SICK FLOWSIC500 Operating Instructions Manual
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SICK FLOWSIC500 Operating Instructions Manual

Ultrasonic gas flow measuring devices
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Title Page
FLOWSIC500
Ultrasonic Gas Flow Meter with
Optional Volume Conversion
Installation
Operation
Maintenance
O P E R A T I N G I N S T R U C T I O N S

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Summary of Contents for SICK FLOWSIC500

  • Page 1 Title Page O P E R A T I N G I N S T R U C T I O N S FLOWSIC500 Ultrasonic Gas Flow Meter with Optional Volume Conversion Installation Operation Maintenance...
  • Page 2 © SICK Engineering GmbH. All rights reserved. Volume conversion as function of the temperature and a fixed pressure value and with consideration of the compression factor FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH...
  • Page 3 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 Hazards which could result in property damage FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH...

  • Page 4: Table Of Contents

    Fitting the FLOWSIC500 in the pipeline ........
  • Page 5 FLOWSIC500 menu ........
  • Page 6 Volume conversion (device option) spare parts ......106 FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH...
  • Page 7 Installation examples ............119 Connection diagrams for operation of the FLOWSIC500 in accordance with CSA . 122 Connection diagrams for operation of the FLOWSIC500 in accordance with ATEX/IECEx .
  • Page 8 Contents FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH...

  • Page 9: Important Information

    Important Information FLOWSIC500 Important Information Main hazards About this document Intended use Responsibility of user FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH...

  • Page 10: Main Hazards

    Make sure that your FLOWSIC500 is equipped with optically isolated inputs and outputs: ▸ Check the type code, position 23 "I/O", on the type plate (→ Fig. 2) of your FLOWSIC500: – FLOWSIC500 with interface configurations F, G H, I and J have optically isolated inputs and outputs.

  • Page 11: Intended Use

    1. 3 Purpose of the device 1.3.1 The FLOWSIC500 serves for measuring the gas volume, volume flow rate and gas velocity of natural gas in pipelines. The FLOWSIC500 with optional volume conversion serves for measuring the gas volume and converting the gas volume measured to base conditions as well as registering data on meter readings, maximums and other data.

  • Page 12: Operation In Potentially Explosive Atmospheres

    The operator should install a suitable filter or cone screen ahead of the gas flow meter when the gas is contaminated. NOTICE: ● The FLOWSIC500 is suitable for use in pressurized lines within the parame- ters specified in the device. The device complies with Pressure Equipment Directive 2014/68/EU.

  • Page 13: Cleaning

    The manufacturer bears no responsibility for any other use. ▸ Do not carry out any work or repairs on the FLOWSIC500 not described in this manual. ▸ Do not remove, add or change any components in or on the FLOWSIC500 unless such changes are officially allowed and specified by the manufacturer.

  • Page 14: Additional Documentation/Information

    ● Printout of the Data Book ● Product CD with: – Operating Instructions – Operating program FLOWgate500 – FLOWgate500 Software Manual – Key code – Instructions for Kamstrup test valve BDA04 FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH...

  • Page 15: Product Description

    Product Description FLOWSIC500 Product Description Operating principle Device components Meter sizes Power supply Interfaces Device option: Volume conversion Totalizers Logbooks and Archives Parameter protection Sealing FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH...

  • Page 16: Operating Principle

    The FLOWSIC500 calculates the volume flow rate internally from the gas velocity and the diameter of the measuring section of the gas flow meter.

  • Page 17: Flowsic500 Measuring System

    Depending on the version, the adapter is designed for assembly on line flanges PN16 in accordance with DIN EN1092-1, CL150 in accordance with ASME B16.5, or 1.6MPa in accordance with GOST 12815-80. Fitting lengths available: → p. 117, §9.4. FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH...

  • Page 18: Gas Flow Meter

    LF pulses Malfunction Serial RS485 ● Information on explosion-technical characteristics and rated voltage → p. 37, §3.4. ● Details on standard interface configurations available → p. 42, §3.4.6. FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH...

