SICK Flow-X User manual

MMMI MMMOPERATING INSTRUCTIONS
O P E R A T I N G I N S T R U C T I O N S
Flow-X
Gas Flow Computer
Description, installation, operation
Title Page

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Described product
Product name: Flow-X
Manufacturer
SICK Engineering GmbH
Bergener Ring 27 · D-01458 Ottendorf-Okrilla · Germany
Phone: [phone]
Fax: [phone]
E-mail: [email protected]
Legal information
This work is protected by copyright. Any rights derived from the copyright shall be
reserved for SICK Engineering GmbH. Reproduction of this document or parts of this
document is only permissible within the limits of the legal determination of Copyright
Law.
Any modification, shortening or translation of this document is prohibited without the
express written permission of SICK Engineering GmbH.
The trademarks stated in this document are the property of their respective owner.
© SICK Engineering GmbH. All rights reserved.
Original document
This document is an original document of SICK Engineering GmbH.

CONTENTS
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1 About this document................................................................................. 6
1.1 Function of this document..............................................................................6
1.2 Scope of application .......................................................................................6
1.3 Target groups ..................................................................................................6
1.4 Symbols and document conventions .............................................................6
1.4.1 Warning symbols.............................................................................6
1.4.2 Warning levels and signal words.................................................... 7
1.4.3 Information symbols .......................................................................7
1.5 Data integrity...................................................................................................7
2 For your safety............................................................................................ 8
2.1 Basic safety information.................................................................................8
2.2 Intended use ...................................................................................................8
2.2.1 Purpose of the device.....................................................................8
2.2.2 Correct use......................................................................................8
2.3 Responsibility of user.....................................................................................8
3 Product description ................................................................................... 9
3.1 Flow-X flow computer......................................................................................9
3.2 Flow-X/M Module ............................................................................................9
3.3 Flow-X enclosure ...........................................................................................10
3.3.1 Flow-X/P ........................................................................................10
3.3.2 Flow-X/C ........................................................................................11
3.3.3 Flow-X/S ........................................................................................11
3.4 Flow-X.............................................................................................................11
3.5 Type plate ......................................................................................................12
3.6 Multi-module operation ................................................................................12
3.7 Configuration protection...............................................................................12
3.7.1 Parameter locking switch .............................................................12
3.7.2 Metrological seal ..........................................................................12
3.7.3 Passwords .....................................................................................12
3.8 User interfaces..............................................................................................13
3.8.1 Flow-X/P and Flow-X/C touchscreen............................................13
3.8.2 Touchscreen for the Flow-X ..........................................................13
3.8.3 Flow-X/M module LCD display......................................................13
3.8.4 Flow-X web interface.....................................................................14
3.8.5 Touchscreen user interface layout...............................................14
3.9 XML interface ................................................................................................16
Contents
Contents

