SICK FLOWSIC60 Operating Instructions Manual
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SICK FLOWSIC60 Operating Instructions Manual

SICK FLOWSIC60 Operating Instructions Manual

Continuous air flow measurement for mining applications
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Front page
FLOWSIC60
Continuous air flow measurement
for mining applications
Installation
Operation
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 FLOWSIC60

  • Page 1 Front page O P E R A T I N G I N S T R U C T I O N S FLOWSIC60 Continuous air flow measurement for mining applications Installation Operation...
  • Page 2 Prozessindustrie" (www.namur.de) The English version 8014241 of this document is an original document 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.
  • 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 Hazard which could result in property damage. FLOWSIC60 Operating Instructions 8014241/YTG9/V1-0/2016-02 © SICK Engineering GmbH...

  • Page 4: Table Of Contents

    FLOWSIC60 Sensor ........
  • Page 5 Ex Certificate..............61 FLOWSIC60 · Operating Instructions · 8014241/YTG9/V1-0/2016-02 · © SICK Engineering GmbH...
  • Page 6 Contents FLOWSIC60 · Operating Instructions · 8014241/YTG9/V1-0/2016-02 · © SICK Engineering GmbH...

  • Page 7: Important Information

    Important Information FLOWSIC60 Important Information About this document Main hazards Intended use Responsibility of user Safety instructions and protective measures FLOWSIC60 · Operating Instructions · 8014241/YTG9/V1-0/2016-02 · © SICK Engineering GmbH...

  • Page 8: About This Document

    The front cover of the device electronics is sealed. Do not open the front cover! Otherwise the explosion protection of the device expires and serious damage and injury can occur. The FLOWSIC60 is approved for use in Ex Zone 0. The device designation for use in hazardous areas is: Electronics: –...

  • Page 9: Restrictions Of Use

    Correct use  Use the FLOWSIC60 only as described in these Operating Instructions. The manufac- turer bears no responsibility for any other use.  Observe all measures necessary for conservation of value, e.g. for maintenance and inspection and/or transport and storage.

  • Page 10: Safety Instructions And Protective Measures

    Read this section and the notes and warnings in the individual sections of this manual carefully and observe the instructions given therein when carrying out any work on the FLOWSIC60 measuring system. General instructions: ...
  • Page 11  Neither failures nor erroneous measurements lead to operational states that can cause damage or become dangerous  The specified maintenance and inspection tasks are carried out regularly by qualified, experienced personnel. FLOWSIC60 · Operating Instructions · 8014241/YTG9/V1-0/2016-02 · © SICK Engineering GmbH...
  • Page 12 Repairs NOTICE: Any repair work on FLOWSIC60 and its components will be carried out at the manufacturer only. In case of malfunction, the defective component can be exchanged and sent to the manufacturer for repair.

  • Page 13: Product Description

    Product description FLOWSIC60 Product description System information FLOWSIC60 · Operating Instructions · 8014241/YTG9/V1-0/2016-02 · © SICK Engineering GmbH...

  • Page 14: System Information

    Product description System information 2. 1 The FLOWSIC60 transducers consist of two ultrasonic sensors, sensor cables and a signal processing unit. The transducer is mounted in the holder. Coaxial connection cables are used for the communication with the SPU. System components 2.1.1...

  • Page 15: Determinig The Gas Velocity

    (2.3) 2 · cos α i.e. a relation in which, except for the two transit times measured, only the active measuring path and the path angle exist as constants. FLOWSIC60 · Operating Instructions · 8014241/YTG9/V1-0/2016-02 · © SICK Engineering GmbH...

  • Page 16: Operating Principle

    Product description Operating principle 2.1.3 FLOWSIC60 operates by measuring the transit time difference of ultrasonic pulses. The sensors are mounted on both sides of the tunnel at a certain angle to the flow direction ( Fig. 1). The sensors alternately send ultrasonic pulses to each other. Depending on the installation angle α...