  • Page 19: Pulse And Status Outputs

    Product Description Pulse and status outputs 2.5.1 FLOWSIC500 has 4 digital switching outputs. Digital switching outputs DO_0, DO_2 and DO_3 are electrically isolated according to EN 60947-5-6. Alternatively, digital switching outputs DO_2 and DO_3 can also be configured as Open Col- lector.

  • Page 20: Device Option: Volume Conversion

    The FLOWSIC500 checks the permissible entry limits of the parameters for the selected calculation method. If one of the entry values is outside the limit values, the FLOWSIC500 switches to malfunction state and uses the fixed value of the compressibility factor for cal- culation of the basis volume.

  • Page 21: Integrated Pressure And Temperature Transmitters

    2 Kamstrup test valve BDA04 3 Temperature transmitter A three-way test valve (→ Fig. 6) that is fitted next to the FLOWSIC500 is used for gas tem- peratures to -40°C. FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH...

  • Page 22: Totalizers

    Device status and totalizers used 2.7.1 Various volume totalizers are fitted on the FLOWSIC500 depending on the configuration. Meter V is used in the configuration as gas flow meter. If the gas flow meter has a malfunc- tion, the measured volume is also recorded in the error volume counter errV.

  • Page 23: Reverse Flow

    All events with timestamp, user logged on and totalizer reading, max. number of entries: 1000 When the Event logbook is 90% full, the FLOWSIC500 changes to device status "Warn- ing", warning W-2001 is shown on the display. When the Event logbook is full, the FLOWSIC500 changes to device status "Malfunc- tion", error E-3001 is shown on the display (→...

  • Page 24: Parameter Protection

    V (for gas flow meters) or Vb (for gas flow meters with device option volume conversion) and the logged on user. The Metrology logbook can have a maximum of 100 entries. The FLOWSIC500 switches to status "Warning" when the Metrology logbook is full.
  • Page 25 Unit for temperature values, used for entry and display Gas hour Billing hour for the day archive Gas day Billing day for month archive Measuring period Period for billing archive FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH...

  • Page 26: Sealing

    Sealing 2. 1 0 The FLOWSIC500 is secured at the factory with a seal on the cover. Gas flow meter and adapter can be secured at the joint by a user seal (adhesive label) glued with approximately equal spread on gas flow meter and adapter.
  • Page 27 Fig. 10 Seal on the temperature transmitter (example) 1 Temperature transmitter 2 Locknut 3 Wire seal FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH...
  • Page 28 1 Pressure transmitter 2 Kamstrup test valve BDA04 3 Wire seal 4 Wire loop NOTICE: Make sure that the wire loop is placed tight around the pressure transmitter. FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH...

  • Page 29: Installation

    Installation FLOWSIC500 Installation Hazards during installation General information Mechanical installation Electrical installation External pressure and temperature transmitters installation FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH...

  • Page 30: Hazards During Installation

    Inspect for transport damage when unpacking the device. ▸ Document any damage found and report this to the manufacturer. NOTICE: Do not put the FLOWSIC500 into operation if you notice any damage! ▸ Check the scope of delivery for completeness. The standard scope of delivery comprises: ●...

  • Page 31: Transport

    DIN EN 1591-4. The FLOWSIC500 normally does not need straight inlet and outlet sections and can be fit- ted directly after bends in the pipe.

  • Page 32: Choosing Flanges, Gaskets And Other Components

    Class 150 / ASME B16.5 2"/ Cl150 3"/ Cl150 novapress® FLEXIBLE/815 4"/ Cl150 6"/ Cl150 [1] Da = outer diameter, Di = inner diameter, S = thickness, → Fig. 12 FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH...
  • Page 33 Installation Fig. 12 Dimensions of gaskets FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH...

