design data and firmware version . . . . . . . . . 54

4.5 Field setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

4.5.1 Disconnecting from the meter and closing the session. . . . . . . . . . . . . . . . . . . . . . . . 56

4.6 Function test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

4.6.1 Function test on FLOWSIC600 BIO with LCD front panel . . . . . . . . . . . . . . . . . . . . . . 57

4.6.2 Function test with MEPAFLOW600 CBM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

4.7 Activation of path compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

5Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

5.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

5.2 Routine checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

5.2.1 Comparing theoretical and measured Speed of Sound (SOS) . . . . . . . . . . . . . . . . . . 65

5.2.2 Checking the meter state . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

5.2.3 Time synchronization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

5.2.4 Battery lifespan / capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

5.3 Maintenance report. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

5.4 Optional data download . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

5.4.1 Logbook check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

5.4.1.1 Downloading and saving logbook entries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

5.4.1.2 Acknowledging logbook entries on the meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

5.4.1.3 Clearing logbooks on the meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

6 Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

6.1 General troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

6.2 Displaying meer status alarms and warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

6.2.1 Checking the meter status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

6.2.2 Checking the "User Warnings" window. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

6.2.3 Battery lifespan / capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

6.3 Generation of a diagnosis session. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

6.4 Meter connection troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

7List of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

7.1 Tools and accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

7.2 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Contents

6 FLOWSIC600 BIO · Operating Instructions · 8014158/YZO8/V1-0/2016-07 · © SICK Engineering GmbH

8 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

8.1 Conformities and technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

8.1.1 CE certificate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

8.1.2 Standards compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

8.1.3 Dimensions of FLOWSIC600 BIO in stainless steel piping . . . . . . . . . . . . . . . . . . . . 87

8.1.4 Dimensions of FLOWSIC600 BIO in PE piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

8.1.5 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

8.2 Logbooks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

8.2.1 Overview of entries in logbooks and MEPAFLOW600 CBM . . . . . . . . . . . . . . . . . . . . 95

8.3 Wiring example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

8.3.1 Intrinsically safe installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

8.3.2 Non-intrinsically safe installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

8.4 Type plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

Important Information

FLOWSIC600 BIO · Operating Instructions · 8014158/YZO8/V1-0/2016-07 · © SICK Engineering GmbH 7

Subject to change without notice

FLOWSIC600 BIO

1 Important Information

About this document

For your safety

Authorised staff

General safety instructions and protective measures

Environmental information and instructions for disposal

8 FLOWSIC600 BIO · Operating Instructions · 8014158/YZO8/V1-0/2016-07 · © SICK Engineering GmbH

Important Information

Subject to change without notice

1.1 About this document

This manual describes the FLOWSIC600 BIO measuring system which is used to determine

the volumetric flow rate, volume and speed of sound in gases transported in pipelines. It

provides general information on the measuring method employed, design and function of

the entire system and its components, on planning, assembly, installation, calibration com-

missioning, maintenance and troubleshooting. A detailed description of the various system

capabilities, options and settings which will assist in optimizing the meter configuration for

a specific application is also included.

This manual covers standard applications which conform with the technical data specified.

Additional information and assistance for special applications are available from your SICK

representative. However, it is generally recommended that advantage be taken of qualified

consulting services provided by SICK experts for your specific application.

This manual is a part of the FLOWSIC600 BIO device documentation. It comprises the

following documents (optional and only for trained staff):

● FLOWSIC600 service manual

● FLOWSIC600 MODBUS specification document

Documentation available via www.FLOWSIC600.com or from your local representative:

The following terms will be used for measurands:

Scope of Document

This document applies to meters with S/N 10xxxxxx, with firmware version

3.4.00 or higher and extended memory for the storage of e.g. hourly and daily

mean values.

The software description in this document refers to MEPAFLOW600 CBM

V1.3.00

Basic abbreviations and units

Measured value FLOWSIC600 MEPAFLOW600 CBM

software

LCD-Display

Volume at flowing conditions Vf m

Vf m³ Vf m³

Volume at base conditions Vb Nm

Vb Nm³ Vb m³

Error volume at flowing conditions Ef m

Ef m³ Ef m³

Error volume at base conditions Eb Nm

Eb Nm³ Eb m³

Total volume at flowing conditions Vo m

Vo m³ Vo m³

Volume flow rate in operating state Qf m

3/h

Qf m³/h Qf m³/h

Volume flow rate in standard state Qb Nm

3/h

Qb Nm³/h Qb m³/h

Mass counter M t M t M t

Error mass Me t M t M t

Mass flow at base conditions Mf t/h M t/h M t/h

Important Information

FLOWSIC600 BIO · Operating Instructions · 8014158/YZO8/V1-0/2016-07 · © SICK Engineering GmbH 9

Subject to change without notice

1.2 Safety instructions

1.2.1 Intended use of the equipment

The FLOWSIC600 BIO measuring system is used for measuring the actual volumetric flow

rate of gases transported in pipelines. It can be used for measuring the actual corrected

volume and the speed of sound in gases.

