ABB Sensyflow iG Operating Manual
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ABB Sensyflow iG Operating Manual

ABB Sensyflow iG Operating Manual

Intelligent gas-mass flowmeter
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Sensyflow iG
Preliminary
Operating manual
Intelligent gas-mass flowmeter
PROFIBUS DPV1
PA Profile 3.0
Version 1.00
42/14-39 EN
Rev. 00

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  • Page 1 Sensyflow iG Intelligent gas-mass flowmeter PROFIBUS DPV1 PA Profile 3.0 Version 1.00 Preliminary Operating manual 42/14-39 EN Rev. 00...

  • Page 2: Operating Manual

    +49 6023- Fax: +49 6023-3210 © Copyright 2002 by ABB Automation Products GmbH Subject to changes without notice. This technical documentation is protected by copyright. Translating, photocopying and diseminating it in any form whatsoever - even editings or excerpts thereof - especially as reprint, photomechanical or elec- tronic reproduction or storage on data processing systems or networks is not allowed without the permis- sion of the copyright owner and non-compliance will lead to both civil and criminal prosecution.

  • Page 3: Table Of Contents

    4.1.2 Adaption of a Sensyflow iG transducer by using a weld-on adapter ....12 Installating the transducer in areas with high ambient temperature ....13 Aligning housing head and display .
  • Page 4 Cleaning the transducer ..........50 Sensyflow iG: measuring principle .

  • Page 5: Correct Use, General Safety Instructions

    Correct use, general safety instructions 1.1 Range of applications, proper use Sensyflow iG has been designed for mass flow measurement of gases and gas conglomerates in closed pipe circuits. These operating instructions describe the device version with PROFIBUS DPV1 interface according to PA profile 3.0.

  • Page 6: Notice According To The German Hazardous Material Directive

    1986-10-01 ((GefStoffV, §17 General Protection Duties) the employer is also obliged to protect his employees. Therefore, we must point out the following: a) All flow sensors and/or flow transducers sent to ABB Automation Products GmbH for repair must be free of any hazardous substances (acids, lyes, solutions, solids).

  • Page 7: Important Information In Advance

    For every measuring system leaving our factory a file documenting the production process is kept. The most important document in this case is the calibration certificate. It contains important information of the respective instrument such as, for example, measuring medium, measuring range(s), fabrication num- bers, and order number. 42/14-39 EN Sensyflow iG, Version 1.00...
  • Page 8 (fabrication) number Customer data regarding the application Calibration data: Data regarding test bench and boundary conditions Calibration result: Tolerances determined on the test bench in form of tables and diagrams Fig. 2-1 Calibration certificate sample Sensyflow iG, Version 1.00 42/14-39 EN...

  • Page 9: System Description

    System description System description The mass flow meters of the Sensyflow iG family operate according to the hot-film anenometer principle. An exact description can be found in Section 9, "Measuring principle" The compact version of the metering system comprises a transducer (sensor with transducer electronics) and a pipe component (in different construction types).

  • Page 10: Pipe Components

    (which can also be displayed in the SERVICE MENU). A multitude of configurations allow the adaption of the device to different measuring tasks. A complete listing of all parameterization possibilities can be found in see section 7.7 "Parameterization" on page Sensyflow iG, Version 1.00 42/14-39 EN...

  • Page 11: Mechanical Installation

    Reducer X = 15 90° elbow X = 20 Z-18941 Two 90° elbows in one level X = 25 Two 90° elbows in two levels X = 40 Z-18943 Valve/slide X = 50 Z-18944 42/14-39 EN Sensyflow iG, Version 1.00...

  • Page 12: Adaption Of A Sensyflow Ig Transducer By Using A Weld-On Adapter

    Under certain circumstances, special calibration can be performed for insufficient steadying run lengths. For this purpose and in individual cases, consult ABB's DKD Calibration Department at Alzenau. For gases with extremely low density (hydrogen, helium) the stated steadying run lengths must be dou- bled.

  • Page 13: Installating The Transducer In Areas With High Ambient Temperature

    Fig. 4-2 Recommended mounting of the device in case Fig. 4-3 Sensor mounting in 12 o'clock position for uncri- of hot pipelines, display rotated by 90° tical ambient temperatures 42/14-39 EN Sensyflow iG, Version 1.00...

