SICK FLOWSIC500 User manual

OPERATING INSTRUCTIONS
Installation
Operation
Maintenance
Title Page
FLOWSIC500
Ultrasonic Gas Flow Meter with
Optional Volume Conversion

2 FLOWSIC500 · Operating Instructions · 8015391/Z261/V2-3/2016-10 · © SICK Engineering GmbH
Document Information
Described Product
Product name: FLOWSIC500
Document ID
Title: Operating Instructions FLOWSIC500
Part No.: 8015391
Document ID: 9186957
Version: 2-3
Release: 2016-10
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 8015391 of this document is an original docu-
ment from 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.
Legal Information
Subject to change without notice.
© SICK Engineering GmbH. All rights reserved.
Glossary
AC Alternating Current
Al Aluminium
ATEX ATEX: Atmosphères Explosifs: Abbreviation for Euro-
pean standards that govern safety in potentially
explosive atmospheres
CSA Canadian Standards Association (www.csa.ca)
DC Direct Current
HF High frequency, e. g. HF pulses
IEC International Electronical Commission
IECEx IEC system for certification in accordance with stan-
dards for devices for use in potentially explosive
atmospheres
IPxy Ingress Protection: Degree of protection of a device
in accordance with IEC/DIN EN 60529; xspecifies
the protection against contact and impurities, ypro-
tection against moisture.
LF Low frequency, e. g. LF pulses
MDR Manufacturer Data Record
NAMUR Abbreviation for "Normen-Arbeitsgemeinschaft für
Mess- und Regeltechnik in der chemischen Indust-
rie", now "Interessengemeinschaft Automatisier-
ungstechnik der Prozessindustrie" (www.namur.de)
pTZ Volume conversion as a function of the pressure,
the temperature and with consideration of the com-
pression factor
TZ Volume conversion as function of the temperature
and a fixed pressure value and with consideration
of the compression factor

FLOWSIC500 · Operating Instructions · 8015391/Z261/V2-3/2016-10 · © 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 personal injury or
property damage.
NOTICE
Hazards which could result in property damage
Information Symbols
IMMEDIATE HAZARD
of severe injuries or death
Hazard (general)
Hazard by electrical voltage
Hazard in potentially explosive atmospheres
Hazard by explosive substances/mixtures
Hazard by unhealthy substances
Hazard by toxic substances
Information on product condition with regard to protec-
tion against explosions (general)
Information on product characteristics related to Euro-
pean Directive ATEX
Information on product characteristics related to explo-
sion protection in accordance with the IECEx scheme.
Important technical information for this product
Important information on electric or electronic func-
tions
Nice to know
Supplementary information
Link referring to information at another place

Contents
4 FLOWSIC500 · Operating Instructions · 8015391/Z261/V2-3/2016-10 · © SICK Engineering GmbH
1 Important Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.1 Main hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.2 About this document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.3 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.3.1 Purpose of the device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.3.2 Product identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.3.3 Operation in potentially explosive atmospheres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.3.4 Combustible gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.3.5 Restrictions of use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.3.6 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.4 Responsibility of user . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.5 Additional documentation/information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2 Product Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.1 Operating principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.1.1 Gas flow meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.1.2 Volume conversion (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.2 FLOWSIC500 measuring system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.2.1 Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.2.2 Gas flow meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.3 Meter sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.4 Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.5 Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.5.1 Pulse and status outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.5.2 Encoder totalizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.5.3 Serial data interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.5.4 Optical data interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.6 Device option: Volume conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.6.1 Volume conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.6.2 Integrated pressure and temperature transmitters . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.6.3 External pressure and temperature transmitters . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.7 Totalizers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.7.1 Device status and totalizers used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.7.2 Reverse flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.8 Logbooks and Archives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.9 Parameter protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.9.1 Parameter locking switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.9.2 Metrology logbook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.10 Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.1 Hazards during installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.2 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.2.1 Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.2.2 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.3 Mechanical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.3.1 Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.3.2 Choosing flanges, gaskets and other components . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.3.3 Fitting the FLOWSIC500 in the pipeline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Contents

