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/ZOR6/V3-0/2017-06 · © SICK Engineering GmbH
Document Information
Described Product
Product name: FLOWSIC500
Document ID
Title: Operating Instructions FLOWSIC500
Part No.: 8015391
Document ID: 9186957
Version: 3-0
Release: 2017-06
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
document 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 representative
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 Electrotechnical Commission
IECEx IEC system for certification in accordance with
standards 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
NAMUR Abbreviation for “Normen-Arbeitsgemeinschaft für
Mess- und Regeltechnik in der chemischen
Industrie”, now “Interessengemeinschaft Automa-
tisierungstechnik 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/ZOR6/V3-0/2017-06 · © 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
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 characteristics related to pro-
tection against explosions (general)
Information on product characteristics related to
Explosion Protection Regulation (ATEX)
Information on product characteristics related to
explosion protection in accordance with the IECEx
scheme.
Important technical information for this product
Important information on electric or electronic
functions
Nice to know
Supplementary information
Link referring to information at another place

Contents
4 FLOWSIC500 · Operating Instructions · 8015391/ZOR6/V3-0/2017-06 · © 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 Measuring principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.1.1 Gas flow meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.1.2 Volume conversion (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.2 System components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.2.1 Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.2.2 Gas flow meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.2.3 Meter sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.3 FLOWgateTM operating software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.3.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.3.2 System requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.3.3 Access rights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.4 Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.4.1 Pulse and status outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.4.2 Encoder totalizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.4.3 Serial data interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.4.4 Optical data interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.5 Totalizers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.5.1 Device status and totalizers used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.5.2 Reverse flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.6 Data processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.6.1 Logbooks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.6.2 Archives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.7 Device option: Volume conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.7.1 Volume conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.7.2 Integrated pressure and temperature transmitters . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.7.3 External pressure and temperature transmitters . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.8 Parameter protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.8.1 Parameter locking switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.8.2 Metrology logbook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.9 Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.10 PowerIn TechnologyTM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Contents

Contents
FLOWSIC500 · Operating Instructions · 8015391/ZOR6/V 3-0/2017-06 · © SICK Engineering GmbH 5
3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.1 Hazards during installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.2 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.2.1 Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.2.2 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
3.3 Mechanical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.3.1 Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.3.2 Choosing flanges, gaskets and other components . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.3.3 Fitting the FLOWSIC500 in the pipeline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3.4 Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
3.4.1 Requirements for use in potentially explosive atmospheres . . . . . . . . . . . . . . . . . . . 41
3.4.2 Criteria for electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
3.4.3 Opening and closing the electronics cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
3.4.4 Rotating the control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
3.4.5 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3.4.6 Pin assignment of plug-in connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
3.4.7 Cable specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3.4.8 Operation with external power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
3.4.9 Battery operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
3.5 Installing the external pressure and temperature transmitters . . . . . . . . . . . . . . . . . . . 51
3.5.1 Fitting the plug-in connector cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
3.5.2 Installing the pressure transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
3.5.3 Installing the temperature transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
4 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
4.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
4.2 Commissioning on the display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
4.2.1 Commissioning sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
4.2.2 Setting the date and time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
4.2.3 Configuring volume conversion (device option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
4.2.4 Checking the device status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
4.3 Commissioning with the FLOWgateTM operating software . . . . . . . . . . . . . . . . . . . . . . . 63
4.3.1 Connect to the device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
4.3.2 Field setup wizard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
4.3.3 Activate and configure the daylight saving time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
4.3.4 Configure the power management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
4.3.5 Function check after commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Contents
6 FLOWSIC500 · Operating Instructions · 8015391/ZOR6/V3-0/2017-06 · © SICK Engineering GmbH
5Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
5.1 Control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
5.2 Operating using the display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
5.2.1 Display in the symbol bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
5.2.2 Battery fill level display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
5.2.3 Main screen (without device option volume conversion) . . . . . . . . . . . . . . . . . . . . . . 74
5.2.4 Main display (with device option volume conversion) . . . . . . . . . . . . . . . . . . . . . . . . 76
5.2.5 Configuration of main display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
5.2.6 FLOWSIC500 menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
5.2.7 Changing the user level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
5.2.8 Setting the language . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
5.2.9 Changing the device mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
5.2.10 Changing parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
5.2.11 Resetting the error volume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
5.2.12 Resetting the event summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
5.2.13 Confirming battery replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
5.2.14 Checking the external power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
5.2.15 Testing the display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
6 Clearing Malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
6.1 Contacting Customer Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
6.2 Status messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
6.3 Additional messages in the Event logbook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
6.4 Starting a diagnostic session . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
7 Maintenance and Meter Exchange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
7.1 Information on handling lithium batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
7.1.1 Information on storage and transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
7.1.2 Disposal information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
7.2 Maintenance when using external power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
7.2.1 Service life of backup battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
7.2.2 Changing the backup battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
7.3 Maintenance when using battery power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
7.3.1 Service life of battery packs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
7.3.2 Changing the battery packs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
7.4 Meter exchange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
7.4.1 Prerequisites for meter exchange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
7.4.2 Hazards during meter exchange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
7.4.3 Sequence of meter exchange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
7.4.4 Required tools and auxiliary material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
7.4.5 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
7.4.6 Backup of user-specific configuration of installed gas flow meter . . . . . . . . . . . . 104
7.4.7 Disconnecting electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
7.4.8 Removing the installed gas flow meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
7.4.9 Installing the replacement gas flow meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
7.4.10 Perform a leak tightness check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
7.4.11 Loading the parameter backup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
7.4.12 Check the function of the new gas flow meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
7.4.13 Secure metrologically . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