  • Page 17: Flowsic60 Sensor

    Product description FLOWSIC60 Sensor 2.1.4 Fig. 2 Sensor Safety screw Mounting Sensor front bracket Fig. 3 Dimensions - Sensor FLOWSIC60 · Operating Instructions · 8014241/YTG9/V1-0/2016-02 · © SICK Engineering GmbH...

  • Page 18: Signal Processing Unit (Spu)

    Product description Signal Processing unit (SPU) 2.1.5 Fig. 4 Signal processing unit Signal Processing Unit (SPU) Junction box Cable holder Cabling from transducer units FLOWSIC60 · Operating Instructions · 8014241/YTG9/V1-0/2016-02 · © SICK Engineering GmbH...
  • Page 19 Product description Fig. 5 Dimensions - Signal processing unit FLOWSIC60 · Operating Instructions · 8014241/YTG9/V1-0/2016-02 · © SICK Engineering GmbH...
  • Page 20 Product description FLOWSIC60 · Operating Instructions · 8014241/YTG9/V1-0/2016-02 · © SICK Engineering GmbH...

  • Page 21: Installation

    Installation FLOWSIC60 Installation Mechanical installation Electrical installation FLOWSIC60 · Operating Instructions · 8014241/YTG9/V1-0/2016-02 · © SICK Engineering GmbH...

  • Page 22: Mechanical Installation

    10 m. The possible range of the installation angle can be found in the diagram in Fig. 6. Fig. 6 Installation angle Installation angle in degrees Tunnel diameter in m FLOWSIC60 · Operating Instructions · 8014241/YTG9/V1-0/2016-02 · © SICK Engineering GmbH...
  • Page 23 45 - 60° Positive direction of air flow Sensor B Sensor A Fig. 8 Clearance requirements for measuring path Clearance max. 5 ° > 2 m max. permitted vehicle height FLOWSIC60 · Operating Instructions · 8014241/YTG9/V1-0/2016-02 · © SICK Engineering GmbH...
  • Page 24 Installation WARNING: In order to ensure a proper function of FLOWSIC60, the measuring path  between the sensors must be free of obstructions in order to guarantee that the signal propogation is not hindered. Constant or temporary interruption of the signal path through persons or ...

  • Page 25: Mounting Of Sensors To Tunnel Wall

     p. 23, Fig. 7 Fig. 9 Drill hole Tunnel wall/roof Heavy duty anchor Mounting bracket Depth Mounting set Dia. Depth Notes 60 2M8-1.4571 The anchor should be flush with the tunnel wall/roof FLOWSIC60 · Operating Instructions · 8014241/YTG9/V1-0/2016-02 · © SICK Engineering GmbH...
  • Page 26 In case of ceiling mounting, optional, spacer elements have to be installed at the ceiling in order to ensure the required clearance to the ceiling. ( pg. 23, Fig. 8) Fig. 10 Ceiling installation FLOWSIC60 · Operating Instructions · 8014241/YTG9/V1-0/2016-02 · © SICK Engineering GmbH...

  • Page 27: Mounting Of Signal Processing Unit (Spu) And Cable Holder

    8 Take measures against accidental misalignment. Fig. 11 Screws for alignment Safety screw Mounting Sensor front bracket FLOWSIC60 · Operating Instructions · 8014241/YTG9/V1-0/2016-02 · © SICK Engineering GmbH...

  • Page 28: Determination Of Path Length And Path Angle

    ( Fig. 12).    --- - atan   Fig. 12 Path angle α FLOWSIC60 · Operating Instructions · 8014241/YTG9/V1-0/2016-02 · © SICK Engineering GmbH...

  • Page 29: Electrical Installation

    WARNING: Cable connections must comply with Zone 0 requirements Only the SICK original cables provided may be used for connecting the trans- ducers to the SPU.  Ensure that cable entries are closed so as to be leak tight ...