  • Page 34: Fitting The Flowsic500 In The Pipeline

    3.3.3 NOTICE: The lifting lug is designed for transporting the measuring device only. Do not lift or transport the FLOWSIC500 with additional loads using this lug. ▸ The FLOWSIC500 must not swing or tilt on the hoisting equipment during transport.
  • Page 35 [mm] [in] [mm] [in] [mm] [in] DN50/2" 11.81 13.39 7.87 DN80/3" 18.11 20.08 9.84 DN100/4" 20.47 22.44 12.6 DN100/6" 20.47 22.44 12.6 FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH...
  • Page 36 3.3.3.3 1 Select suitable bolts. Recommended bolts → Table 7. 2 Use the hoisting equipment to position the FLOWSIC500 in the desired location in the pipeline. Lay the pipelines without tension to the device to be installed! 3 Insert and align the gaskets.

  • Page 37: Electrical Installation

    The documentation for zone categorization in accordance with IEC60079-10 must be available ▸ The FLOWSIC500 must have been checked for suitability for the actual installation loca- tion and the Ex marking on the device must match the requirements. ▸ After installation and before initial start-up, the complete equipment and the system must be inspected in compliance with IEC 60079-17.
  • Page 38 – Air with normal oxygen content, normally 21 percent by volume The ambient temperature must be within the range specified on the type plate. The gas flow meter becomes part of the pipeline as soon as the FLOWSIC500 is installed in the pipeline.

  • Page 39: Criteria For Electrical Connection

    Opening and closing the electronics cover 3.4.3 The Ex i terminal compartment of the FLOWSIC500 can be accessed after the electronics cover has been opened. The cover may also be opened in the hazardous area when under voltage. However, safe separation between the various intrinsically safe power circuits must not be breached.

  • Page 40: Rotating The Control Unit

    4 display screws 3 Rotate the display in the desired direction. 4 Tighten the display screws evenly. Tightening torque: 1.0 Nm (9 lbf in) 5 Close the electronics cover again. FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH...

  • Page 41: Electrical Connections

    Installation Electrical connections 3.4.5 The FLOWSIC500 interfaces are accessible from the outside via external plug-in connec- tors. Fig. 18 Connections 1 Plug-in connector 1 (B-coded): External power supply and signal output 2 Plug-in connector 2 (A-coded): Signal output 3 Ground screw 4 Connections for pressure/temperature transmitters (optional) Fig.

  • Page 42: Pin Assignment Of Plug-In Connectors

    = 0.7 mA DO_3- LF pulses Passive, electrically isolated, configu- rable as OC (Open Collector)* or NAMUR, see Configuration 1 for oper- DO_3+ ating parameters * Standard configuration FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH...

  • Page 43: Cable Specifications

    Internal terminal assignment→ p. 118, §9.5 Cable specifications 3.4.7 When the plugs available from SICK are used, a shielded control cable with 4x0.25 mm cross-section, with PVC insulation and approx. 5 mm outer diameter is required. WARNING: Requirements on cables and installation ▸...

  • Page 44: Operation With External Power Supply

    2 Connect the back-up battery (part No. 2065928) to connection BAT2 in the terminal compartment (→ Fig. 22). 3 Close the electronics cover again. Fig. 22 Connected back-up batteries FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH...

  • Page 45: Operation With Batteries

    2 Insert the battery packs as shown and connect to connections BAT1 and BAT2 in the terminal compartment. The FLOWSIC500 is initialized. Fig. 23 Connected battery packs 3 Close the electronics cover again. 4 Set the date and time (→ p. 54, §4.1). FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH...

  • Page 46: Installing The External Pressure And Temperature Transmitters

    3.5.1 Fit the plug-in connector cover before installing the transmitters. 1 Guide the transmitter plugs through the openings in the plug-in connector cover. Fig. 25 Plug-in connector cover FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH...
  • Page 47 3 Push the plug-in connector cover over the plugs and fasten with both capstan screws. Fig. 27 Fastening the plug-in connector cover 1 Capstan screw 2 Plug-in connector cover FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH...