The measuring system shall only be used as specified by the manufacturer and as set forth

below. Always observe the following information:

● Make sure the use of the equipment complies with the technical data, information

about the permitted use, assembly and installation specifications and ambient as well

as operating conditions. Relevant information is provided in the order documentation,

type plate, certification documents and this manual.

● Any actions for the purpose of maintaining the value of the equipment, e.g. service and

inspection, transport and storage etc., shall be performed as specified.

● Do not expose the equipment to mechanical stress, such as pigging or flushing with

liquids with abrasive constituents.

Should it be necessary to flush the FLOWSIC600 BIO, please contact the manufacturer

prior to doing so:

1.3 Authorized staff

Persons responsible for safety shall ensure the following:

● Any work on the measuring system shall only be carried out by qualified staff and must

be approved by skilled staff responsible for the plant.

Due to their professional training, knowledge and vocational experience, as well as their

knowledge of the relevant standards, regulations, health and safety regulations and

equipment conditions, qualified persons shall be assigned by the person responsible

for personal and plant safety to carry out such work. Qualified persons must be able to

identify possible dangers and to take preventive action in due time.

Skilled persons are defined in DIN VDE 0105 and IEC 364, or comparable standards.

● Skilled persons shall have precise knowledge of process-specific dangers, e.g. due to

the effects of hot, toxic and pressurized gases, gas-liquid mixtures and other process

media, and of the design and working principle of the measuring system and shall have

received and be able to document appropriate training.

WARNING:



The pressure during flushing may not exceed more than 1.2 times the

nominal pressure (when transducers are assembled).

In hazardous areas with potentially explosive atmospheres, wiring and installa-

tion shall only be carried out by staff trained according to EN60079-14 and

according to national regulations.

10 FLOWSIC600 BIO · Operating Instructions · 8014158/YZO8/V1-0/2016-07 · © SICK Engineering GmbH

Important Information

Subject to change without notice

1.4 General safety instructions and protective measures

Using the equipment for any purpose other than that intended by the manufacturer, 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 contained therein when carrying out any work on the FLOWSIC600 BIO

measuring system.

General instructions to be adhered to:

● Always comply with the statutory provisions and the associated technical rules and

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

the measuring system. Pay particular attention to potentially hazardous aspects of the

equipment, such as pressurized piping and explosion protection zones. Always observe

the relevant regulations.

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

when carrying out any work on the equipment.

● Operating and service instructions and equipment documentation shall always be

available on site. Always observe the safety instructions and notes on the prevention of

injuries and damage given in these manuals.

● Ensure appropriate protective accessories are available in sufficient supply. Always use

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

working correctly.

1.5 Dangers due to hot, corrosive and explosive gases and high pressure

The FLOWSIC600 BIO measuring system is directly integrated into gas-carrying pipelines.

The plant operator is responsible for safe operation and for complying with additional

national and company-specific regulations.

WARNING:

In plants with toxic and explosive gases, high pressure or high temperatures,

the FLOWSIC600 BIO measuring system shall only be installed or removed

after the associated piping has been isolated and depressurized (i.e. vented to

atmosphere).

The same applies to repair and service work which involves opening any

pressurized component or the explosion-proof signal processing unit (SPU).

NOTICE:

Design, manufacture and inspection of the FLOWSIC600 BIO measuring

system are performed in compliance with the safety requirements set forth in

the European Pressure Equipment Directive 2014/68/EU. All data relevant for

the special application are considered. These data were supplied by the

customer by means of a technical questionnaire when ordering the measuring

system and confirmed by the customer before the start of order processing.

Important Information

FLOWSIC600 BIO · Operating Instructions · 8014158/YZO8/V1-0/2016-07 · © SICK Engineering GmbH 11

Subject to change without notice

1.6 Electrostatic charge

1.7 Environmental information and instructions for disposal

The FLOWSIC600 BIO components are easily disassembled and do not contain toxic,

radioactive or any other environmentally hazardous materials. The device consists

primarily of plastic, stainless steel and aluminium, and consequently there are few

restrictions for disposal, except for the printed circuit boards, which must be disposed of as

electronic scrap.