  • Page 30: General Information

    3.2.1 Pre-requisites Wiring work (routing and connecting of power supply and signal cables), which is necessary when installing FLOWSIC60, is not included in the scope of delivery. The mechanical instal- lation must be completed first. Cable routing  Keep cables in conduits or laid on cable trays to provide protection from mechanical damage.

  • Page 31: Cable Specifications For Power Supply And Analog Output

    Fixing range of the cable glands WARNING: The FLOWSIC60 may only be connected to a safe power supply certified to be intrinsically safe, otherwise the intrinsic safety of the device may be compro- mised. The FLOWSIC60 may only be operated with intrinsically safe electrical equipment according to Ex ia (EPL Ga/Ma).

  • Page 32: Checking The Cable Loops

    59, Fig. ). Repairs to the electronics with casting may only be carried out by the manufacturer. Incorrect cabling may cause failure of the FLOWSIC60 and compromise its  intrinsic safety. This will invalidate any warranty claims. The manufacturer assumes no liability for consequential damage.

  • Page 33: Electrical Installation Of Signal Processing Unit

    A schematic wiring diagram is provided on the inside of the rear housing cover  p. 60, Fig. 23. Figure 16 SPU housing Open the cover Cover Securing clip FLOWSIC60 · Operating Instructions · 8014241/YTG9/V1-0/2016-02 · © SICK Engineering GmbH...
  • Page 34 Field connections (10-pole terminal box) Figure 18 Terminal assignment Terminals 2 and PE are bridged internally, i.e. there is no insulation between PE and negative potential (see  p. 34, Fig. 17). FLOWSIC60 · Operating Instructions · 8014241/YTG9/V1-0/2016-02 · © SICK Engineering GmbH...
  • Page 35 Digital status output passive 41/42 "open": 16 V ≤ U ≤ 30 V, 0 mA ≤ I ≤ CE H CE H 0.2 mA (H=High) 81/82 "Check request" (default) FLOWSIC60 · Operating Instructions · 8014241/YTG9/V1-0/2016-02 · © SICK Engineering GmbH...
  • Page 36 All parts connected to the Signal processing unit must be grounded by using the grounding conductior connections at the SPU, terminal box and sensor cables as shown Fig. 19. Fig. 19 Grounding of SPU and junction box Grounding conductor connection FLOWSIC60 · Operating Instructions · 8014241/YTG9/V1-0/2016-02 · © SICK Engineering GmbH...

  • Page 37: Operation In Hazardous Areas

    Cable routing via 2x Ex cable gland terminal integrated into housing section (cast-on part). Connection options The protection concept for the FLOWSIC60 permits intrinsically safe power supply connection and field connections (“i“) only: FLOWSIC60 · Operating Instructions · 8014241/YTG9/V1-0/2016-02 · © SICK Engineering GmbH...
  • Page 38  The SPU housing must not be insulated.  Figure 20 on page 39 gives an overview of the FLOWSIC60 components and their type of Ex safety. Applicable requirements are: – IEC 60079-0 –...
  • Page 39 Signal processing unit (SPU) Analog/Status “ia” output SICK internal service interface RS485/Modbus Junction box Ultrasonic sensors “ia” NOTICE: Potential equalization  PE: Have to be connected with potential equalization system. FLOWSIC60 · Operating Instructions · 8014241/YTG9/V1-0/2016-02 · © SICK Engineering GmbH...
  • Page 40  The applicable national regulations shall also be observed. NOTICE: Special requirements for installation in hazardous zones in mines are of first importance and must be observed. FLOWSIC60 · Operating Instructions · 8014241/YTG9/V1-0/2016-02 · © SICK Engineering GmbH...
  • Page 41 = 327 mW = 248 mW Internal capacity: negligible negligible negligible Internal inductance: = 20.6 mH = 15.5 mH = 6.7 mH For further details see CoC IECEx TUN 10.0023X FLOWSIC60 · Operating Instructions · 8014241/YTG9/V1-0/2016-02 · © SICK Engineering GmbH...
  • Page 42 Installation FLOWSIC60 · Operating Instructions · 8014241/YTG9/V1-0/2016-02 · © SICK Engineering GmbH...