  • Page 48: Installing The Pressure Transmitter

    It is recommended to connect the pressure transmitter with the three-way test valve or with the FLOWSIC500 so that there is a downward slope from the pres- sure transmitter to the connection point and from the three-way test valve to the FLOWSIC500.
  • Page 49 Installation Table 13 Kamstrup test valve BDA04 positions Measuring posi- Pressure transmitter tion FLOWSIC500 Test pressure Test position Pressure transmitter FLOWSIC500 FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH...
  • Page 50 Here, a conventional three-way test valve is used. Install the three-way test valve with pressure transmitter fitted at a suitable location next to the FLOWSIC500. A pressure line serves to connect the pressure measuring connection of the FLOWSIC500 to the three-way test valve.
  • Page 51 1 Remove the dummy plug on the pressure measuring port marked “P ”. 2 Fit the pressure transmitter. Fig. 30 Installation without three-way test valve 1 Pressure transmitter FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH...

  • Page 52: Installing The Temperature Transmitter

    1 Insert the temperature transmitter into the immersion sleeve to the stop. 2 Tighten the locknut. 3 Have the wire seal attached by a calibration inspector (→ Fig. 10). Fig. 31 Installing the temperature transmitter 1 Temperature transmitter FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH...

  • Page 53: Start-Up

    Start-up FLOWSIC500 Start-up Sequence of start-up Setting the date and time Configuring volume conversion (device option) Checking the device status FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH...

  • Page 54: Sequence Of Start-Up

    Setting the date and time 4. 2 Date and time must be set after the power supply has been connected. The FLOWSIC500 displays error E-3007 ("Time" invalid) until the time has been set. Detailed information on operating using the display and on menu navigation →...

  • Page 55: Configuring Volume Conversion (Device Option)

    1 Log on as "Authorized user" (→ p. 72, §5.2.7). 2 Start the configuration mode → p. 72. 3 In the FLOWSIC500 menu, switch to submenu "Pressure parameters" or "Temperature parameters" 4 Select the view "p Fixed value" or "T Fixed value".

  • Page 56: Configuring The Gas Composition

    – Contact SICK Customer Service for any malfunctions you cannot clear yourself (→ p. 78, §6.1, “Contacting Customer Service”). 4 The event overview can be reset when all warnings and errors have been cleared (→ p. 73, §5.2.12). FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH...

  • Page 57: Operation

    Operation FLOWSIC500 Operation Control unit Operating using the display Operating using the optical data interface FLOWgate500 operating software Parameter protection FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH...

  • Page 58: Control Unit

    Toggles between single menu entries ter by 1, toggles between several selec- on one level  tion options. ENTER Calls a submenu, starts edit mode. Confirms an input. FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH...

  • Page 59: Display In The Symbol Bar

    ● The last segment of the battery symbol starts to blink when the battery fill level drops below 10%. ● When the battery is completely empty, the empty battery symbol blinks and the FLOWSIC500 has switched to the second battery. FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH...

  • Page 60: Main Screen (Without Device Option Volume Conversion)

    → "Resetting the event summary" (p. 73). NOTICE: A parameter with Malfunction status is shown on the display by a blinking exclamation mark after the parameter (e. g. Q!). FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH...
  • Page 61 Main display: Event Summary ○ ○ ○ ○ List of stored events ○ ○ ○ ○ Main display: Last Event Reset ○ ○ ● ● → p. 73, §5.2.12 FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH...

  • Page 62: Main Display (With Device Option Volume Conversion)

    Q = Volume flow at measurement conditions Qb = Volume flow at base conditions 0.000 m3/h 0.000 m3/h SOS = Sound velocity currently measured VOG = Gas velocity currently measured 430.00 m/s 0.000 m/s FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH...
  • Page 63 → "Resetting the event summary" (p. 73). NOTICE: A parameter with Malfunction status is shown on the display by a blinking exclamation mark after the parameter (e. g. Q!). FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH...
  • Page 64 ● ● Heating value unit ○ ○ ● ● FLOWSIC500 menu: Pressure parameters ○ ○ ○ ○ → p. 70, §5.2.6.6 p Sensor type ○ ○ ○ ○ FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH...
  • Page 65 Main display: Event Summary ○ ○ ○ ○ List of stored events ○ ○ ○ ○ Main display: Last Event Reset ○ ○ ● ● → p. 73, §5.2.12 FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH...