Contents
FLOWSIC500 · Operating Instructions · 8015391/ZOR6/V 3-0/2017-06 · © SICK Engineering GmbH 7
7.5 Function check of a pressure or temperature transmitter . . . . . . . . . . . . . . . . . . . . . .120
7.6 Exchanging an external pressure or temperature transmitter . . . . . . . . . . . . . . . . . . .120
7.6.1 Exchanging the pressure transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120
7.6.2 Exchanging the temperature transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .121
8 Accessories and Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123
8.1 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124
8.1.1 Gas flow meter accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124
8.1.2 Volume conversion (device option) accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125
8.1.3 Transport accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125
8.2 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126
8.2.1 Gas flow meter spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126
8.2.2 Volume conversion (device option) spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126
9 Annex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127
9.1 Conformities and Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128
9.1.1 CE certificate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128
9.1.2 Standards compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128
9.1.3 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129
9.1.4 Flow rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131
9.1.5 Overload protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131
9.2 Type code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132
9.3 Type plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .134
9.3.1 Metrology and electronics type plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .134
9.3.2 Type plate, Pressure Equipment Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136
9.4 Dimensional drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137
9.5 Internal terminal assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138
9.6 Installation examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139
9.7 Connection diagrams for operation of the FLOWSIC500 in accordance
with CSA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
9.8 Connection diagrams for operation of the FLOWSIC500 in accordance
with ATEX/IECEx . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .149

Contents
8 FLOWSIC500 · Operating Instructions · 8015391/ZOR6/V3-0/2017-06 · © SICK Engineering GmbH

Important Information
FLOWSIC500 · Operating Instructions · 8015391/ZOR6/V 3-0/2017-06 · © SICK Engineering GmbH 9
Subject to change without notice
FLOWSIC500
1Important Information
Main hazards
About this document
Intended use
Responsibility of user
Additional documentation/information

10 FLOWSIC500 · Operating Instructions · 8015391/ZOR6/V3-0/2017-06 · © 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.
Application area of the document
Make sure this document is valid for your FLOWSIC500:
▸ Check the type code, position 23 “I/O (Interface configurations)” on the type plate
(→Fig. 2) of your FLOWSIC500.
– The FLOWSIC500 interface configurations F, G, H, I, J, K and L are described in this
document.
– Information on FLOWSIC500 with interface configurations A, B, C, D and E can be
found in document “8018707, Addendum to Operating Instructions FLOWSIC500:
Interface configurations”.
Fig. 1 Type code
▸ For the complete type code description, see →p. 132, §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 is only valid for FLOWSIC500 interface configurations F, G, H, I,
J, K and L.
23
-
2523 24
FFL5
23 I/O (Interface configurations)
;;

Important Information
FLOWSIC500 · Operating Instructions · 8015391/ZOR6/V 3-0/2017-06 · © 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 levels, 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.
Type plate examples, see →p. 134, §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, Pressure Equipment Directive
Marking according to CSA
Marking according to ATEX/IECEx
4
1
3
2

12 FLOWSIC500 · Operating Instructions · 8015391/ZOR6/V3-0/2017-06 · © 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. 41, §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 (45 psi/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
parameters specified in the device. The device conforms to Pressure Device
Equipment 2014/68/EC.
●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/ZOR6/V 3-0/2017-06 · © 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 for use in lines pressurized above 0.5 bar (7.25 psi) is no longer valid.
WARNING: Ignition hazard through electrostatic charges
In certain extreme conditions in gas group IIC, unprotected plastic parts and
non-grounded enclosure metal parts can reach an ignitable measure of
electrostatic charges.
▸ Take precautionary measures to prevent electrostatic charges, localize, e.g.
the components where a charge generating mechanism could occur (e.g.
due to dust deposits caused by wind) and clean these with a damp cloth.
NOTICE: Cleaning information
▸ 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 mix-
tures or other media as well as adequate knowledge of the measuring system
gained through training.

