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  7. FLOWSIC600 BIO Ultrasonic Gas Flow Meter for Biogas

SICK FLOWSIC600 BIO Ultrasonic Gas Flow Meter for Biogas Operating instructions

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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.
© SICK Engineering GmbH. All rights reserved.
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
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
3
Vf m³ Vf m³
Volume at base conditions Vb Nm
3
Vb Nm³ Vb m³
Error volume at flowing conditions Ef m
3
Ef m³ Ef m³
Error volume at base conditions Eb Nm
3
Eb Nm³ Eb m³
Total volume at flowing conditions Vo m
3
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
2
), 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
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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
16 FLOWSIC600 BIO · Operating Instructions · 8014158/YZO8/V1-0/2016-07 · © SICK Engineering GmbH
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
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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.
18 FLOWSIC600 BIO · Operating Instructions · 8014158/YZO8/V1-0/2016-07 · © SICK Engineering GmbH
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
FLOWSIC600 BIO · Operating Instructions · 8014158/YZO8/V1-0/2016-07 · © SICK Engineering GmbH 19
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
***
20 FLOWSIC600 BIO · Operating Instructions · 8014158/YZO8/V1-0/2016-07 · © SICK Engineering GmbH
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
/