CONTENTS
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4 Installation................................................................................................17
4.1 Necessary decisions..................................................................................... 17
4.1.1 Installation location..................................................................... 17
4.1.2 Internationale Standards ............................................................. 17
4.1.3 Number of modules...................................................................... 17
4.1.4 Redundancy.................................................................................. 18
4.1.5 Fast data exchange...................................................................... 18
4.1.6 Display requirements ................................................................... 18
4.1.7 Power supply ................................................................................ 18
4.2 Mechanical installation ................................................................................ 19
4.2.1 Flow-X/P and Flow-X/C................................................................. 19
4.3 Electrical installation ................................................................................... 20
4.3.1 Introduction .................................................................................. 20
4.3.2 General connection...................................................................... 21
4.3.3 Cable specification ...................................................................... 21
4.3.4 Electrical connections ................................................................. 22
4.3.5 Power supply plug ....................................................................... 23
4.3.6 Field connections ......................................................................... 24
4.3.7 9-pin D-sub connection port (serial communication) ................. 27
4.3.8 Ethernet ........................................................................................ 27
5 Commissioning ........................................................................................ 28
5.1 Device settings ............................................................................................. 28
5.2 Connecting devices with HART protocol ...................................................... 29
5.2.1 Pressure sensor ........................................................................... 29
5.2.2 Temperature transmitter.............................................................. 29
5.3 Connecting analog devices .......................................................................... 30
5.3.1 Pressure transmitter .................................................................... 30
5.3.2 Temperature transmitter.............................................................. 31
5.4 Device configuration and connection check ............................................... 31
5.4.1 FLOWSIC600-XT ........................................................................... 31
5.4.2 Pressure transmitter .................................................................... 33
5.4.3 Temperature transmitter.............................................................. 34
5.4.4 Deleting log files and reports....................................................... 35
5.5 Metrological settings ...................................................................................35
6 Troubleshooting ....................................................................................... 36
6.1 Testing gas flow meter communication....................................................... 36
6.2 Interface configurations of gas meter connection ...................................... 38
6.2.1 Configuration with FLOWgate™ ................................................... 38
6.2.2 Configuration with Flow-X flow computer, webserver or module
screen ........................................................................................... 39
6.3 Checking the measuring mode setting of the pressure transmitter .......... 40
6.4 Verifying the analog temperature transmitter ............................................. 40

CONTENTS
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7 Appendix ...................................................................................................41
7.1 Conformities ..................................................................................................41
7.1.1 CE certificate.................................................................................41
7.1.2 Standards compatibility and type approvals ...............................41
7.2 General specifications .................................................................................41
7.3 Flow-X/M I/O specifications .........................................................................43
7.3.1 I/O signal specifications ..............................................................43
7.3.2 Specifications for flow calculation ..............................................44
7.3.3 Supported devices .......................................................................45
7.4 Power consumption .....................................................................................45
7.5 Weight............................................................................................................45
7.6 Dimensions....................................................................................................46
7.7 Wiring example..............................................................................................52

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1ABOUT THIS DOCUMENT
1 About this document
1.1 Function of this document
These Operating Instructions describe:
●Device components
●Installation
●Commissioning
●Operation
●Maintenance work required for reliable operation
These Operating Instructions only cover standard applications which conform with the
technical data specified.
Additional information and assistance for special applications are available from your SICK
representative. It is generally recommended to take advantage of qualified consulting
services provided by SICK experts for your specific application.
1.2 Scope of application
●These Operating Instructions are only applicable for the measuring device described in
the product identification.
●They are not applicable for other SICK measuring devices.
●The standards referred to in these Operating Instructions are to be observed in the
respective valid version.
1.3 Target groups
This Manual is intended for persons who install, operate and maintain the device.
1.4 Symbols and document conventions
1.4.1 Warning symbols
Symbol Significance
Hazard (general)
Hazard in potentially explosive atmospheres

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ABOUT THIS DOCUMENT 1
1.4.2 Warning levels and 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 less severe or minor injuries.
NOTICE:
Hazard which could result in property damage.
Note:
Tips
1.4.3 Information symbols
1.5 Data integrity
SICK AG uses standardized data interfaces, such as standard IP technology, in its products.
The focus here is on the availability of the products and their properties.
SICK AG always assumes that the customer is responsible for the integrity and
confidentiality of data and rights involved in connection with using the products.
In all cases, the customer is responsible for the implementation of safety measures
suitable for the respective situation, e.g., network separation, firewalls, virus protection and
patch management.
Symbol Significance
Information on product characteristics with regard to protection against explosions
(general)
Information on product characteristics with regard to European Directive
ATEX 2014/34/EU
Important technical information for this product
Important information concerning electrical or electronic functions

