SICK FLOWSIC200 User manual

OPERATING INSTRUCTIONS
FLOWSIC200
Flow Velocity Monitor
Installation
Operation
Maintenance

2 FLOWSIC200 · Operating Instructions · 8013271/1CJ9/V2-0/2022-01 · © SICK Engineering GmbH
Document Information
Described product
Product name: FLOWSIC200
Document identification
Title: Operating Instructions FLOWSIC200
Order No.: 8013271
Version: 2-0
Release: 2022-01
Manufacturer
SICK Engineering GmbH
Bergener Ring 27 · D-01458 Ottendorf-Okrilla · Germany
Phone: [phone]
Fax: [phone]
E-mail: [email protected]
Original documents
The English version 8013271 of this document is an original
document of SICK Engineering GmbH.
SICK Engineering GmbH assumes no liability for the correctness of
an unauthorized translation.
In case of doubt, please contact SICK Engineering GmbH or your
local representative.
Legal information
Subject to change without notice.
© SICK Engineering GmbH. All rights reserved.

FLOWSIC200 · Operating Instructions · 8013271/1CJ9/V2-0/2022-01 · © SICK Engineering GmbH 3
Warning symbols
Warning levels / signal words
DANGER
Risk or hazardous situation which will result in severe personal
injury or death.
WARNING
Risk or hazardous situation which could result in severe personal
injury or death.
CAUTION
Hazard or unsafe practice which could result in less severe or
minor injuries.
NOTICE
Hazard which could result in property damage.
Information symbols
Hazard (general)
Hazard through voltage
Important technical information for this product
Supplementary information

Contents
4 FLOWSIC200 · Operating Instructions · 8013271/1CJ9/V2-0/2022-01 · © SICK Engineering GmbH
1 Important information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.1 Function of this document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2 Scope of application. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.3 Target groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.4 Data integrity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.5 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.6 Safety information and protective measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.6.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.6.2 Basic safety information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.6.3 Recognizing malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.6.4 Preventing damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2 Product description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.1 System overview, functional principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.1.1 System overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.1.2 Communication between sender/receiver units and control unit . . . . . . . . . . . . . . 15
2.1.3 Functional principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.2 System components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.2.1 FLSE200 sender/receiver unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.2.2 Bracket for sender/receiver unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.2.3 MCU control unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.2.4 Connection cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.2.5 Mounting kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.3 Computations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.3.1 Flow velocity calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.3.2 Temperature calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.3.3 Response time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.4 Check cycle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.4.1 Zero point check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.4.2 Span test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.4.3 Check cycle output on the analog output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3 Assembly and installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.1 Project planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.1.1 Planning steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.1.2 Requirements for the installation location for the sender/receiver units. . . . . . . . 32
3.2 Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.2.1 Fitting the brackets for the sender/receiver units . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.2.2 Setting the bus systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.2.2.1 Check the termination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.2.2.2 Bus addressing via hardware setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.2.3 Fitting the sender/receiver units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3.2.4 Aligning the sender/receiver units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.2.5 Installing the junction box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3.2.6 Installing the MCU control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Contents
FLOWSIC200 · Operating Instructions · 8013271/1CJ9/V2-0/2022-01 · © SICK Engineering GmbH 5
3.3 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
3.3.1 General information, prerequisites. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
3.3.2 Information on wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
3.3.2.1 Cable specification (connection of a measuring point) . . . . . . . . . . . . . . . . . . . . . 44
3.3.2.2 Cable lengths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3.3.3 Connecting sender/receiver units and junction boxes. . . . . . . . . . . . . . . . . . . . . . . . . 45
3.3.4 Connecting the control unit with wall housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
3.3.5 Connecting the control unit in the 19" housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
4 Commissioning and parameterization . . . . . . . . . . . . . . . . . . . . . . . . . . 55
4.1 Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
4.1.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
4.1.2 Installing the SOPAS ET program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
4.1.3 Connecting to the device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
4.1.3.1 Changing the language . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
4.1.3.2 Connecting to the device via the “Device family” mode (recommended
search settings). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
4.1.3.3 Connect to the device with advanced mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
4.1.4 Information on using the program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
4.2 Standard commissioning procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
4.2.1 Assigning sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
4.2.2 Activating connected sender/receiver units. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
4.2.3 Assigning the measuring system to the measuring location . . . . . . . . . . . . . . . . . . . 70
4.2.4 Entering system data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
4.2.5 Setting the check cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
4.2.6 Configuring the analog output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
4.2.7 Configuring the analog inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
4.2.8 Configuring the limit value relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
4.2.9 Setting the response time (damping time) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
4.2.10 Output flow direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
4.2.11 Data backup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
4.2.12 Starting normal measuring operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
4.3 Advanced commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
4.3.1 Parameterizing optional analog and digital output modules . . . . . . . . . . . . . . . . . . . 85
4.3.1.1 Analog outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
4.3.1.2 Digital outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
4.3.1.3 Assigning and configuring limit value switches to optional digital outputs . . . . 88
4.3.2 Configuring optional Interface modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
4.3.2.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
4.3.2.2 Changing the field bus address for the Profibus module . . . . . . . . . . . . . . . . . . . 90
4.3.2.3 Configuring the Ethernet module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
4.3.3 Calibrating velocity and temperature measurement . . . . . . . . . . . . . . . . . . . . . . . . . . 92
4.3.4 Bus addressing using SOPAS ET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
4.3.5 Configuring automatic system restart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
4.4 Operating / parameterization with the LC display option. . . . . . . . . . . . . . . . . . . . . . . . . 95
4.4.1 General information on use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
4.4.2 Menu structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
4.4.3 Configuring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
4.4.3.1 MCU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
4.4.3.2 Sender/receiver units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
4.4.4 Changing the display settings with SOPAS ET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

