SICK FLOWSIC500 User manual

O P E R A T I N G I N S T R U C T I O N S
Installation
Operation
Maintenance
Title Page
FLOWSIC500
Ultrasonic Gas Flow Meter with
Optional Volume Conversion

2 FLOWSIC500 · Operating Instructions · 8025733/1GMJ/V4-2/2022-07 · © SICK Engineering GmbH
Document information
Described product
Product name: FLOWSIC500
Document ID
Title: Operating Instructions FLOWSIC500
Part No.: 8025733
Document ID: 9325387
Version: 4-2
Release: 2022-07
Manufacturer
SICK Engineering GmbH
Bergener Ring 27 · D-01458 Ottendorf-Okrilla · Germany
Phone: [phone]
Fax: [phone]
E-mail: i[email protected]
Original documents
The English version 8025733 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
European 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; x specifies
the protection against contact and impurities, y
protection against moisture.
LF Low frequency, e. g. LF pulses
NAMUR Abbreviation for “Normen-Arbeitsgemeinschaft für
Mess- und Regeltechnik in der chemischen
Industrie”, now “Interessengemeinschaft
Automatisierungstechnik der Prozessindustrie”
(www.namur.de)
pTZ Volume conversion as a function of the pressure,
the temperature and with consideration of the
compression factor
TZ Volume conversion as function of the temperature
and a fixed pressure value and with consideration
of the compression factor

FLOWSIC500 · Operating Instructions · 8025733/1GMJ/V4-2/2022-07 · © 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
protection 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

Co n t en ts
4 FLOWSIC500 · Operating Instructions · 8025733/1GMJ/V4-2/2022-07 · © 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
1.6 Information on cybersecruity threats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2 Product description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.1 Measuring principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.1.1 Gas flow meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.1.2 Volume conversion (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.2 System components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.2.1 Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.2.2 Gas flow meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.2.3 Meter sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.3 FLOWgateTM operating software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.3.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.3.2 System requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.3.3 Access rights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.4 Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.4.1 Pulse and status outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.4.2 Encoder totalizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.4.3 Serial data interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.4.4 Optical data interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.5 Totalizers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.5.1 Device status and totalizers used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.5.2 Reverse flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.6 Data processing in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.6.1 Logbooks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.6.2 Archives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.7 Device option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.7.1 Volume conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.7.2 Load recording device with maximum load display . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.7.3 Extension measurement capability up to 30% hydrogen . . . . . . . . . . . . . . . . . . . . . . 30
2.7.4 Gas Quality Indicator (GQI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.8 Parameter protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.8.1 Parameter locking switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.8.2 Metrology logbook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.8.3 Gas composition logbook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.9 Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2.10 PowerIn TechnologyTM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Contents

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FLOWSIC500 · Operating Instructions · 8025733/1GMJ/V4-2/2022-07 · © SICK Engineering GmbH 5
3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3.1 Hazards during installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3.2 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3.2.1 Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3.2.2 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.3 Mechanical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.3.1 Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.3.2 Choosing flanges, gaskets and other components . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3.3.3 Fitting in the pipeline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
3.4 Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
3.4.1 Requirements for use in potentially explosive atmospheres . . . . . . . . . . . . . . . . . . . 46
3.4.2 Criteria for electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3.4.3 Opening and closing the electronics cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3.4.4 Rotating the control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
3.4.5 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
3.4.6 Pin assignment of plug-in connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
3.4.7 DO configuration switch (Open Collector - Namur) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
3.4.8 Cable specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
3.4.9 Operation with external power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
3.4.10 Battery operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
3.5 Installing the external pressure and temperature sensors . . . . . . . . . . . . . . . . . . . . . . . 59
3.5.1 Fitting the plug-in connector cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
3.5.2 Installing the pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
3.5.3 Installing the temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
3.6 Fitting a display protector (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
4 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
4.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
4.2 Commissioning on the display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
4.2.1 Commissioning sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
4.2.2 Setting the date and time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
4.2.3 Configuring volume conversion (device option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
4.2.4 Checking the device status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
4.3 Commissioning with the FLOWgateTM operating software . . . . . . . . . . . . . . . . . . . . . . . 71
4.3.1 Connect to the device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
4.3.2 Field setup wizard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
4.3.3 Activate and configure the daylight saving time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
4.3.4 Configure the power management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
4.3.5 Function check after commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