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2FOR YOUR SAFETY
2 For your safety
2.1 Basic safety information
Improper use or handling can cause health or material damage. Therefore, it is imperative
that the following points are observed to prevent damage:
The legal stipulations and associated technical regulations relevant for the respective
system must be observed when preparing and carrying out work.
●All work must be carried out in accordance with the local, system-specific conditions and
with due consideration of operating hazards and specifications.
●The Operating Instructions belonging to the Flow-X flow computer as well as plant
documentations must be available on site.
●Always observe the information on the prevention of danger and damage given therein.
2.2 Intended use
2.2.1 Purpose of the device
The Flow-X flow computer measures and calculates, using standard algorithms and process
data, standardized volume flow based on the connected devices, such as FLOWSIC gas flow
meters and process transmitters.
It may only be used as specified by the manufacturer.
2.2.2 Correct use
The device may only be used as described in the Operating Instructions.
Pay special attention that:
●The usage of the technical data corresponds to the specifications on allowable use as
well as assembly, connection, ambient and operating conditions (see the order
documents, device pass, type plates and documentation delivered with the device)
●All measures required to maintain the device, e.g. for maintenance and inspection,
transport and storage are complied with.
2.3 Responsibility of user
▸Read the Operating Instructions before putting the Flow-X flow computer into operation.
▸Observe all safety information.
▸If anything is not clear: Please contact SICK Customer Service.
WARNING:
The SICK Flow-X flow computer is neither intrinsically safe nor explosion proof and can
therefore only be used in a non-hazardous area (safe area).
For details on the installation of other devices in a hazardous area, always refer to the
documentation supplied by the manufacturer.
When connecting to a device located in a hazardous area, it may be necessary to use
safety barriers or galvanic isolation between the device and the SICK Flow-X flow
computer. Corresponding information can be found in the device documentation.

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PRODUCT DESCRIPTION 3
3 Product description
3.1 Flow-X flow computer
The Flow-X flow computer consists of 1 to 4 Flow-X modules (Flow-X) and an enclosure
(Flow-X/S, Flow-X/P or Flow-X/C). For a Flow-X/S or Flow-X/P enclosure, the Flow-X modules
are exchangeable whereas for a Flow-X/C, the Flow-X module is permanently installed inside
and therefore cannot be exchanged.
3.2 Flow-X Module
The Flow-X module is the core element and represents the complete gas flow computer. It
represents a measuring section in a gas measuring system. The Flow-X module is operated
in a Flow-X/S, Flow-X/P or Flow-X/C enclosure. It has its own 4-inch display and four
navigation keys which serve to check values and change parameters.
Fig. 1: Flow-X module
Signal type Qty. Specification
Analog inputs 6 [1] Analog transmitter input, high accuracy
Input types: 4 … 20 mA, 0 … 20 mA, 0 … 5 V, 1 … 5 V
Accuracy mA inputs; 0.002% FS at 21 °C, 0.008% at full
ambient range of 0 ... 60°C, long-term stability 0.01%/year,
resolution 24 bit.
Analog inputs share a common, floating ground in relation to all
other electronics.
4-wire PRT inputs 2 Resolution 0.02 °C for 100 Ohm input.
Error depending on range 0 ... 50 °C: Error <0.05 °C or better
-220 ... +220 °C: Error <0.5 °C or better
HART input 4 [1] Independent HART current loop inputs, in addition to the
4 ... 20 mA signals (analog inputs)
Support includes multi-drop for each measuring section and
support for redundant flow computer operation
Analog outputs 4 Analog output for process outputs and flow/pressure control,
resolution 14 bit, 0.075% FS.
Analog inputs share a common, floating ground in relation to all
other electronics.
Pulse inputs 4 [2] Single or double pulse input.
Adjustable trigger level at different voltages.
Frequency range up to 10 kHz for single and double pulse.
Compliant with ISO6551, IP252 and API 5.5.
True Level A and Level B implementation.
Table 1: Flow-X/M inputs and outputs