Contents
6 FLOWSIC200 · Operating Instructions · 8013271/1CJ9/V2-0/2022-01 · © SICK Engineering GmbH
5 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
5.2 Measures to be taken when cleaning the tunnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
6Malfunctions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
6.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
6.1.1 Implausible measured values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
6.1.2 General system malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
6.2 Sender/receiver unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
6.3 Control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
7 Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
7.1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
7.2 Dimensions, Part Nos. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
7.2.1 Sender/receiver units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
7.2.2 Bracket for sender/receiver unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
7.2.3 MCU control unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
7.2.4 Junction box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
7.3 Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
7.3.1 Accessories for mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
7.3.2 Connection cable, sender/receiver unit - junction box . . . . . . . . . . . . . . . . . . . . . . . 118
7.4 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
7.4.1 MCU control unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
7.4.2 Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
7.5 Consumable parts for 2-years operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
7.6 Password. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

Important information
FLOWSIC200 · Operating Instructions · 8013271/1CJ9/V2-0/2022-01 · © SICK Engineering GmbH 7
FLOWSIC200
1Important information
Function of this document
Intended use
Safety information and protective measures

8 FLOWSIC200 · Operating Instructions · 8013271/1CJ9/V2-0/2022-01 · © SICK Engineering GmbH
Important information
1.1 Function of this document
These Operating Instructions describe for the FLOWSIC200 measuring system:
●Device components
●Installation
●Operation
●For the maintenance work required for safe operation, detailed information on function
testing/device setting, data backup, software update, fault and error handling and
possible repairs, see the Service Manual.
Retention of documents
 Keep these Operating Instructions and all associated documents available for
reference.
 Pass the documents on to a new owner.
1.2 Scope of application
These Operating Instructions apply exclusively to the FLOWSIC200 measuring system
with the described system components.
They are not applicable for other SICK measuring devices.
These Operating Instructions cover only 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.
1.3 Target groups
This Manual is intended for persons who install, operate and maintain the device.
Requirements for personnel qualification
The measuring system may only be installed and operated by skilled technicians who,
based on their technical training and knowledge as well as knowledge of the relevant
regulations, can assess the tasks given and recognize the hazards involved. Skilled
technicians are persons according to DIN VDE 0105, DIN VDE 1000-10 or IEC 60050-
826 or directly comparable standards.
The persons named must have precise knowledge of operational hazards, e.g. due to low
voltage, hot, toxic, explosive or pressurized gases, gas-liquid mixtures or other media, as
well as sufficient knowledge of the measuring system through training.