  • Page 14: Aligning Housing Head And Display

    After loosening the four fastening screws you can pull out the board and plug it in again in the desired position. Subsequently tighten the fastening screws again, attach the display cover and screw on the hou- sing lid. Fig. 4-4 The display can be rotated in steps of 90°. Sensyflow iG, Version 1.00 42/14-39 EN...

  • Page 15: Mounting The Evaluation Electronics (Remote Version)

    (dimensions in mm) Fig. 4-5 Dimensions of the Sensyflow iG mounting plate ( Remote-Version) Due to the rotating housing head the rear terminal box is still accessible. The connection between sensor and evaluation electronics is made via 10-pole, numbered terminal blocks that can be accessed after removing the covers at the sensor connection housing and the terminal box of the electronics unit.

  • Page 16: Electrical Installation

    5.4 "Connecting PROFI- BUS DP via PROFIBUS M12 bus connector" on page Caution Remove all power from the device before opening the rear device cover and the cover of the supply ter- STOP minal block! Sensyflow iG, Version 1.00 42/14-39 EN...
  • Page 17 Jumper for PROFIBUS PROFIBUS lines termination resistor Z-20276 Fig. 5-2 Sensyflow iG terminal box with direct PROFIBUS connection Caution Before connecting the power supply lines make sure that the device is operated with the correct supply voltage (see device rating plate)! First you connect the grounding cable to the PE terminal, then the actual supply lines at the power supply terminal block.

  • Page 18: Connecting Profibus Dp Via Profibus M12 Bus Connector

    PROFIBUS cable. This version allows pulling the T-plug and disconnecting the device from PROFIBUS DP without interfering with the bus operation. Note Suitable T-plugs and cable sockets/plugs are available as accessories. (see Sensyflow iG data sheets and PROFIBUS accessories) Signal Description Supply voltage, positive (P 5 V) RxD/TxD-N Receive/transmit data, –N, line A (green wire)

  • Page 19: Profibus Bus Terminator And Cable

    You can use a round data cable LIYCY 10 × 0.5 mm² with braided copper shield. Note Ready-made cables can be ordered in lengths of 5, 15, and 25 m as accessories (see data sheet). 42/14-39 EN Sensyflow iG, Version 1.00...

  • Page 20: Commissioning

    The power supply may only be switched on when the connection box cover is closed. Danger of electric shock! • Switch on the power supply The system is automatically booted, and the Sensyflow iG is initialized; subsequently the system chan- ges over to the pre-set display screen and starts normal measuring operation. Note In case of error, a simple troubleshooting display pops up automatically.

  • Page 21: Operation, Configuration And Communication

    Operation, configuration and communication 7.1 PROFIBUS communication Bus communication of the "Sensyflow iG" thermal gas-mass flow meter with PROFIBUS interface is ba- sed on the "Profile For Process Control Devices" version 3.0 ( PA profile 3.0 ) released in October 1999.

  • Page 22: Module Configuration For Cyclic Data Communication (Dp)

    Operation, configuration and communication 7.1.2 Module configuration for cyclic data communication (DP) Sensyflow iG provides cyclic data communication for the following modules, which are described in the vendor-specific GSD file. Module Module Byte Data type Byte Data type Input Input...

  • Page 23: Gsd File

    Sensor failure Out of service • Quality = uncertain Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 Type Non-specific Last usable value Engineering unit range violation 42/14-39 EN Sensyflow iG, Version 1.00...

  • Page 24: Hexadecimal Status Byte Messages

    Active advisory alarm (prio. < 8) 0x8C – 0x8F Active critical alarm (prio. < 8) 0x90 – 0x93 Unacknowledged update event 0x94 – 0x97 Unacknowledged advisory alarm 0x98 – 0x9B Unacknowledged critical alarm 0xA4 – 0xA7 Maintenance required Sensyflow iG, Version 1.00 42/14-39 EN...

  • Page 25: Diagnosis

    Cold start with default data Maintenance required Characteristics invalid Ident_Number violation Diagnostic Type byte Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Diagnostic Type byte Reserved Reserved Reserved Reserved Reserved Reserved Reserved Extension available 42/14-39 EN Sensyflow iG, Version 1.00...
  • Page 26 Res. temp error Sensor wire error Max. gas temp. error Reserved Reserved Diagnostic Type byte Total overflow Reserved Reserved Reserved Reserved Reserved Reserved Reserved Diagnostic Type byte Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Sensyflow iG, Version 1.00 42/14-39 EN...