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3PRODUCT DESCRIPTION
3.3 Flow-X enclosure
3.3.1 Flow-X/P
The Flow-X/P enclosure is a multi-stream flow computer with integrated station module and
7-inch touchscreen and can accommodate up to 4 Flow-X modules.
Fig. 2: Flow-X/P enclosure incl. four Flow-X modules
Density/viscosity 4[2] Periodic time input, 100 μs to 5000 μs.
Resolution < 1ns
Digital inputs 16[2] Digital status inputs. Resolution 100 ns (10 MHz)
Digital outputs 16[2] Digital output, open collector (0.5 A DC)
Rated value 100 V, 24 mA
Pulse outputs 4[2] Open collector, 0.01 to 500 Hz
Inputs of the sphere
detector
4[2] Supports 1, 2 and 4 detector configuration mode
Resolution 100 ns (10 MHz)
Prover bus outputs 1[2] Meter pulse output for remote flow computers.
Resolution 100 ns (1 MHz)
Frequency outputs 4[2] Frequency outputs for emulation of flow meter signals. Maximum
frequency 10 KHz, accuracy 0.1%
Serial 2 RS485 / RS-232 serial input for ultrasonic counter, printer or
generic, 115kb
Ethernet 2 RJ45 Ethernet Interface, TCP/IP
[1] There are 6 analog inputs per module. Analog inputs 1 to 4 support HART.
[2] Total number of pulse inputs + digital inputs + digital outputs + pulse outputs + density inputs + sphere detector
inputs + prover bus outputs + frequency outputs = 16
Signal type Qty. Specification
Table 1: Flow-X/M inputs and outputs

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PRODUCT DESCRIPTION 3
3.3.2 Flow-X/C
The Flow-X/C is the compact version of the Flow-X/P with a Flow-X module integrated in the
enclosure. It has three serial and two Ethernet interfaces.
Fig. 3: Flow-X/C enclosure with internally installed Flow-X module
3.3.3 Flow-X/S
The Flow-X/S enclosure is a single module enclosure with DIN rail enclosure with direct
screw terminals for the field connections and is used as single measuring section.
Fig. 4: Flow-X/S enclosure with a Flow-X module
3.4 Flow-X
The Flow-X/T is a 7-inch color touchscreen that can be installed in an instrument panel. It
serves as operator interface for Flow-X/S.
Fig. 5: Flow-X

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3PRODUCT DESCRIPTION
3.5 Type plate
The Flow-X flow computer type plate contains the following information: CE code, MID
approval number, notified body, serial number, year of manufacture, operating temperature
according to MID approval and Test Certificate number.
Fig. 6: Type plate
3.6 Multi-module operation
The Flow-X/P flow computers normally have more than one Flow-X module. These modules
can be used in single or multi-module operation. In single module operation, each module
acts as an independent flow computer. In multi-module operation, all modules work
together as one flow computer, with data exchange via the Ethernet interface.
3.7 Configuration protection
3.7.1 Parameter locking switch
Each individual Flow-X module has a mechanical parameter locking switch, which prevents
the change of crucial parameters within the program.
Fig. 7: Parameter locking switch
3.7.2 Metrological seal
All Flow-X enclosures have the option of sealing the parameter locking switch of the
individual Flow-X modules with a seal. On a Flow-X/P enclosure, one bar is used to seal all
installed Flow-X modules with one lead seal.
3.7.3 Passwords
Access to the parameters and functions of the Flow-X computer via the touchscreen or a
connected computer is password protected.
1 2 3
1 Label with MID code affixed after confirmation of
compliance with the Measuring Instruments
Directive
2 MID code, where yy is the year of conformity
3 XXXX is the number of the Notified Body under
whose responsibility conformity has been
confirmed.
Parameter locking switch