Contents
FLOWSIC500 · Operating Instructions · 8015391/Z261/V2-3/2016-10 · © SICK Engineering GmbH 5
3.4 Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3.4.1 Requirements for use in potentially explosive atmospheres . . . . . . . . . . . . . . . . . . . 37
3.4.2 Criteria for electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.4.3 Opening and closing the electronics cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.4.4 Rotating the control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3.4.5 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
3.4.6 Pin assignment of plug-in connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
3.4.7 Cable specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
3.4.8 Operation with external power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
3.4.9 Operation with batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3.5 Installing the external pressure and temperature transmitters . . . . . . . . . . . . . . . . . . . 46
3.5.1 Fitting the plug-in connector cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
3.5.2 Installing the pressure transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3.5.3 Installing the temperature transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
4Start-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
4.1 Sequence of start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
4.1.1 Start-up of gas flow meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
4.1.2 Start-up of gas flow meter with device option volume conversion . . . . . . . . . . . . . . 54
4.2 Setting the date and time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
4.3 Configuring volume conversion (device option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
4.3.1 Setting fixed values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
4.3.2 Checking the configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
4.3.3 Configuring the gas composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
4.4 Checking the device status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
5Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
5.1 Control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
5.2 Operating using the display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
5.2.1 Display in the symbol bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
5.2.2 Battery fill level display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
5.2.3 Main screen (without device option volume conversion) . . . . . . . . . . . . . . . . . . . . . . 60
5.2.4 Main display (with device option volume conversion) . . . . . . . . . . . . . . . . . . . . . . . . . 62
5.2.5 Configuration of main display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
5.2.6 FLOWSIC500 menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
5.2.7 Changing the user level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
5.2.8 Setting the language . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
5.2.9 Changing the device mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
5.2.10 Changing parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
5.2.11 Resetting the error volume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
5.2.12 Resetting the event summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
5.2.13 Confirming battery replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
5.2.14 Checking the external power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
5.2.15 Testing the display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
5.3 Operating using the optical data interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
5.4 FLOWgate500 operating software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Contents
6 FLOWSIC500 · Operating Instructions · 8015391/Z261/V2-3/2016-10 · © SICK Engineering GmbH
6 Clearing Malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
6.1 Contacting Customer Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
6.2 Status messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
6.3 Additional messages in the Event logbook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
7 Maintenance and Meter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 81
7.1 Information on handling lithium batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
7.1.1 Information on storage and transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
7.1.2 Disposal information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
7.2 Maintenance when using external power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
7.2.1 Service life of backup battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
7.2.2 Changing the backup battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
7.3 Maintenance when using battery power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
7.3.1 Service life of battery packs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
7.3.2 Changing the battery packs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
7.4 Meter exchange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
7.4.1 Prerequisites for meter replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
7.4.2 Hazards during meter replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
7.4.3 Sequence of meter replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
7.4.4 Required tools and auxiliary material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
7.4.5 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
7.4.6 Back-up of user-specific configuration of installed gas flow meter . . . . . . . . . . . . . 90
7.4.7 Disconnecting electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
7.4.8 Removing the installed gas flow meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
7.4.9 Installing the replacement gas flow meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
7.4.10 Performing a leak tightness check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
7.4.11 Checking the function of the gas flow meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
7.4.12 Securing metrologically . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
7.5 Function check of a pressure or temperature transmitter . . . . . . . . . . . . . . . . . . . . . . 100
7.6 Exchanging an external pressure or temperature transmitter . . . . . . . . . . . . . . . . . . . 100
7.6.1 Exchanging the pressure transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
7.6.2 Exchanging the temperature transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
8 Accessories and Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
8.1 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
8.1.1 Gas flow meter accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
8.1.2 Volume conversion (device option) accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
8.1.3 Transport accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
8.2 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
8.2.1 Gas flow meter spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
8.2.2 Volume conversion (device option) spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Contents
FLOWSIC500 · Operating Instructions · 8015391/Z261/V2-3/2016-10 · © SICK Engineering GmbH 7
9 Annex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107
9.1 Conformities and Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108
9.1.1 CE certificate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108
9.1.2 Standards compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108
9.1.3 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109
9.1.4 Flow rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111
9.1.5 Overload protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111
9.2 Type code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112
9.3 Type plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114
9.3.1 Metrology and electronics type plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114
9.3.2 PED type plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
9.4 Dimensional drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117
9.5 Internal terminal assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .118
9.6 Installation examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119
9.7 Connection diagrams for operation of the FLOWSIC500 in accordance with CSA .122
9.8 Connection diagrams for operation of the FLOWSIC500 in accordance with
ATEX/IECEx . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129

Contents
8 FLOWSIC500 · Operating Instructions · 8015391/Z261/V2-3/2016-10 · © SICK Engineering GmbH