  • Page 27: Acyclic Data Communication (Dpv1)

    DEVICE MESSAGE String 32 blanks DEVICE INSTALL DATE String 8 blanks IDENT_NUMBER_ SELECTOR Uint8 40.. 26-32 Reserved by PNO 32-49 Reserved Manufacturer String Order- SAP Order No. specific Manufacturer Uint8 Default Mask 0 .. 4 42/14-39 EN Sensyflow iG, Version 1.00...

  • Page 28: Flow

    Block-specific permitted normal Alarm_SUM DS-42 0,0,0,0 Calibr_Factor float Sensor-specific M LOW_FLOW_CUTOFF float Zero_Point float Sensor-specific M Zero_POINT_ ADJUST unit8 0:cancel 1:execute Zero_Poinit_Unit uint16 10xx Nominal_Size float Nominal_Size_Unit uint16 1013 Mass_FLOW DS-33 Mass_FLOW_Unit uint16 1322 Sensyflow iG, Version 1.00 42/14-39 EN...

  • Page 29: Function Block Flow Analog Input (Ai)

    Min. value permitted normal Alarm_SUM DS-42 Batch DS-39 DS-39 PV_scale DS-39 Out_scale DS-39 LIN_Type DS-50 Disable Channel OctetString PV_FTIME Float 0.2 sec. FSAFE_Type *** UINT8 FSAFE_Value Float ALARM_HYS Float HI_HI_LIM Float HI_LIM Float 42/14-39 EN Sensyflow iG, Version 1.00...

  • Page 30: Gas Temperature

    Alarm_SUM DS-42 0,0,0,0 Primary_value DS-33 Primary_value_unit Uint16 deg C Secondary_value_1 DS-33 Secondary_value_2 DS-33 Sensor_meas_type Uint8 Input_range (sensor1) Uint8 Lin_type(sensor1) Uint8 Pt100 Bias_1 Float Bias_2 Float Upper_sensor_Limit (sensor1) Float Lower_sensor_Limit (Sensor1) Float Sensyflow iG, Version 1.00 42/14-39 EN...

  • Page 31: Function Block Gas Temperature Analog Input (Ai)

    Min.Value permitted normal Alarm_SUM DS-42 Batch DS-39 DS-39 PV_scale DS-39 Out_scale DS-39 LIN_Type DS-50 Disable Channel Octet- String PV_FTIME Float 0.2 sec. FSAFE_Type *** UINT8 FSAFE_Value Float ALARM_HYS Float HI_HI_LIM Float HI_LIM Float 42/14-39 EN Sensyflow iG, Version 1.00...
  • Page 32 Operation, configuration and communication LO_LIM Float LO_LO_LIM Float HI_HI_ALM DS-39 HI_ALM DS-39 LO_ALM DS-39 LO_LO_ALM DS-39 Simulate DS-50 OUT_UNIT_TEXT String 36-44 Reserved by PNO First Manufacturer Parameter Sensyflow iG, Version 1.00 42/14-39 EN...

  • Page 33: Totalizer

    1:Hold 2:Me- mory Preset_Tot Float Alaram_Hys Float HI_HI_LIM Float Max. Value HI_LIM Float Max. Value HI_HI_ALM DS-39 HI_HI_ALM DS-39 HI_HI_ALM DS-39 HI_HI_ALM DS-39 26-35 Reserved by PNO Manufacturer String Integrator Time Years, Days, Hours, Minutes, 42/14-39 EN Sensyflow iG, Version 1.00...

  • Page 34: Description Of Function Blocks

    Input Function Blocks (AI FB) and in the Totalizer Block (Integrator). Within the individual blocks, parameters can be set for signal output, units, limit values, etc. Fig. 7-1 Flow Transducer Block Fig. 7-2 Temp Transducer Block Sensyflow iG, Version 1.00 42/14-39 EN...

  • Page 35: Smart Vision Dtm Configuration

    The description for the DTM configuration via SMART VISION is currently being prepared. 7.4 Display, operation, and configuration Local operation of Sensyflow iG is performed via the graphical display (120 x 32 pixels) and three buttons that are operated with a magnetic pen.
  • Page 36 Caution! Take ESD precautions before touching the assemblies! The context-sensitive button functions are shown in the display. This allows easy operation and configu- ration of the Sensyflow iG. ENTER button (also shown inverted in the display) – Access to submenus –...