  • Page 66: Configuration Of Main Display

    ● Date, time (line 2 – SICK standard) ● Pressure p ● Temperature T ● Conversion factor C ● Compressibility factor K ● Volume flow rate Q ● Base flow Qb ● VOG ● SOS FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH...

  • Page 67: Flowsic500 Menu

    Minimum operating overpressure Max. oper. pressure Maximum operating overpressure Meter factor Pulse valency, relation between frequency and flow [Imp/m Frequency at Qr Frequency for overload flow Qr=1.2 Qmax FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH...
  • Page 68 Temperature (measurement) Temperature (base) Velocity of Gas Speed of Sound K-factor (fixed) Conversion factor Z (measurement) Z (base) LCD test Display test → "Testing the display" (p. 74) FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH...
  • Page 69 Select from: 3 s, 10 s, 20 s, 30 s, 60 s K-factor (fixed) Entry of K factor for method "Fixed value" when the calculation of the K- factor is incorrect. FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH...
  • Page 70 Select from: Default, ° C, ° F, K, °R Default = Standard setting according to selected unit system (SI or Impe- rial), configured in accordance with the order FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH...
  • Page 71 Measuring range: 1 ... 28 Default: 1 Measuring period Defines the period for the billing archive Select from: 3 min, 5 min,15 min, 30 min, 60 min Default: 60 min FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH...

  • Page 72: Changing The User Level

    5 Confirm with ENTER. The display texts are now shown in the selected language. Changing the device mode 5.2.9 On the FLOWSIC500, the device modes Configuration and Calibration can be activated independently from each other. Starting and terminating configuration mode 5.2.9.1 Start configuration mode 1 Switch to the "Device mode”...

  • Page 73: Changing Parameters

    In calibration mode, message "CALIBRATION MODE" blinks on the main display with the meter factor now effective for the calibration (set at the factory). The FLOWSIC500 outputs test pulses with a maximum possible frequency of 2 kHz at 120% Q max.on digital switching output DO_1 (→ p. 42, §3.4.6.1).

  • Page 74: Confirming Battery Replacement

    2 Call up "LCD Test”. 3 Press ENTER to start the display test. All display segments on the display are activated and deactivated three times. Defective display segments can thus be detected. FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH...

  • Page 75: Operating Using The Optical Data Interface

    A data connection can be established with the device using the optical data interface and the infrared/USB adapter HIE-04 (part no. 6050502). This interface serves to configure the FLOWSIC500. The infrared adapter has a USB 2.0 interface. This interface provides the connection to the PC and transfers the FLOWSIC500 data.
  • Page 76 Operation FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH...

  • Page 77: Clearing Malfunctions

    Clearing Malfunctions FLOWSIC500 Clearing Malfunctions Contacting Customer Service Status messages Additional messages in the Event logbook FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH...

  • Page 78: Contacting Customer Service

    → p. 85, §7.3.2 “Changing the battery packs” W-2018 External power supply failure. Check the connection and function of the external power supply. → p. 44, §3.4.8 “Operation with external power supply”. FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH...
  • Page 79 E-3021 = Gas pressure is below the alarm limit E-3022 = Gas pressure is above the alarm limit E-3021 Check the set alarm limit values. E-3022 → p. 70, §5.2.6.7 "Temperature parameters" FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH...

  • Page 80: Additional Messages In The Event Logbook

    Additional messages in the Event logbook 6. 3 The FLOWSIC500 saves all status messages (→ p. 78, §6.2) as well as further supplemen- tary messages concerning events and status changes in the Event logbook. Each message code is supplemented with a (+) or (-) to identify an incoming message = (+) or an outgoing message = (-).

  • Page 81: Maintenance And Meter Replacement

    Maintenance when using external power supply Maintenance when using battery power supply Meter exchange Function check of a pressure or temperature transmitter Exchanging an external pressure or temperature transmitter FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH...

  • Page 82: Information On Handling Lithium Batteries

    It is recommended to contact the local EPA office. Refer to FLOWSIC500 user manual for further information. Description Variable Serial No. Date QR-Code Order No. + FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH...