Important Information
FLOWSIC500 · Operating Instructions · 8015391/Z261/V2-3/2016-10 · © SICK Engineering GmbH 9
Subject to change without notice
FLOWSIC500
1Important Information
Main hazards
About this document
Intended use
Responsibility of user

10 FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH
Important Information
Subject to change without notice
1.1 Main hazards
1.2 About this document
This Manual describes:
– Device components
– Installation
– Operation of the FLOWSIC500.
It contains the main safety information for safe operation of the FLOWSIC500.
Scope of document
Make sure that your FLOWSIC500 is equipped with optically isolated inputs and outputs:
▸ Check the type code, position 23 "I/O", on the type plate (→Fig. 2) of your FLOWSIC500:
–FLOWSIC500 with interface configurations F, G H, I and J have optically isolated
inputs and outputs.
–For information on FLOWSIC500 with interface configurations A, B, C, D and E,
please refer to document "8018707, Addendum to Operating Instructions
FLOWSIC500: Interface Configurations".
Fig. 1 Type code
▸ For a complete description of the type code refer to →p. 112, §9.2.
DANGER: Risk of explosion when the gas flow meter is damaged
Natural gas flows with line pressure through the gas flow meter. Natural gas
can escape when the gas flow meter is damaged which creates a risk of
explosion.
▸ Prevent any possible damage to the gas flow meter. When necessary, fit
protection devices.
▸ If the gas flow meter is damaged: Stop natural gas feed immediately and
purge the FLOWSIC500 with inert gas.
WARNING: Hazards through leaks
Operation in leaky condition is not allowed and potentially dangerous.
▸ Regularly check leak tightness of equipment.
NOTICE: Interface Configurations
This document only applies to FLOWSIC500 gas flow meters with optically iso-
lated inputs and outputs.
23
-
23 I/O (Interface configurations)
FL5 F
2523 24

Important Information
FLOWSIC500 · Operating Instructions · 8015391/Z261/V2-3/2016-10 · © SICK Engineering GmbH 11
Subject to change without notice
1.3 Intended use
1.3.1 Purpose of the device
The FLOWSIC500 serves for measuring the gas volume, volume flow rate and gas velocity
of natural gas in pipelines.
The FLOWSIC500 with optional volume conversion serves for measuring the gas volume
and converting the gas volume measured to base conditions as well as registering data on
meter readings, maximums and other data.
1.3.2 Product identification
The type plates for metrological and electrical parameters are located on the gas flow
meter. The type plate for the Pressure Equipment Directive is located on the adapter.
Examples for the type plates see →p. 114, §9.3.
Fig. 2 Location of type plates
Product name: FLOWSIC500
Manufacturer:
SICK Engineering GmbH
Bergener Ring 27
01458 Ottendorf-Okrilla
Germany
5
3
1 Type plate, metrological and electrical parameters
(metrology and electronics)
4 Type plate, electrical parameters (electronics)
2 Pin assignment of plug-in connectors 5 Type plate, metrological parameters (metrology)
3 Type plate PED
Labelling according to CSA
Labelling according to ATEX/IECEx
4
1
3
2

12 FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH
Important Information
Subject to change without notice
1.3.3 Operation in potentially explosive atmospheres
1.3.4 Combustible gas
▸ The FLOWSIC500 is suitable for measuring combustible and occasionally ignitable
gases corresponding to zones 1 and 2.
1.3.5 Restrictions of use
▸ Refer to the type plate for the configuration of your FLOWSIC500.
▸ Check the FLOWSIC500 is suitably equipped for your application (e.g. gas conditions).
The FLOWSIC500 is suitable for use in potentially explosive atmospheres:
ATEX: II 2G Ex ia [ia] IIB T4 Gb, II 2G Ex ia [ia] IIC T4 Gb, II 2G Ex op is IIC T4 Gb
IECEx: Ex ia [ia] IIB T4 Gb, Ex ia [ia] IIC T4 Gb, Ex op is IIC T4 Gb
US/C: Class I Division 1, Groups C, D T4, Ex/AEx ia IIB T4 Ga
Further information on potentially explosive atmospheres →p. 37, §3.4.1.
WARNING: Hazard through material fatigue
The FLOWSIC500 has been designed for use under mainly static loads.
▸ Maximum allowed gradient of static pressure: 3 bar/s (45psi/sec)
The number of complete pressure application and release processes should
be kept low during operation.
▸ Replace the device when 500 cycles have been reached.
NOTICE:
The FLOWSIC500 is designed for measuring clean and dry natural gas.
▸ The operator should install a suitable filter or cone screen ahead of the gas
flow meter when the gas is contaminated.
NOTICE:
●The FLOWSIC500 is suitable for use in pressurized lines within the parame-
ters specified in the device. The device complies with Pressure Equipment
Directive 2014/68/EU.
●It is the user's responsibility to ensure the maximum values specified for
pressure and temperature on the type plate are not exceeded during opera-
tion.