  • Page 37: Operating Structure Overview

    Untermenü PROFIBUS MENUE Ebene 1 Ebene 2 Untermenü SERVICE MENUE Ebene 1 ∧ ∨ Fig. 7-5 Operating structure overview The menu structure is described in detail in see section 7.6 "Menu structure" on page 42/14-39 EN Sensyflow iG, Version 1.00...

  • Page 38: Display Modes

    ENTER button again and can be used to exit the password entry mask. When the correct password has been entered, the confir- mation OK is briefly displayed before displaying the opera- ting mode that has been set. Sensyflow iG, Version 1.00 42/14-39 EN...

  • Page 39: Entering And Changing Data

    TOT. (For explanations see sections 7.1.2.2 and 7.1.2.3) Furthermore, eight diagnostic signal are available in the SERVICE MENU, showing information about the device status. (For explanation see section 7.1.3 "Acyclic data communication (DPV1)" on page 42/14-39 EN Sensyflow iG, Version 1.00...

  • Page 40: Overview Of Parameterization Options

    Integrator behavior in case of error RUN ( integrator continues to run with faulty TOTAL MENU measuring value) ERROR BEHAVIOR HOLD (integrator stopped) MEMORY ( integrator continues to run with last valid measuring value) Sensyflow iG, Version 1.00 42/14-39 EN...

  • Page 41: Menu Structure

    • MIN. VALUES ( flow and gas temperature) • DEVICE TEMP. / MAX HOUS. TEMP • CAL. DATE / TIME • STATUS FLOW TEMP TOT • DIAG 1 - 4 • DIAG 5 -8 • END SERVICE MENU 42/14-39 EN Sensyflow iG, Version 1.00...
  • Page 42 • TOTAL UNIT * • TOTAL SET * • TOTAL RUN/STOP * • TOTAL FAILSAFE TYPE * • TOTAL PRESET VALUE * • TOTAL ALARM HIGH * • TOTAL WARNING HIGH * • END TOTAL MENU Sensyflow iG, Version 1.00 42/14-39 EN...

  • Page 43: Parameterization

    MANUFACTURER ID Indication of manufacturer identification number DEVICE ID Indication of device identification number SERIAL NO. Indication of the device serial number (manufacturing number) ORDER NO. Indication of manufacturer order number END PARAMETER MENU 42/14-39 EN Sensyflow iG, Version 1.00...

  • Page 44: Submenu Level 1 → Profibus Menu

    Display of diagnostic bytes 1 to 4 Display 0x80 … 0x83 → OK (see section 7.1.3 DIAG 5…8 Display of diagnostic bytes 5 to 8 Display 0x80 … 0x83 → OK (see section 7.1.3 END SERVICE MENU Sensyflow iG, Version 1.00 42/14-39 EN...

  • Page 45: Submenu Level 2

    /m, Nm Nl/d, Nl/h, Nl/m, Nl/s SCFD, SCFH, SCFM, SCFS MIN MASS FLOW Lower range value. MASS_FLOW_LO_LIM Default = 0 MAX MASS FLOW Upper range value of selected characteristics MASS_FLOW_HI_LIM END TB FLOW MENU 42/14-39 EN Sensyflow iG, Version 1.00...

  • Page 46: Submenu Level 2 → Ai Flow Menu

    Simulation of the STATUS signal, selection from the signals described in section 7.1.2.2 7.1.2.3 GOOD OK, GOOD UPDATE EVENT… STATUS LIMIT Simulation of the limit value STATUS, selection between LOW_LIMIT HIGH_LIMIT CONSTANT END AI FLOW Sensyflow iG, Version 1.00 42/14-39 EN...

  • Page 47: Submenu Level 2 → Tb Gas Temp Menu

    Input of a zero offset compensation value for the heater temperature in the selected unit (e. g. 5 °C) BIAS_2 Caution: This function shifts the entire characteristics! Default = 0 END TB GAS TEMP 42/14-39 EN Sensyflow iG, Version 1.00...

  • Page 48: Submenu Level 2 → Ai Gas Temp Menu

    Simulation of the STATUS signal, selection from the signals described in section 7.1.2.2 and 7.1.2.3 GOOD OK, GOOD UPDATE EVENT… STATUS LIMIT Simulation of the limit value STATUS, selection between LOW_LIMIT HIGH_LIMIT CONSTANT END AI GAS TEMP Sensyflow iG, Version 1.00 42/14-39 EN...