  • Page 83: Information On Storage And Transport

    ▸ If anything is unclear, contact the local office of the Environmental Protection Agency (EPA). In other countries: Please observe national regulations for the disposal of lithium batteries. FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH...

  • Page 84: Maintenance When Using External Power Supply

    7 Confirm battery replacement on the display (→ p. 74, §5.2.13). NOTICE: The battery symbol on the display shows full straight away after the battery change. The check whether the battery is really operational then takes 20 minutes. FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH...

  • Page 85: Maintenance When Using Battery Power Supply

    Only loosen one connection at a time to ensure continuous voltage supply! If both battery packs are to be exchanged at the same time, first replace the empty battery pack and then the still used battery pack. FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH...
  • Page 86 4 Remove the battery pack and replace by the new one. 5 Reconnect the electrical system. The FLOWSIC500 now continues to use the second battery pack and then switches back to the new battery pack. 6 Close the electronics cover (→ p. 39, §3.4.3) 7 Confirm battery replacement on the display (→...

  • Page 87: Meter Exchange

    (→ p. 90, §7.4.6). 8 Check the function of the gas flow meter (→ p. 99, §7.4.11). 9 If necessary, secure metrologically (→ p. 99, §7.4.12). FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH...

  • Page 88: Required Tools And Auxiliary Material

    ● Silicone grease ● Leak detection spray ● Anti-seize paste, metal-free or suitable for aluminium, e.g. OKS 235, to prevent thread mountings seizing up NOTICE: Do not use copper paste! FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH...

  • Page 89: Overview

    1 Securing screws 6 Connecting pieces with seals 2 Ripplock washers 7 Adapter 3 Center bolt 8 Locking cap 4 Ripplock washer 9 Test cap 5 Gas flow meter FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH...

  • Page 90: Back-Up Of User-Specific Configuration Of Installed Gas Flow Meter

    Remove the battery packs and dispose of or store properly according to → p. 82, §7.1. SICK recommends inserting new batteries during every meter replacement. 6 Close the electronics cover again (→ p. 39, §3.4.3). FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH...

  • Page 91: Removing The Installed Gas Flow Meter

    Secure the gas flow meter before loosening the screw fitting, e.g. by sup- porting the gas flow meter or with the help of another person holding the gas flow meter. 2 Unscrew the closure cap. FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH...
  • Page 92 The center bolt pushes the seals upwards and lifts the gas flow meter approx. 5 FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH...
  • Page 93 11 Secure the removed gas flow meter with the transport protection before shipping: – Fit the gas flow meter on the transport protection. – Secure the gas flow meter with the strap provided. FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH...
  • Page 94 Operation in leaky condition is not allowed and potentially dangerous. ▸ In this case, the adapter has to be exchanged. ▸ Please contact your local SICK Customer Service. FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH...

  • Page 95: Installing The Replacement Gas Flow Meter

    7 Carefully fit the gas flow meter on the adapter. Pay attention to the correct orienta- tion of the gas flow meter. The posi- tion of the center bolt allows only one fitting direction. FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH...
  • Page 96 12 Then tighten the securing screws with the Allen key to the specified tightening torque. Meter size Tighenting torque [Nm] DN50 DN80 DN100 DN150 13 Check the leak tightness, → p. 97, §7.4.10. FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH...

  • Page 97: Performing A Leak Tightness Check

    – When no gas escapes from the opening of the test cap, see → p. 98, §7.4.10.1 – When gas escapes from the opening of the test cap, see → p. 98, §7.4.10.2. FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH...
  • Page 98 When the sealing elements are damaged, a new seal set is available as spare part. Meter size Item number DN50 2076394 DN80 2076395 DN100 2076396 DN150 FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH...

  • Page 99: Checking The Function Of The Gas Flow Meter

    (→ p. 26, §2.10). ▸ When the parameter locking switch has been opened during the meter replacement, secure the parameter locking switch anew metrologically (→ Fig. 9, p. 27). FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH...