Important Information
FLOWSIC500 · Operating Instructions · 8015391/Z261/V2-3/2016-10 · © SICK Engineering GmbH 13
Subject to change without notice
1.3.6 Cleaning
1.4 Responsibility of user
▸ Only put the FLOWSIC500 into operation after reading the Operating Instructions.
▸ Observe all safety information.
▸ If anything is not clear: Please contact the SICK Customer Service.
Designated users
The FLOWSIC500 may only be operated by skilled technicians who, based on their techni-
cal training and knowledge as well as knowledge of the relevant regulations, can assess
the tasks given and recognize the hazards involved.
Correct use
▸ Only use the FLOWSIC500 as described in these Operating Instructions (→p. 11, §1.3.1).
The manufacturer bears no responsibility for any other use.
▸ Do not carry out any work or repairs on the FLOWSIC500 not described in this manual.
▸ Do not remove, add or change any components in or on the FLOWSIC500 unless such
changes are officially allowed and specified by the manufacturer.
Otherwise
– Any warranty by the manufacturer becomes void
– The FLOWSIC500 can become dangerous
– The approval for use in potentially explosive atmospheres is no longer valid
– The approval fur use in lines pressurized above 0.5 bar (7.25 psi) bar is no longer
valid.
WARNING: Risk of ignition due to electrostatic charge
Under certain extreme circumstances, in Gas Group IIC, exposed plastic and
unearthed metal parts of the enclosure may store an ignition-capable level of
electrostatic charge.
▸ Implement precautions to prevent the build up of electrostatic charge, e.g.
locate the equipment where a charge-generating mechanism (such as
wind-blown dust) might occur and clean with a damp cloth.
NOTICE: Cleaning instructions
▸ Only clean the FLOWSIC500 with a damp cloth.
▸ Do not use solvents for cleaning.
▸ Only use materials for cleaning which do not damage the surface of the
FLOWSIC500.
NOTICE:
Skilled persons are persons in accordance with DIN VDE 0105 or IEC 364, or
directly comparable standards.
These persons must have exact knowledge on hazards arising from operation,
e.g. through hot, toxic, explosive gases or gases under pressure, gas-liquid
mixtures or other media as well as adequate knowledge of the measuring
system gained through training.

14 FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH
Important Information
Subject to change without notice
Danger identification on device
Special local conditions
▸ Follow all local laws, regulations and company-internal operating directives applicable
at the installation location.
Retention of documents
These Operating Instructions must be
▸ Kept available for reference
▸ Passed on to new owners.
1.5 Additional documentation/information
Some parameter settings, components and characteristics depend on the individual
device configuration. This individual device configuration is described in the device docu-
mentation delivered with the device.
●Certificate of conformity/EX certificates (depending on configuration)
●Material certificate
●Inspection certificate
– Device configuration sheet
– Encoder test protocol (if configured)
– Low-pressure calibration test protocol (if ordered)
– Labels according to Pressure Equipment Directive 2014/68/EU, Annex 1 Part 3.3
●Printout of the Data Book
●Product CD with:
– Operating Instructions
– Operating program FLOWgate500
– FLOWgate500 Software Manual
–Keycode
– Instructions for Kamstrup test valve BDA04
WARNING: Danger identification on device
The following symbol draws attention to important dangers directly on the
device:
▸ Consult the Operating Instructions in all cases where the symbol is
attached to the device or shown on the display.