Important information
FLOWSIC200 · Operating Instructions · 8013271/1CJ9/V2-0/2022-01 · © SICK Engineering GmbH 9
1.4 Data integrity
SICK Engineering GmbH 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 Engineering GmbH always assumes that the customer ensures the integrity and
confidentiality of data and rights affected in connection with the use of 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.
1.5 Intended use
Purpose of the device
The FLOWSIC200 measuring system is used for non-contact measurement of flow velocity
and air temperature in traffic tunnels (road, railroad tunnels) or can be used in other tunnel
facilities.
Correct use
 Only use the device as described in these Operating Instructions. The manufacturer
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.
 Do not remove, add or modify any components to or on the device unless described and
specified in the official manufacturer information. Otherwise, the device could become
a hazard, any warranty of the manufacturer is void.

10 FLOWSIC200 · Operating Instructions · 8013271/1CJ9/V 2-0/2022-01 · © SICK Engineering GmbH
Important information
1.6 Safety information and protective measures
1.6.1 General information
WARNING: General information
Improper use or handling can cause health or material damage. Read this
Section carefully and ensure you observe the safety precautions during all
work on the FLOWSIC200, as well as the warning and caution information in
the individual Sections of these Operating Instructions.
Adhere to the following:
 The relevant legal stipulations and associated technical regulations must be
observed when preparing and carrying out work on the installation.
 All work must be carried out in accordance with the local, system-specific
conditions and with due consideration to operating hazards and
specifications.
 The Operating Instructions belonging to the measuring system as well as
system documentation must be available on site. Always observe the
information on the prevention of injuries and damage given therein.
WARNING: Danger through power voltage
The FLOWSIC200 measuring system is an item of electrical equipment
designed for use in industrial high-voltage systems.
 Disconnect power supply lines before working on power connections or
parts carrying power voltage.
 Refit any contact protection removed before switching the power voltage
back on again.
 The device may only be operated with the cover closed.
 Before opening the cover, the device must be disconnected from the power
supply.
 The device must not be used when the electrical wiring (cables,
terminals, ...) is damaged.
WARNING:
WARNING: Hazards through ultrasonic signals
Do not expose unprotected hearing to the sonic beam of the transducer.
 Wearing suitable hearing protection is recommended when inspecting the
duct, connecting the device outside the duct or similar activities.
NOTICE:
The user must ensure:
 Neither failures nor erroneous measurements can 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.