  • Page 100: Function Check Of A Pressure Or Temperature Transmitter

    7 Install a new pressure transmitter on the pressure measuring port marked “P ” → p. 48, §3.5.2. 8 Enter the serial number of the new transmitter in the FLOWSIC500 with the operating software FLOWgate500. 9 Check the function by comparing the operating point or checking the display value (remove adapter on test connection) against a reference measurement.

  • Page 101: Exchanging The Temperature Transmitter

    6 Screw the plug-in connector cover tight. 7 Fit the new temperature transmitter in the protective tube → p. 52, §3.5.3. 8 Enter the serial number of the new transmitter in the FLOWSIC500 with the operating software FLOWgate500. 9 Check the function by comparing the operating point or checking the display value (remove adapter on test connection) against a reference measurement.
  • Page 102 Maintenance and Meter Replacement FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH...

  • Page 103: Accessories And Spare Parts

    Accessories and Spare Parts FLOWSIC500 Accessories and Spare Parts Accessories Spare parts FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH...

  • Page 104: Accessories

    Tamper-proof protection of connectors 2067397 Elgas midiDatcom: Battery powered Data Logger with integrated GSM/GPRS 6058324 modem; ATEX II 1G Ex ia IIA T3 Ga; Battery lifetime > 5 years FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH...

  • Page 105: Volume Conversion (Device Option) Accessories

    Transport protection for gas flow meter, rated width DN80/3 2079001 Transport protection for gas flow meter, rated width DN100/4" 2079022 Transport protection for gas flow meter, rated width DN150/6" FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH...

  • Page 106: Spare Parts

    Sealing plug G1/4" 2067400 Pipe screw fitting for pipe diameter 6 mm 2071771 Pipe screw fitting for pipe diameter 1/4" 2069071 Adapter from G1/4" to NPT 1/4" 2072456 FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH...

  • Page 107: Annex

    Annex FLOWSIC500 Annex Conformities and Technical Data Dimensional drawings Type plates Type code Internal terminal assignment Installation examples FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH...

  • Page 108: Conformities And Technical Data

    Annex Conformities and Technical Data 9. 1 CE certificate 9.1.1 The FLOWSIC500 has been developed, manufactured and tested in accordance with the following EU Directives: ● Pressure Equipment Directive 2014/68/EU ● ATEX Directive 2014/34/EU ● EMC Directive 2014/30/EU ● Measuring Instruments Directive 2014/32/EU Conformity with the above Directives has been determined and the CE label attached to the device.

  • Page 109: Technical Data

    See dimensional drawings (→ p. 117, §9.4) Weight See dimensional drawings (→ p. 117, §9.4) Material in contact with media Aluminium AC-42100-S-T6 Mounting Horizontal or vertical installation with 0 D straight inlet/outlet piping FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH...
  • Page 110 4.0 ... 20.0 bar (a) 0 ... 20 bar (g) Temperature transmitter (only for device option volume conversion) Measuring ranges -25 ... +60 ° C -40 ... +70 ° C (optional) FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH...

  • Page 111: Flow Rates

    150 % Q 8,475 DN80 / 3" 14,125 150 % Q 21,187.5 DN100 / 4" 22,955 150 % Q 34,432.5 DN150 / 6" 1000 35,314 120 % Q 1200 42,376.8 FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH...

  • Page 112: Type Code

    18 Gas temperature / ambient temperature 19 Pressure range p-sensor 20 Cable connection Power supply 22 EX certification 23 I/O (Interface configurations) 24 Conformity Customized solution A 2 A 1 FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH...
  • Page 113 Qmax 65 m³/h Qmax 100 m³/h Qmax 160 m³/h Qmax 250 m³/h Qmax 400 m³/h Qmax 650 m³/h Qmax 1000 m³/h Measuring span 1:50 1:100 1:160 1:200 1:250 FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH...