Product Description
FLOWSIC500 · Operating Instructions · 8015391/Z261/V2-3/2016-10 · © SICK Engineering GmbH 15
Subject to change without notice
FLOWSIC500
2Product Description
Operating principle
Device components
Meter sizes
Power supply
Interfaces
Device option: Volume conversion
Totalizers
Logbooks and Archives
Parameter protection
Sealing

16 FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH
Product Description
Subject to change without notice
2.1 Operating principle
2.1.1 Gas flow meter
The FLOWSIC500 works according to the principle of ultrasonic transit time difference
measurement.
Fig. 3 Functional principle
Measured signal transit times tAB and tBA are defined by the current sound and gas veloc-
ity.
Gas velocity v is determined from the difference between the signal transit times. There-
fore changes in the sound velocity caused by pressure or temperature fluctuations do not
affect the calculated gas velocity with this measurement method.
The FLOWSIC500 calculates the volume flow rate internally from the gas velocity and the
diameter of the measuring section of the gas flow meter.
2.1.2 Volume conversion (optional)
The integrated volume conversion converts the measured gas volume from measurement
conditions to base conditions.
Calculation according to EN 12405:
The measurement conditions are either determined with pressure and temperature trans-
mitters or entered as fixed value.
v=Gasvelocity
L=Measuringpath
= Angle of inclination in °
tAB = Sound transit time
in flow direction
tBA = Sound transit time
against flow direction
DI= Pipe inner diameter
Q=Volumeflow
The following short forms are used in this document for better readability:
●Volume at base conditions = base volume
●Volume at measurement conditions = measurement volume
Q
4
---DI
2L
2cos
----------------tBA tAB
–
tAB tBA

----------------------
=
VbCV
m
=Vb= Volume at base conditions
C = Conversion factor
Vm= Volume at measurement conditions
p = Gas pressure at measurement conditions
pb= Pressure at base conditions
T = Gas temperature at measurement conditions
Tb= Temperature at base conditions
Zb= Compression factor at base conditions
Z = Compression factor at measurement conditions
Cp
pb
----- Tb
T
------Zb
Z
------
=

Product Description
FLOWSIC500 · Operating Instructions · 8015391/Z261/V2-3/2016-10 · © SICK Engineering GmbH 17
Subject to change without notice
2.2 FLOWSIC500 measuring system
The FLOWSIC500 measuring system comprises:
●FLOWSIC500 gas flow meter,
●Adapter for installation in pipeline and
●optional p&T sensors for the volume conversion device option.
Fig. 4 FLOWSIC500 components
2.2.1 Adapter
The adapter is available in various flange standards and fitting lengths to connect the gas
flow meter to the system pipeline.
Depending on the version, the adapter is designed for assembly on line flanges PN16 in
accordance with DIN EN1092-1, CL150 in accordance with ASME B16.5, or 1.6MPa in
accordance with GOST 12815-80.
Gas flow meter
Adapter
Fitting lengths available: →p. 117, §9.4.

18 FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH
Product Description
Subject to change without notice
2.2.2 Gas flow meter
An internal flow conditioner rectifies the gas flow in the gas flow meter so that flow profile
disturbances caused by pipe bends in the inlet or outlet sections or components projecting
into the pipe (e.g., a thermowell) have no influence on measuring results.
The gas flow meter can be replaced without taking the adapter out of the pipeline.
The gas flow meter is fitted with:
●Control unit
●Optical and electrical interfaces
●Measuring cell with ultrasonic transducers
●Electronics.
The product variant with volume conversion and integrated pressure and temperature
transmitters also has the calibrated pressure transmitter and calibrated temperature
transmitter fitted in the gas flow meter.
2.3 Meter sizes
Available meter sizes →p. 117, §9.4.
2.4 Power supply
The FLOWSIC500 is available with two configurations:
●For operation with external intrinsically safe power supply with backup battery (backup
duration: Approx. 3 months).
●Self-sufficient power configuration: 2 internal longlife battery packs (typical service life:
At least 5 years).
The second battery pack is activated automatically when the first pack is empty and a
message displayed (→p. 58, §5.2).
2.5 Interfaces
The FLOWSIC500 supports various digital and serial interfaces.
The configuration of the interfaces as delivered is described in the delivery documents pro-
vided with the respective device.
Table 1 Interface configurations
Config. 1 (LF) Config. 2 (HF) Config 3 (Encoder + LF) Config. 4 (RS485) Config. 5 (Encoder + HF)
Type code I/O: F Type code I/O: G Type code I/O: H Type code I/O: I or J Type code I/O: K
DO_0 - HF pulses Encoder - Encoder
DO_1 Normal mode: Diagnosis warning, test mode: Test pulses HF pulses
DO_2 LF pulses - - - -
DO_3 Malfunction Malfunction LF pulses - Malfunction
Serial - - RS485 -
●Information on explosion-technical characteristics and rated voltage
→p. 37, §3.4.
●Details on standard interface configurations available →p. 42, §3.4.6.