1.8 Specified service life

WARNING: Hazard caused by damaged coating

The meter body made of PE100 has an antistatic coating. The meter only com-

plies with the explosion protection requirements with this coating and may

then be operated!



The coating must not be damaged!



If the coating is damaged (surface defect larger than 1000 mm

), contact

SICK Customer Service for technical clarification.

NOTICE:

The outside of the meter body has antistatic coating. The inside is not coated.

It must be expected that the inside is charged electrostatically.

It must be ensured that no electrostatic charges by friction and no explosive

gas mixtures are generated inside the pipeline. If raw biogas flows through the

pipeline, this hazard does not exist due to the specific gas composition.

NOTICE:

The meter body made of PE material has been designed for a service life of 25

years according to the requirements of DIN EN 15494.

12 FLOWSIC600 BIO · Operating Instructions · 8014158/YZO8/V1-0/2016-07 · © SICK Engineering GmbH

Important Information

Subject to change without notice

Product Description

FLOWSIC600 BIO · Operating Instructions · 8014158/YZO8/V1-0/2016-07 · © SICK Engineering GmbH 13

Subject to change without notice

FLOWSIC600 BIO

2 Product Description

System components

Operating modes, meter states and signal output

MEPAFLOW600 CBM software

14 FLOWSIC600 BIO · Operating Instructions · 8014158/YZO8/V1-0/2016-07 · © SICK Engineering GmbH

Product Description

Subject to change without notice

2.1 System components

The FLOWSIC600 BIO measuring system consists of the following hardware components:

● Meter body

● Ultrasonic transducers

● Signal processing unit (SPU)

The MEPAFLOW600 CBM software is the user interface used to facilitate operation,

configuration and diagnosis (see



p. 21, §2.4).

Figure 1 FLOWSIC600 BIO

2.1.1

Meter body

The meter body consists of a mid section for mounting the ultrasonic transducers, with

flanges on either end.

The internal diameter, design of the sealing surface, and standard dimensions of the

flanges are in accordance with the specifications in the key code. The meter body is made

of polyethylene (PE100).

The meter bodies can be delivered in several nominal sizes (see



p. 92, §8.1.5).

Meter body

Flange

SPU

Marking for direction of

flow (forward)

Position of the ultrasonic transducers

(underneath strap retainer)

Fold flange

Product Description

FLOWSIC600 BIO · Operating Instructions · 8014158/YZO8/V1-0/2016-07 · © SICK Engineering GmbH 15

Subject to change without notice

2.1.2 Ultrasonic transducers

The FLOWSIC600 BIO ultrasonic transducers are optimized to suit the application

requirements. The high quality of the transducer 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".

2.1.3 SPU

The Signal processing unit (SPU) contains all the electrical and electronic components for

controlling the ultrasonic transducers. 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 counter readings, errors, warnings and power failures are written to non-volatile

memory (FRAM) with a timestamp (logbooks



p. 94, §8.2.) On system restart, the counter

readings that were last saved are restored as the start values for the volume counters. The

FRAM backup provides an unlimited number of writing cycles and guarantees saved data

protection for a minimum of 10 years.

The SPU is equipped with a front panel containing a two-line LCD to display current

measured values, diagnostics and logbook information (



Figure 2). Selection using a

magnetic pen is possible with the front cover closed. The MEPAFLOW600 CBM program

supports user-friendly information displays.

Figure 2 FLOWSIC600 BIO front panel LCD

The power supply and interface terminals are located on the back of the SPU in a separate

terminal section of the enclosure (



p. 38, §3.4.4).

The electronics are fitted in a pressure-proof housing certified in accordance with EN

60079-1 resp. IEC 60079-1 with ignition protection type "d" – 'flameproof enclosure'.

Sensor power circuits are intrinsically safe (category "ia").

Measured values

Control buttons for the magnetic pen

Control buttons for manual use

Product Description

Subject to change without notice

2.2 Terminal assignment

Figure 3 Terminal assignment in the SPU terminal box (cover open)

Table 1 Output configuration

Digital output Assignment

Output DO0 (31/32) AO output 4 .. 20mA or 4 .. 20mA

Communication (33/34) Communication port RS485 MODBUS

[1]

[1] For more information on the serial interface according to the RS485 standard, see

document "FLOWSIC600 MODBUS Specification”.