  • Page 43: Commissioning And Operation

    Commissioning and Operation FLOWSIC60 Commissioning and Operation Commissioning Operation Calibration Operating modes FLOWSIC60 · Operating Instructions · 8014241/YTG9/V1-0/2016-02 · © SICK Engineering GmbH...

  • Page 44: Operation And Menu Structure Of The Spu Via Lc-Display

    Operational concept 4. 2 FLOWSIC60 is equipped with a front panel containing a two-line LCD to display current measured values and diagnostics and enter installation specific parameters. The values to be displayed or modified can be selected using the magnetic pen without removal of the front cover.

  • Page 45: Menu Structure On The Lcd Display

    "Configuration"). Use the ENTER function to switch the mode. Measurement Confirmation dialog for switching to the indicated operating Configuration mode. Use the ENTER function to confirm or the C/CE button Cancel to cancel the dialog. FLOWSIC60 · Operating Instructions · 8014241/YTG9/V1-0/2016-02 · © SICK Engineering GmbH...
  • Page 46 Reset Service? Submenu "LCD Display" with language parameter for the LCD Settings display LCD Display Set parameter "Language" to Language - English English - German - French - Russian FLOWSIC60 · Operating Instructions · 8014241/YTG9/V1-0/2016-02 · © SICK Engineering GmbH...
  • Page 47 Conformity with the manufacturer settings can be checked by comparing this check sum with the original check sum. Unauthorized modification of these parameters may lead to failure of the device! FLOWSIC60 · Operating Instructions · 8014241/YTG9/V1-0/2016-02 · © SICK Engineering GmbH...
  • Page 48 Act. voltage 21.30V "Parameters" menu. FLOWSIC600 Parameters Display of all parameters stored in the meter‘s Reg.: 3001 registers. Navigate through the list of registers 0000 with STEP or DATA. FLOWSIC60 · Operating Instructions · 8014241/YTG9/V1-0/2016-02 · © SICK Engineering GmbH...

  • Page 49: Data Editing In Configuration Mode

    Path length Enter desired value x * DATA Path length Confirm new value ENTER Path length 6.2 m Return to standard display 3 x CE/C 0 m/s Aout 12.0 mA FLOWSIC60 · Operating Instructions · 8014241/YTG9/V1-0/2016-02 · © SICK Engineering GmbH...

  • Page 50: Comissioning And Initial Start-Up

    Commissioning and Operation Comissioning and initial start-up 4. 3 Comissioning procedure of FLOWSIC60 consists of only a few steps in order to enter instal- lation parameters into the device and verify proper readings: Complete all mechanical and electrical installation work before start-up.

  • Page 51: Meter States

    Check proper alignment and cabling of ultrasonic sensors and signal processing unit  If FLOWSIC60 is unable to calculate a valid air velocity over a certain period of time, the meter status becomes “Error – measurement invalid”. Error – Measurement invalid...
  • Page 52 Commissioning and Operation FLOWSIC60 · Operating Instructions · 8014241/YTG9/V1-0/2016-02 · © SICK Engineering GmbH...

  • Page 53: Maintenance

    Maintenance FLOWSIC60 Maintenance General notes In case of works in tunnel FLOWSIC60 · Operating Instructions · 8014241/YTG9/V1-0/2016-02 · © SICK Engineering GmbH...

  • Page 54: General Notes

    A normal maintenance period is 24 weeks. FLOWSIC60 is equipped with intelligent self-diagnostics which continuously monitors the performance of the FLOWSIC60 and provides a warning via the digital status output if there is any risk of failure caused e.g. by heavy pollution.