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PRODUCT DESCRIPTION 3
3.8 User interfaces
3.8.1 Flow-X/P and Flow-X/C touchscreen
The Flow-X/P and Flow-X/C have an integrated 7-inch touchscreen with which to access
and enter the data. The touchscreen is an integral part and cannot be removed or replaced.
3.8.2 Touchscreen for the Flow-X
All Flow-X flow computers can be operated with differing touchscreens. For this purpose,
SICK provides the program 'StandaloneGUI.exe' which supports the following platforms:
●Windows 32 bit / x86
●WinCE5 / ARM
●WinCE6 / x86
A single touch panel can be used for several Flow-X flow computers providing a cost-
effective user interface.
SICK offers a 7-inch touch panel PC version designed for cabinet installation.
3.8.3 Flow-X module LCD display
Each Flow-X module has an LCD display. The display provides access to local Flow-X module
data and, when the module is installed in a Flow-X/P enclosure, access to the Station
module and external modules installed in the same Flow-X/P. It has the same range of
functions as the main user interface , except for entering alphanumeric characters.
Fig. 8: Flow-X LC display
1 2 3
4
5
1 Up one menu level
2 Up in the menu or changes a value
3 Selects a menu item
4 Down in the menu or changes a value
5 Alarm

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3PRODUCT DESCRIPTION
3.8.4 Flow-X web interface
All Flow-X flow computers have an integrated web server that allows external operation via
common web browsers (Windows Internet Explorer, Mozilla Firefox, Google Chrome, Opera,
etc.). The web browser offers the same features as the main user interface, plus an
Explorer Tree for easy navigation. It also serves to download reports and historical data.
3.8.5 Touchscreen user interface layout
Flow-X flow computer user interfaces have the following layout and buttons:
Fig. 9: Main menu of the Flow-X flow computers
1 Go to “Main menu”
2 Up one menu level
3 One step backward
4 One step forward
5 Go to “Login” menu
6 One page up
7 To end of page
8 Go to “Alarms” menu
9 One page down
1 2 3 4
5
6
7
8
9

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PRODUCT DESCRIPTION 3
Fig. 10: Menu tree of relevant menu items of the Flow-X flow computer
Live Values
Flow Rates
Flow Meter
Configuration
System
IO
Communication
Smart Meter
Run
COM Ports
Diagnostics
Configuration
FLOWSIC600
Flow Meter
Pressure Transmitter
Temperature Transmitter
Pressure
Temperature
COM1
Analog Inputs
Analog Inputs
FLOWSIC600 Communication
FLOWSIC600 Path Data
Pressure Communication
Temperature Communication
Main menu Submenu Submenu

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3PRODUCT DESCRIPTION
3.9 XML interface
The Flow-X flow computer has a secured XML interface to to establish an automated
interface with a host computer.
Web services are available for the following data and actions:
●Alarm states and acknowledgment
●General device information
●Menu structure of the display
●Text translations to foreign languages
●Event logs
●Historical data archives
●List of archived reports
●Reading out individual reports
●Reading and writing data values
●Units and item lists
A detailed description of the Flow-X XML interface can be requested from SICK.

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INSTALLATION 4
4 Installation
4.1 Necessary decisions
This Section contains a brief overview to help select the appropriate Flow-X products.
4.1.1 Installation location
The Flow-X flow computer is designed to operate in the following temperature ranges:
In practice, the modules are usually mounted on racks in a controlled environment, such as
a control room, rack room, analyzer house or similar.
The Flow-X modules should not be exposed to direct sunlight during operation and storage.
4.1.2 Internationale Standards
The SICK Flow-X flow computer supports an extensive list of international standard
calculations for natural gas and other applications:
●Gas:
– AGA5, AGA8 Parts 1 and 2, AGA10
– AGA-NX19
– SGERG-88
– GERG-2008
– GOST 30319-2
– GPA 2172
– ISO 6976 (all editions)
– GSSSD MR113
– Wet gas (De Leeuw, Reader Harris)
●Flow:
– ISO 5167-1, 2, 3 and 4 (all editions)
– ISO/TR15377
– AGA3, AGA7, AGA9, AGA11
– V-cone
4.1.3 Number of modules
One module typically represents a metering run.
Station totals can be calculated in any module in the same enclosure, including the Flow-X/
P panel display module.
The serial ports require special attention. Each module has 2 serial ports. If more ports are
needed, an Flow-X/P can be considered because it has 3 additional serial ports.
The Flow-X/C, Flow-X/P1 and Flow-X/S support the connection of up to 3 metering run per
device with the special application “3runs”.
Flow-X flow computer Temperature Humidity
Flow-X/S 5 ... 55 °C (41 ... 131 °F) 5 … 95%, non-condensing
Flow-X/P -25 ... 55 °C (-13 ... 131 °F) 5 … 90%, non-condensing
Flow-X/C -25 ... 55 °C (-13 ... 131 °F) 5 … 90%, non-condensing
Table 2: Permissible temperature and humidity of the Flow-X flow computer