Important information
FLOWSIC200 · Operating Instructions · 8013271/1CJ9/V2-0/2022-01 · © SICK Engineering GmbH 11
1.6.2 Basic safety information
Observe the safety information here and the warning information in the following Sections
of these Operating Instructions to reduce health risks and avoid dangerous situations.
In the case of warning symbols on the devices, the Operating Instructions must be
consulted to determine the nature of the potential hazard and the actions required to avoid
the hazard.
 Only put the FLOWSIC200 into operation after reading the Operating Instructions.
 Observe all safety information.
 If anything is not clear: Please contact SICK Customer Service.
 Only use the FLOWSIC200 measuring system as described in these Operating
Instructions. The manufacturer bears no responsibility for any other use.
 Do not carry out any work or repairs on the FLOWSIC200 not described in this Manual.
 Do not remove, add or modify any components to or on the FLOWSIC200 unless
described and specified in the official manufacturer information.
 Only use accessories approved by the manufacturer.
 Do not use damaged components or parts.
 If you do not follow these guidelines, the following applies:
 Any warranty by the manufacturer becomes void
 The FLOWSIC200 can become dangerous
 The approval for use in potentially explosive atmospheres is no longer valid.
1.6.3 Recognizing malfunctions
Any deviations from normal operation must be regarded as a serious indication of a
functional impairment. This includes, amongst others:
●Significant drifts in measured results
●Increased power consumption
●Increased temperatures of system components
●Triggering of monitoring devices
●Unusually strong vibrations or unusual operating noise from a purge air/cooling air
blower
●Smells or smoke emission
NOTICE:
The operator must ensure the following to avoid malfunctions that can
indirectly or directly lead to injuries to persons or material damage:
 The responsible maintenance personnel are at hand at all times and as
quickly as possible,
 The maintenance personnel are adequately qualified to react correctly to
malfunctions of the measuring system and any resulting operational
interruptions (e.g., when used for measurement and control purposes),
 The malfunctioning equipment is switched off immediately in case of doubt
and that switching off does not cause collateral malfunctions.

12 FLOWSIC200 · Operating Instructions · 8013271/1CJ9/V 2-0/2022-01 · © SICK Engineering GmbH
Important information
1.6.4 Preventing damage
To prevent personal injury or damage to the system, the operator must ensure:
●The responsible maintenance personnel are at hand at all times and as quickly as
possible
●The maintenance personnel is sufficiently qualified to respond to malfunctions on the
FLOWSIC200 and any resulting operational malfunctions
●Malfunctioning equipment is switched off immediately in case of doubt and that
switching off does not cause collateral failures

Product description
FLOWSIC200 · Operating Instructions · 8013271/1CJ9/V2-0/2022-01 · © SICK Engineering GmbH 13
FLOWSIC200
2Product description
System overview, functional principle
System components
Computations
Check cycle

14 FLOWSIC200 · Operating Instructions · 8013271/1CJ9/V 2-0/2022-01 · © SICK Engineering GmbH
Product description
2.1 System overview, functional principle
2.1.1 System overview
 FLSE200 sender/receiver unit
for transmitting and receiving ultrasonic pulses
 Bracket for FLSE200
for mounting the sender/receiver units on the tunnel wall
 MCU control unit
For control, evaluation and output of data of sensors connected via RS485 interface
 Connection cable
Junction box for connection cable
 Connection cable to connect the FLSE200 to the junction box
Fig. 1 FLOWSIC200 system components
Tak
-40° 60°
18,7°
SOPAS ET
Sender/receiver unit Slave Connection cable
Tunnel
Sender/receiver unit Master Junction box MCU

t
r
t
v
Flow direction

Product description
FLOWSIC200 · Operating Instructions · 8013271/1CJ9/V2-0/2022-01 · © SICK Engineering GmbH 15
2.1.2 Communication between sender/receiver units and control unit
Standard version
The two sender/receiver units (FLSE) work as Master and Slave. The master FLSE has a
second interface to be able to completely separate communication to the slave FLSE and to
the MCU. The master triggers the slave and controls measurement. The MCU can request
measured values from the master unit independent of the measuring cycle (asynchronous).
For wiring, the junction box is installed on both FLSEs. Interface division runs in the master
FLSE junction box.
Fig. 2 Bus connection FLSE200 - MCU with one measuring point
Fig. 3 Bus connection FLSE200 - MCU with several measuring points
With the bus version, up to eight sensors can be connected to one MCU.
FLSE200
Master
FLSE200
Slave
Junction box
FLSE200
Master
FLSE200
Slave
FLSE200
Slave
FLSE200
Master
Bus line Junction box
NOTICE:
 For bus wiring, the factory-set termination must be disabled in the system
components not at the end of the line.
 To ensure the power supply for all connected measuring points, follow the
instructions on
 p. 45, §3.3.2.2.
 The S/R units of the FLOWSIC200 must be set to address 1 ... 7 on the
hardware side (
 p. 36, §3.2.2.2).
 The physical order of the sensors on the bus does not necessarily have to
match the logical address assignment, it is just not allowed to assign
addresses twice.