  • Page 55: Troubleshooting

    Troubleshooting FLOWSIC60 Troubleshooting General troubleshooting FLOWSIC60 · Operating Instructions · 8014241/YTG9/V1-0/2016-02 · © SICK Engineering GmbH...

  • Page 56: General Troubleshooting

    Troubleshooting General troubleshooting 6. 1 Please refer to the attached table for general troubleshooting. In case the instructions provided cannot solve the issue, contact your local SICK service organization for support. Problem Possible causes Actions No display, no signal outputs Faulty power supply ...

  • Page 57: Annex

    Annex FLOWSIC60 Annex Technical data Labelling Wiring diagram Ex Certificate FLOWSIC60 · Operating Instructions · 8014241/YTG9/V1-0/2016-02 · © SICK Engineering GmbH...

  • Page 58: Technical Data

    Voltage 13.5 to 24 V DC, intrinsically safe supply Power consumption ≤ 1 W General Scope of delivery The scope of delivery depends on application and customer specifica- tions. FLOWSIC60 · Operating Instructions · 8014241/YTG9/V1-0/2016-02 · © SICK Engineering GmbH...

  • Page 59: Labelling

    - 40 °C T 70 °C Ui = 30 V - 40 °C T 70 °C For further details see Certificate No. IP 66/67 IECEx TUN 10.0023 X Issue No. 1 FLOWSIC60 · Operating Instructions · 8014241/YTG9/V1-0/2016-02 · © SICK Engineering GmbH...

  • Page 60: Wiring Diagram

    Annex Wiring diagram 7. 3 Fig. 23 FLOWSIC60 wiring plan FLOWSIC60 · Operating Instructions · 8014241/YTG9/V1-0/2016-02 · © SICK Engineering GmbH...

  • Page 61: Ex Certificate

    Annex Ex Certificate 7 . 4 Fig. 24 IECEx certificate of conformity FLOWSIC60 · Operating Instructions · 8014241/YTG9/V1-0/2016-02 · © SICK Engineering GmbH...
  • Page 62 Annex Fig. 25 IECEx certificate of conformity FLOWSIC60 · Operating Instructions · 8014241/YTG9/V1-0/2016-02 · © SICK Engineering GmbH...
  • Page 63 Annex Fig. 26 IECEx certificate of conformity FLOWSIC60 · Operating Instructions · 8014241/YTG9/V1-0/2016-02 · © SICK Engineering GmbH...
  • Page 64 Annex Fig. 27 IECEx certificate of conformity FLOWSIC60 · Operating Instructions · 8014241/YTG9/V1-0/2016-02 · © SICK Engineering GmbH...
  • Page 65 Annex Fig. 28 IECEx certificate of conformity FLOWSIC60 · Operating Instructions · 8014241/YTG9/V1-0/2016-02 · © SICK Engineering GmbH...
  • Page 66 Annex Fig. 29 IECEx certificate of conformity FLOWSIC60 · Operating Instructions · 8014241/YTG9/V1-0/2016-02 · © SICK Engineering GmbH...
  • Page 67 Annex Fig. 30 IECEx certificate of conformity FLOWSIC60 · Operating Instructions · 8014241/YTG9/V1-0/2016-02 · © SICK Engineering GmbH...
  • Page 68 Annex Fig. 31 IECEx certificate of conformity FLOWSIC60 · Operating Instructions · 8014241/YTG9/V1-0/2016-02 · © SICK Engineering GmbH...
  • Page 69 Annex Fig. 32 IECEx certificate of conformity FLOWSIC60 · Operating Instructions · 8014241/YTG9/V1-0/2016-02 · © SICK Engineering GmbH...
  • Page 70 Annex Fig. 33 IECEx certificate of conformity FLOWSIC60 · Operating Instructions · 8014241/YTG9/V1-0/2016-02 · © SICK Engineering GmbH...
  • Page 71 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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