Output DO1 (51/52) Pulse

Output DO2 (41/42) Error, warning, flow direction, check request

Output DO3 (81/82) Error, warning, flow direction, check request

Product Description

Subject to change without notice

2.3 Operating modes and signal output

The FLOWSIC600 BIO has two operating modes (



p. 17, §2.3.1):

● Operation mode

● Configuration mode

In Operation Mode, the meter can have the following meter states (



p. 18, §2.3.2):

● Measurement valid

● Check request

● Data invalid

2.3.1 Operation mode and Configuration mode

The meter can be operated by the user in two modes: Operation Mode or Configuration

Mode.

Operation mode

In Operation Mode, the meter runs in one of the three aforementioned meter states,

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 meter 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.

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.

If the meter is in Configuration Mode and there have been no activities either

on the LCD display or via MEPAFLOW600 CBM for more than 15 minutes, the

meter automatically switches to Operation Mode.

Product Description

Subject to change without notice

2.3.2 Meter states

2.3.2.1 Status: Measurement valid

The status "Measurement" is the standard meter status of the FLOWSIC600 BIO.

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).

2.3.2.2 Status: Check request

This status is active when a measuring path has failed and the adaptive path failure

compensation is activated. The multi-path FLOWSIC600 BIO system is able to compensate

for this failure. Measurement continues with slightly lower precision. The measuring

system switches to status "Data invalid" when a path fails with path compensation

deactivated.

Status “Check request” becomes also active when system alarms become active (see

Table



p. 95, 8.2.1).

2.3.2.3 Status: Data invalid

If the quality of the signals received from several measuring paths is insufficient, the

device marks the measured value as invalid and activates meter status "Data invalid".

However, the SPU will cyclically attempt to reestablish valid measurements. As soon as the

signal quality and number of valid measurements meet the required criteria, the SPU will

automatically change back to the "Measurement valid" or "Check request" status.

Product Description

Subject to change without notice

2.3.3 Output of pulse signals and status information

* The meter can be configured to output a fixed frequency if the meter has the status

"Data invalid". The frequency to be output in this case can be configured (0-6 kHz) in Reg.

#3034 "ErrorFreq".

** Default setting on delivery.

*** Optional setting on customer request.

Standard setting for "Check request", "Configuration" and "Data invalid" is "normal closed".

Table 2 Pulse output

Output signal / LCD / port

Signal behavior

Measurement state Check request state Configuration mode Data invalid*

Pulse

output

signals

Inverted with error

signal **

Phase

offset

90 ° ***

Positive

flow

Negative

flow

Separate

outputs

for each

direction*

Positive

flow

Negative

flow

Single pulse output

***

Product Description

Subject to change without notice

State "active" or "inactive" can be assigned to the electrical switching state "normally open"

or "normally closed" using the configuration in the MEPAFLOW600 CBM software (settings

for register #5101 on page "Parameters").

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" for Information

● "W" for Warning

● "E" for Error

The blinking character disappears when all new entries have been acknowledged. For

details see



p. 70, §5.4.1.

Table 3 Status output

Output signal / LCD / port Signal behavior

Measurement state Check request state Configuration mode Data invalid

“Check request"

Status signal

Status

“active / inactive” ***

Measurement valid

Status

“active / inactive” ***

Compensation of path

failure

“Undefined" “Undefined"

“Flow direction"

Status signal

Status

“active / inactive” ***

Positive or negative

direction of flow

Status

“active / inactive” ***

Positive or negative

direction of flow

“Undefined" “Undefined"

“Warning" Status

“active / inactive” ***

Status

“active / inactive” ***

“Undefined" “Undefined"

LCD display

Display flashing Display flashing

Serial port RS485

● Measured value, diagnosis information and parameters

● Measuring data logging, diagnosis and configuration using the MEPAFLOW600

CBM software

● Connection with external process control equipment through implemented

MODBUS protocol (data polling)

+V 123456 m³

-V 1234 m³

1234 m³

FLOWSIC600 BIO

Configuration

+V 123456 m³

-V 1234 m³

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SICK FLOWSIC600 BIO Ultrasonic Gas Flow Meter for Biogas Operating instructions

Brand: SICK

Model: FLOWSIC600 BIO Ultrasonic Gas Flow Meter for Biogas

Category: Temperature & humidity sensors

Type: Operating instructions

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SICK FLOWSIC600 BIO Ultrasonic Gas Flow Meter for Biogas Operating instructions

SICK FLOWSIC600 BIO Ultrasonic Gas Flow Meter for Biogas Operating instructions

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