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4INSTALLATION
4.1.4 Redundancy
If a redundant solution is required for increased availability, two Flow-X modules can be
used per metering run. Two identical SICK Flow-X/P enclosures working in redundant mode
can be used to attain maximum availability.
All modules have an integrated dual 24 V power supply.
4.1.5 Fast data exchange
Flow-X modules located in a SICK Flow-X/P enclosure can exchange the data quickly with
the neighboring Flow-X modules via Ethernet. This is the so-called multi-module operation.
As an example, a module is used that communicates with a gas chromatograph and makes
this data available to four other modules and also serves as a Modbus slave to a central
DCS connection.
Each Flow-X module can use the data from other modules as if it exists in its own data
space. SICK Flow-X/P has two dedicated Ethernet switches for this purpose. Alternatively, it
is possible to set up a Modbus TCP/IP link using Ethernet to exchange data between the
modules.
4.1.6 Display requirements
The Flow-X/P and Flow-X/C touchscreen supports effective and user-friendly data display
and navigation through the menu structure. Multiple languages are supported.
This display function is not always required. Each individual module is equipped with a local
black and white graphic display, which enables data display and parameter setting in the
module itself. The display supports 4 to 8 lines for data and/or parameters.
Apart from these physical displays, each module contains a web server that makes it
possible to display pages that can be accessed with a standard web browser via Ethernet.
4.1.7 Power supply
All Flow-X modules require 24 V DC and have integrated support for redundant power
supply.

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INSTALLATION 4
4.2 Mechanical installation
4.2.1 Flow-X/P and Flow-X/C
The Flow-X/P and Flow-X/C flow computers require a mounting bracket for installation in an
instrument panel. For Flow-X/P, the mounting bracket is designed to allow unobstructed
access to the installed Flow-X modules. The mounting bracket is attached to the back of
the instrument panel in which the Flow-X/P or Flow-X/C flow computer is to be installed. The
respective flow computer is inserted at the front of the instrument panel and connected to
the mounting bracket with a screw.
Fig. 11: Flow-X/P mounting bracket and side view Flow-X/P installed
Fig. 12: Flow-X/C mounting bracket and side view Flow-X/C installed

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4INSTALLATION
All plug connectors for power, field wiring and communication are located on the rear of the
Flow-X/P or Flow-X/C.
Fig. 13: Flow-X/P (left) and Flow-X/C (right) , rear view (installed)
4.3 Electrical installation
4.3.1 Introduction
This Section contains information for electrical installation, including field wiring,
communications, power supply and grounding. Since all models use the same Flow-X
module, the connection diagrams in this Section apply to all models.
The Flow-X modules are fully configurable using the software. No DIP switches or jumpers
need to be set inside. Furthermore, there are no user-replaceable fuses or other
components inside. Opening a module voids all warranty claims.
For the sake of simplicity, the details of the plug-in connections are described first. The loop
diagrams and additional connection drawings then follow.
WARNING:
The device may only then be connected to the power supply when ALL of the other
desired lines and plugs are connected to the device.
A plug or cable may only be disconnected from the device when the voltage supply to
the device has been disconnected beforehand.
Connecting plugs or cables while the device is in operation can cause irreparable
damage to the electronics. Corresponding defects are excluded from a warranty claim.