14 FLOWSIC500 · Operating Instructions · 8015391/ZOR6/V3-0/2017-06 · © 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, device components and characteristics depend on the individual
device configuration. This individual device configuration is described in the device
documentation delivered with the device:
●Conformity Declaration
●Material certificate
●Inspection certificate
– Device configuration sheet
– Encoder test protocol (optional)
– Low pressure calibration test protocol (optional)
– Labels according to Pressure Equipment Directive 2014/68/EC, Annex 1 Part 3.3
●Printed Parameter report
●Product CD:
– Operating Instructions
–FLOWgate
TM operating software
–FLOWgate
TM Software Manual
–Certificates
– Instructions/information for accessory parts
– Calibration instructions
– Modbus specification
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/ZOR6/V 3-0/2017-06 · © SICK Engineering GmbH 15
Subject to change without notice
FLOWSIC500
2Product Description
Measuring principle
System components
FLOWgateTM operating software
Interfaces
Totalizers
Data processing
Device option: Volume conversion
Parameter protection
Sealing
PowerIn TechnologyTM

16 FLOWSIC500 · Operating Instructions · 8015391/ZOR6/V3-0/2017-06 · © SICK Engineering GmbH
Product Description
Subject to change without notice
2.1 Measuring 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 velocity.
Gas velocity v is determined from the difference between the signal transit times. Therefore
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 = Volume flow
The following short forms are used in this document for better readability:
●Volume at base conditions = base volume
●Volume at flowing 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/ZOR6/V 3-0/2017-06 · © SICK Engineering GmbH 17
Subject to change without notice
2.2 System components
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 meter body 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. 137, §9.4.

18 FLOWSIC500 · Operating Instructions · 8015391/ZOR6/V3-0/2017-06 · © 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 exchanged 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.
2.2.3 Meter sizes
Available meter sizes →p. 137, §9.4.

Product Description
FLOWSIC500 · Operating Instructions · 8015391/ZOR6/V 3-0/2017-06 · © SICK Engineering GmbH 19
Subject to change without notice
2.3 FLOWgateTM operating software
The FLOWgateTM operating software allows user-friendly access to all
measured values of the device.
2.3.1 Overview
Software functions
●Measured values overview
●Field setup wizard
●Parameter modification
●Logbook and archive management
●Calibration
●Diagnostics data
●Service actions
●Session browser
Fig. 5 Software platform FLOWgateTM – FLOWSIC500 “Overview”
For FLOWgateTM operating software, see “Software Manual FLOWgateTM”.
The Software Manual is on the delivered Product CD.
The Software Manual is also available using the Help function of the
FLOWgateTM operating software.

20 FLOWSIC500 · Operating Instructions · 8015391/ZOR6/V3-0/2017-06 · © SICK Engineering GmbH
Product Description
Subject to change without notice
2.3.2 System requirements
●Microsoft Windows XP/7/8/10
●Min. 1 GHz CPU
●Min. 512 MB RAM
●Approx. 100 MB free memory (without .NET framework)
●USB or serial interface
●Recommended minimum screen resolution: 1024 x 768 pixels, optimum screen resolu-
tion 1368 x 768 pixels
●Microsoft .NET framework 4.0
2.3.3 Access rights
If the user is not an administrator, the following entries in the registry must
exist or be configured for installation of the system:
●AlwaysInstallElevated = 1
●EnableUserControl = 1
Support: http://msdn.microsoft.com/en-us/library/aa367561(v=vs.85).aspx
Device function
Guest
User 3 User 2 User 1
Auth. user 3
Auth. user 2 Auth. user 1
Standard password - 1111 1111 1111 2222 2222 2222
Usercanbedeactivated -xx-xx-
Read parameters and measured
values
xxxxxxx
Readdataarchive -xxxxxx
Change parameters
not custody
relevant
-xxxxxx
Change custody relevant
parameters - - - - x x x
Usermanagement ------x
Calibration mode - - - - x x x
Configuration mode - - - - x x x
Test digital outputs - - - - x x x