Product Description
FLOWSIC500 · Operating Instructions · 8015391/Z261/V2-3/2016-10 · © SICK Engineering GmbH 19
Subject to change without notice
2.5.1 Pulse and status outputs
FLOWSIC500 has 4 digital switching outputs. Digital switching outputs DO_0, DO_2 and
DO_3 are electrically isolated according to EN 60947-5-6.
Alternatively, digital switching outputs DO_2 and DO_3 can also be configured as Open Col-
lector.
When used as pulse output, maximum 2 kHz can be output on digital switching output
DO_0 and maximum 100 Hz on digital switching outputs DO_2 and DO_3. When used as
status output, status information "Validity of measurement" or the result of the self-diagno-
sis can be represented.
Digital switching output DO_1 is not electrically isolated. In normal mode, the diagnosis
warning is output on DO_1, test pulses are output in test mode.
The digital switching outputs are updated synchronously once per second.
2.5.2 Encoder totalizer
Alternatively, NAMUR switching output DO_0 can be configured so that the reading of total-
izer Vm, the meter status and a meter identification are output via asynchronous serial
communication. This allows the connection of volume convertors with a suitable input for
encoder totalizers.
2.5.3 Serial data interface
The serial interface is designed as externally powered RS485 and requires an external
intrinsically safe power supply for operation. The RS485 interface has no internal line ter-
mination.
2.5.4 Optical data interface
An optical interface according to IEC 62056-21 with serial bit, asynchronous data trans-
mission is located on the front of the FLOWSIC500.
The interface can be used to read out data and parameter settings and to configure the
FLOWSIC500.
NOTICE:
If encoder communication has been configured, ensure that the transferred
number of digits and the counter resolution can be processed by a connected
volume converter.
When the parameter locking switch is open, a parameter change can be per-
formed at the FLOWSIC500 using the FLOWgate500 operating software.

20 FLOWSIC500 · Operating Instructions · 8015391/Z261/V 2-3/2016-10 · © SICK Engineering GmbH
Product Description
Subject to change without notice
2.6 Device option: Volume conversion
2.6.1 Volume conversion
The FLOWSIC500 gas flow meter with volume conversion captures the gas volume under
measurement conditions and converts it to a volume under base conditions.
Gas volume conversion can run selectively (set at the factory) as PTZ or TZ volume conver-
sion: The configuration as temperature volume conversion uses the default value for mea-
surement pressure for calculations.
Measurement conditions are recorded with the pressure and temperature transmitters or
entered as fixed values.
By default, measured values recording and subsequent conversion to the volume under
base conditions are performed every 30 seconds. The update interval can be adjusted
→p. 69, §5.2.6.5, “Calculation”.
Depending on the configuration, the compressibility factor (K-factor) is determined with
one of the following calculation methods or can be entered as a fixed value.
●SGERG88,
●AGA 8 Gross method 1
●AGA 8 Gross method 2
●AGA NX-19
●AGA NX-19 mod.
●Fixed value
The FLOWSIC500 checks the permissible entry limits of the parameters for the selected
calculation method. If one of the entry values is outside the limit values, the FLOWSIC500
switches to malfunction state and uses the fixed value of the compressibility factor for cal-
culation of the basis volume.
An absolute pressure transmitter EDT 23 (optional: relative pressure transmitter EDT 23)
and a temperature transmitter EDT 34 measure current measurement conditions and
transfer the transmitter type, measured value as well as the transmitter status via a digital
interface.
The FLOWSIC500 reads the valid measuring range automatically and, periodically, the cur-
rent status and measured value.
A transmitter is only activated for measurement when the configured serial number
matches the serial number transferred for the transmitter.
If no transmitter is detected or a transmitter is not functioning correctly, the
FLOWSIC500 automatically uses the stored default value (= fixed value) of the state vari-
able.
In this case, the FLOWSIC500 switches to malfunction state and, using the default value,
stores the volume under base conditions calculated for pressure or temperature in the
error volume counter.
If not specified otherwise, the FLOWSIC500 is supplied with the following standard set-
tings:
Table 2 Standard settings
Unit system SI Imperial
T unit °C ° F
P unit bar psi
Symbols according to EN 12405 API
Calculation method SGERG88 AGA 8 Gross method 1
Reference conditions for den-
sity and heating value
(T1/T2/p2)
25 °C/0 °C/1.01325 bar (a)
(T1/T2/p2)
60 °F/60 °F/14.7300 psi (a)
Base pressure 1.01325 bar (a) 14.7300 psi (a)
Base temperature 0 °C 60 °F