16 FLOWSIC200 · Operating Instructions · 8013271/1CJ9/V 2-0/2022-01 · © SICK Engineering GmbH
Product description
2.1.3 Functional principle
The FLOWSIC200 works according to the principle of ultrasonic transit time difference
measurement. Sender/receiver units are mounted on both sides of a tunnel at a certain
angle of inclination to the gas flow (
 Fig. 4).
The sender/receiver units contain piezoelectric ultrasonic transducers which operate
alternately as senders and receivers. The sound pulses are emitted at an angle to the
flow direction. Depending on angle and the flow velocity, the transit time of the respective
sound direction varies as a result of certain “acceleration and braking effects” (formulas
2.1 and 2.2). The higher the flow velocity and the smaller the angle to the flow direction are,
the higher the difference in the transit times of the sound pulses.
Flow velocity v is determined from the difference of both transit times, independent of the
sound velocity value. With this measuring method, changes of the sound velocity due to
pressure or temperature fluctuations therefore have no influence on the flow velocity
determined.
Fig. 4 Functional principle of the FLOWSIC200
Tak
-40° 60°
18,7°
SOPAS ET
Sender/receiver unit Master MCU
v = Flow velocity in m/s
L = Measuring distance in m
= Angle of inclination in °
tv= Sound transit time in flow direction
tr= Sound transit time against the flow
Sender/receiver unit Slave
v = · (-)
L 1 1
2 ·cos tvtr
Flow direction 
t
r
L
t
v

Product description
FLOWSIC200 · Operating Instructions · 8013271/1CJ9/V2-0/2022-01 · © SICK Engineering GmbH 17
Determining the flow velocity
Measuring path L is equal to the active measuring distance, that is, the free flowing
distance. Given measuring path L, sound velocity c, and angle of inclination between the
sound and flow direction, the following applies for the transit time of the sound when sound
is emitted in flow direction (forward direction):
(2.1)
Valid against the flow is:
(2.2)
The resolution to v gives:
(2.3)
A relation in which, apart from the two measured transit times, only the active measuring
distance and the angle of inclination are constants.
Determining the air temperature
The temperature dependency of the sound velocity allows using the calculated transit times
to determine the air temperature.
Simultaneous detection of flow velocity and temperature can be used to warn of icy
conditions when the road surface is wet and temperatures are below or around freezing
point.
The sound velocity is obtained by resolving to c:
(2.4)
For the temperature dependence of the sound velocity, the following applies with standard
sound velocity c0at 0 °C (= 331.4 m/s) and air temperature in °C:
(2.5)
This results in the following for the air temperature:
(2.6)
Formula 2.6 shows that the determined temperature depends not only on the measured
transit times but also quadratically on the measuring distance and the standard sound
velocity.
This means precise temperature measurement is only possible when
measuring distance L has been determined very accurately and a calibration
has been carried out (
 p. 92, §4.3.32) and the air composition is constant.
c = · ()
L tv+ tr
2 tv ·t
r
c = c0· 1 +

273 °C
= 273 °C · ( · ()- 1)
L²tv+ tr
4 · c0²t
v · tr
tv= L
c + v · cos 
tr= L
c - v · cos 
v = · ()
L 1 1
2 · cos tvtr