  • Page 49: Submenu Level 2 → Total Menu

    Upper warning limit (pre-alarm); warning is issued if measuring value ex- ceeds limit HI_LIM END OF TOTAL MENU In case of power failure the integrator value is retained. After switching the device on again, adding continuous automatically. 42/14-39 EN Sensyflow iG, Version 1.00...

  • Page 50: Maintenance And Service

    Maintenance and service All Sensyflow measuring systems are precisely calibrated for the respective application with our own ca- libration equipment, for which ABB Automation is associated with the German Calibration Service. Exten- sive calibration procedures, state-of-the-art production and testing procedures and continuous enhancements guarantee that these measuring systems are operating over extended periods almost maintenance-free.

  • Page 51: Sensyflow Ig: Measuring Principle

    Sensyflow iG: measuring principle For many years, thermal gas-mass flow meters with analog design have been established as complete process measuring devices in the chemical industry.The digital Sensyflow iG represents a logical step in the consequent development of this well-proven technology.
  • Page 52 Sensyflow iG: measuring principle The increased application and cost advantage results from the diagnostic possibilities of the digital Sen- syflow. The functions provided allow for preventive maintenance of the measuring system and the equip- ment, as operating times, temperature peaks, and loads in the system can be evaluated, stored, and reported.

  • Page 53: Type Overview, Technical Data

    < 0.05 %/K of measured value (depending on type of gas) Influence of medium pressure typically 0.2 %/100 kPa (/1 bar) of measured value (depending on type of gas) ≤ 0.5 s Response time = 1 s 42/14-39 EN Sensyflow iG, Version 1.00...
  • Page 54 2 x passive optocoupler (approx. 100 mA) selectable as frequency, pulse, or switching output Digital input 2 x 24 V lin typ. 10 mA (low < 2 mA, high > 10 mA) frequency and switching input Sensyflow iG, Version 1.00 42/14-39 EN...

  • Page 55: Abbreviations

    DVGWDeutscher Verband Gas Wasser (German Gas and Water Association) Class 1 Class 2 Process Automation PCS Process Control System PTB Physikalisch Technische Bundesanstalt (German Federal Institute of Weights and Measures) Rev Revision TOT Totalizer, Integrator 42/14-39 EN Sensyflow iG, Version 1.00...

  • Page 56: Decommissioning And Packaging

    0.2 mm. Adapt the amount of desiccant to the packing volume and the expec- ted transport time (at least sufficient for 3 months). Additionally line the box with a layer of union paper. Sensyflow iG, Version 1.00 42/14-39 EN...

  • Page 57: Appendix: Manufacturer-Specific Gsd File (Device Data File)

    ';' character in front of the line next line GSD_Revision = 2 ;=================================================================== Vendor_Name = "ABB Automation" ; max 32 characters Model_Name = "ABB Sensyflow iG" ; max 32 characters Revision = "Version 1.0.0" ; Version of this file (see HISTORY) Ident_Number = 0x05CA ;...
  • Page 58 Unit_Diag_Bit(24) = "Hardware failure" Unit_Diag_Bit(25) = "Reserved" Unit_Diag_Bit(26) = "Reserved" Unit_Diag_Bit(27) = "Electromic Temp. to high" Unit_Diag_Bit(28) = "Memory error" Unit_Diag_Bit(29) = "Sensor failure" Unit_Diag_Bit(30) = "Device not initialized" Unit_Diag_Bit(31) = "Selfcalibration failed " Sensyflow iG, Version 1.00 42/14-39 EN...
  • Page 59 Unit_Diag_Bit(77) = "Reserved" Unit_Diag_Bit(78) = "Reserved" Unit_Diag_Bit(79) = "Reserved" ;Gerätespezifische Diagnose Byte 8 Unit_Diag_Bit(80) = "Reserved" Unit_Diag_Bit(81) = "Reserved" Unit_Diag_Bit(82) = "Reserved" Unit_Diag_Bit(83) = "Reserved" Unit_Diag_Bit(84) = "Reserved" Unit_Diag_Bit(85) = "Reserved" Unit_Diag_Bit(86) = "Reserved" 42/14-39 EN Sensyflow iG, Version 1.00...
  • Page 60 – especially reprinting, photomechanical or electronic reproduction or storage in data processing systems or data networks without consent of the the legal owner is prohibited and shall be prosecuted under civil and criminal law. Subject to technical changes. ABB Automation Products GmbH Printed in the Fed. R. of Germany Borsigstraße 2 42/14-39 EN Rev.

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