  • Page 114: Type Plates

    U = 20 V; I = 667 mA; P = 753 mW more info: press key 4086840 4086840 VOLUME CONVERSION DEVICE TEC: DE-15-MI002-PTB003 0.5% EN12405-1 at reference conditions more info: press key FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH...
  • Page 115 13.1 ID: 7 SIC00 1451 0014 ID: 7 SIC00 1451 0014 02.1 4086841 4086841 VOLUME CONVERSION DEVICE TEC: DE-13-MI002-PTB007 0.5% EN12405-1 at reference conditions more info: press key FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH...

  • Page 116: Ped Type Plate

    FLOWSIC500 oder FLOWSIC500 CIS) FLOWSIC500 or FLOWSIC500 CIS) Nennweite Size Einheit zur Nennlänge Unit of nominal length Einheit zur Temperatur Unit of temperature Unit of pressure Einheit zum Druck & & FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH...

  • Page 117: Dimensional Drawings

    [1] All dimensions in mm (inch), weights in kg (lb) [2] C = fitting length, two fitting lengths are available for meter sizes DN50 (2") to DN100 (4"). FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH...

  • Page 118: Internal Terminal Assignment

    LOCK EXT. POWER OFF ON SENSORS 4,5..16V BAT1 BAT2 *Optional N.c. 1.5 mm² V see module 2..16V 2..16V 2..16V 5..12V RS485 * (AWG 16) R :100 4074419 NAMUR FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH...

  • Page 119: Installation Examples

    1 + DO 2 (passive) 2 n.c. 2 - DO 2 (passive) 3 - DO 1 (passive) 3 - DO 3 (passive) 4 + DO 1 (passive) 4 + DO 3 (passive) FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH...
  • Page 120 Annex Fig. 49 Operation with safety barrier and external power supply FLOWSIC500 with HF output powered with safety barrier and external power supply, connected to electronic volume corrector Hazardous area Safe area L N PE FLOWSIC 500 intrinsically safe [Ex ia]...
  • Page 121 2 + power supply 2 + data (RS485 A) 3 - DO 1 (passive) 3 - data (RS485 B) 4 + DO 1 (passive) 4 - power supply FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH...

  • Page 122: Connection Diagrams For Operation Of The Flowsic500 In Accordance With Csa

    Annex Connection diagrams for operation of the FLOWSIC500 in accordance with 9 .7 Fig. 51 Control diagram 9215965 (page 1) FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH...
  • Page 123 Annex Fig. 52 Control diagram 9215965 (page 2) FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH...
  • Page 124 Annex Fig. 53 Control diagram 9215965 (page 3) FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH...
  • Page 125 Annex Fig. 54 Control diagram 9215965 (page 4) FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH...
  • Page 126 Annex Fig. 55 Control diagram 9215965 (page 5) FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH...
  • Page 127 Annex Fig. 56 Control diagram 9215965 (page 6) FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH...
  • Page 128 Annex Fig. 57 Control diagram 9215965 (page 7) FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH...

  • Page 129: Atex/Iecex

    Annex Connection diagrams for operation of the FLOWSIC500 in accordance with 9. 8 ATEX/IECEx Fig. 58 Control diagram 9215966 (page 1) FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH...
  • Page 130 Annex Fig. 59 Control diagram 9215966 (page 2) FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH...
  • Page 131 Annex Fig. 60 Control diagram 9215966 (page 3) FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH...
  • Page 132 Annex Fig. 61 Control diagram 9215966 (page 4) FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH...
  • Page 133 Annex Fig. 62 Control diagram 9215966 (page 5) FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH...
  • Page 134 Annex Fig. 63 Control diagram 9215966 (page 6) FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH...
  • Page 135 Annex Fig. 64 Control diagram 9215966 (page 7) FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH...
  • Page 136 Parameter logbook ......23 FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH...
  • Page 137 I nd e x FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH...
  • Page 138 E-Mail sales@sick.co.nz United Arab Emirates China Norway E-Mail sick@sick.no USA/Mexico Denmark Poland E-Mail sick@sick.dk Finland Romania Vietnam France Russia Gemany Singapore Great Britain Slovakia E-Mail mail@sick-sk.sk Hong Kong Slovenia Hungary South Africa www.sick.com SICK AG | Waldkirch | Germany | www.sick.com...

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