18 FLOWSIC200 · Operating Instructions · 8013271/1CJ9/V 2-0/2022-01 · © SICK Engineering GmbH
Product description
2.2 System components
2.2.1 FLSE200 sender/receiver unit
The sender/receiver unit consists of the electronics unit and the ultrasonic transducer. The
electronics unit contains all the necessary assemblies for signal processing, digitalization
and communication. The ultrasonic transducer is firmly connected to the enclosure.
The sender/receiver unit is supplied with 24 V. Communication to the MCU is via a bus-
capable serial connection.
The sender/receiver units are available in three versions:
The protective tube of the FLSE200-M serves to protect the ultrasonic transducer from
excessive contamination and mechanical damage (e.g. during tunnel cleaning).
Fig. 5 FLSE200-M sender/receiver unit
Sender/receiver unit type
FLSE200-M FLSE200-HM FLSE200-H
Use without special
requirements Use in highly saline ambient air
Use in highly saline ambient
air, for large measuring
distances or interference with
ultrasonic transmission
Aluminum transducer,
medium power, in protective
tube made of aluminum
Titanium transducer, medium
power
Titanium transducer, high
power
Electronics unit housing
made of aluminium,
anodized, powder-coated and
painted grey
Electronics unit housing made of
stainless steel V4A
Electronics unit housing made
of stainless steel V4A
Measuring distance 5 ... 25 m Measuring distance 5 ... 40 m
Protective tube
Ultrasonic transducer
Electronics unit
Plug
Connection cable
Tunnel wall
Bracket

Product description
FLOWSIC200 · Operating Instructions · 8013271/1CJ9/V2-0/2022-01 · © SICK Engineering GmbH 19
Fig. 6 FLSE200-H, FLSE200-HM sender/receiver unit
2.2.2 Bracket for sender/receiver unit
The bracket serves mounting the sender/receiver unit. It also allows the FLSE200s to be
aligned with each other with the required accuracy. Two hexagonal bolts and dowels serve
to fasten the bracket on the tunnel wall (or ceiling).
The brackets are adapted to the respective sender/receiver unit design, i.e. there are two
types:
 Bracket for FLSE200-M (  p. 18, Fig. 5)
Parts made of stainless steel and aluminium.
 Bracket for FLSE200-H or FLSE200-HM (  Fig. 6)
All parts made of stainless steel.
Tunnel wall
Bracket
Electronics unit
Plug
Connection cable
A
A
Ultrasonic
transducer

20 FLOWSIC200 · Operating Instructions · 8013271/1CJ9/V 2-0/2022-01 · © SICK Engineering GmbH
Product description
2.2.3 MCU control unit
The control unit has the following functions:
 Control of data transfer and processing the data from the sender/receiver units
connected via RS485 interface
 Signal output via analog output (measured value) and relay outputs (device status)
 Signal input via analog and digital inputs
 Voltage supply for the connected sender/receiver units
 Communication with host control systems via optional modules
System and device parameters can be set easily and conveniently via a USB interface
using a laptop and the user-friendly SOPAS ET operating software. The parameters are
stored reliably even in the case of a power failure.
The control unit is usually installed in a stainless steel housing.
Fig. 7 MCU control unit options
Standard interfaces
DISPLAYMODUL
relay 3 relay 4 relay 5 BUS - S/E unit 1
BUS
Ter m
Ter m
BUS - S/E unit 2
relay 1 relay 2
com nc. no . com nc. no. com nc. no. com nc. no. com nc. no.
Reset
LED
Control
buttons
Processor
board
Option Display module Option Interface module Options I/O module Option Display module
Analog output Analog inputs Relay outputs Digital inputs Communication
1 output 0/2/4...22 mA
(electrically isolated,
active); for selectable
output of measured
variables:
–Velocity
–Airtemperature
Resolution 0.01 mA
2 inputs 0 ... 20 mA
(Standard; without
electric isolation)
Resolution 0.01 mA
5 NC contacts (48 V,
1 A) to output status
signals:
– Operation/
malfunction
– Maintenance
– Check cycle
– Maintenance
request
– Limit value/direction
2 inputs to connect
potential-free
contacts for a
maintenance switch or
triggering a check
cycle
– USB 1.1 and RS232
(on terminals) for
measured value
inquiries, setting
parameters and
software updates
– RS485 for sensor
connection