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6 FLOWSIC500 · Operating Instructions · 8025733/1GMJ/V4-2/2022-07 · © SICK Engineering GmbH
5 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
5.1 Control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
5.2 Operating using the display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
5.2.1 Display in the symbol bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
5.2.2 Battery fill level display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
5.2.3 Main screen (without device option volume conversion) . . . . . . . . . . . . . . . . . . . . . . 82
5.2.4 Main display (with device option volume conversion) . . . . . . . . . . . . . . . . . . . . . . . . 84
5.2.5 Configuration of main display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
5.2.6 FLOWSIC500 menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
5.2.7 Changing the user level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
5.2.8 Setting the language . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
5.2.9 Changing the device mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
5.2.10 Changing parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
5.2.11 Resetting the error volume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
5.2.12 Resetting the event summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
5.2.13 Confirming battery replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
5.2.14 Checking the external power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
5.2.15 Testing the display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
5.2.16 Searching archive entries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
6 Clearing malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
6.1 Contacting Customer Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
6.2 Status messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
6.3 Additional messages in the Event logbook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
6.4 Starting a diagnostic session . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
7 Maintenance and meter exchange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
7.1 Information on handling lithium batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
7.1.1 Information on storage and transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
7.1.2 Disposal information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
7.2 Maintenance when using external power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
7.2.1 Service life of backup battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
7.2.2 Changing the backup battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
7.3 Maintenance when using battery power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
7.3.1 Service life of battery packs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
7.3.2 Changing the battery packs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
7.4 Meter exchange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
7.4.1 Prerequisites for meter exchange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
7.4.2 Hazards during meter exchange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
7.4.3 Sequence of meter exchange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
7.4.4 Required tools and auxiliary material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
7.4.5 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
7.4.6 Backup of user-specific configuration of installed gas flow meter . . . . . . . . . . . . 116
7.4.7 Disconnecting electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
7.4.8 Removing the installed gas flow meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
7.4.9 Installing the replacement gas flow meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
7.4.10 Perform a leak tightness check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
7.4.11 Loading the parameter backup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
7.4.12 Checking the function of the new gas flow meter . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
7.4.13 Securing metrologically . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

Co n t en ts
FLOWSIC500 · Operating Instructions · 8025733/1GMJ/V4-2/2022-07 · © SICK Engineering GmbH 7
7.5 Function check of a pressure or temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . 132
7.6 Exchanging an external pressure or temperature sensor . . . . . . . . . . . . . . . . . . . . . . .132
7.6.1 Exchanging the pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
7.6.2 Exchanging the temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133
8 Accessories and spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
8.1 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136
8.1.1 Gas flow meter accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136
8.1.2 Volume conversion (device option) accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137
8.1.3 Transport accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137
8.2 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138
8.2.1 Gas flow meter spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138
8.2.2 Volume conversion (device option) spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138
9 Annex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139
9.1 Conformities and Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
9.1.1 CE certificate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
9.1.2 Standards compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140
9.1.3 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .141
9.1.4 Flow rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143
9.1.5 Overload protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143
9.2 Application ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .144
9.2.1 Pressure loss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
9.2.2 Methane concentration (CH4) in natural gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .145
9.2.3 Carbon dioxide concentration (CO2) in natural gas . . . . . . . . . . . . . . . . . . . . . . . . . .146
9.2.4 Speed of sound . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .147
9.3 Volume conversion: input variables and limit values of the algorithms . . . . . . . . . . .148
9.3.1 SGERG88 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
9.3.2 AGA 8 Gross method 1 und 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .148
9.3.3 AGA NX-19 und NX-19 mod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .148
9.3.4 AGA NX-19 mod. GOST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
9.3.5 GERG91 mod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .148
9.3.6 AGA8-92DC (AGA-8 Detail) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .149
9.4 Type code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .150
9.5 Type plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .152
9.5.1 Metrology and electronics type plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
9.5.2 Type plate, Pressure Equipment Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .154
9.6 Dimensional drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155
9.7 Internal terminal assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .156
9.8 Installation examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .157
9.9 Connection diagrams for operation of the FLOWSIC500 in accordance
with CSA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .160
9.10 Connection diagrams for operation of the FLOWSIC500 in accordance
with ATEX/IECEx . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .167

Co n t en ts
8 FLOWSIC500 · Operating Instructions · 8025733/1GMJ/V4-2/2022-07 · © SICK Engineering GmbH

Important information
FLOWSIC500 · Operating Instructions · 8025733/1GMJ/V4-2/2022-07 · © 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
Information on cybersecruity threats

10 FLOWSIC500 · Operating Instructions · 8025733/1GMJ/V4-2/2022-07 · © 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
This document is valid for FLOWSIC500 with firmware version 2.15.00 and higher.
FLOWSIC500 with Ex approval acc. CSA
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:
For a French translation of this document, please refer to document 8025734
"Manuel d'utilisation FLOWSIC500".

Important information
FLOWSIC500 · Operating Instructions · 8025733/1GMJ/V4-2/2022-07 · © 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
totalizer 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. 152, §9.5.
Fig. 1 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)
4
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 · 8025733/1GMJ/V4-2/2022-07 · © 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. 46, §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 operating company 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
operation.

Important information
FLOWSIC500 · Operating Instructions · 8025733/1GMJ/V4-2/2022-07 · © 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
technical 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: 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
mixtures or other media as well as adequate knowledge of the measuring
system gained through training.

14 FLOWSIC500 · Operating Instructions · 8025733/1GMJ/V4-2/2022-07 · © 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
– FLOWgateTM operating software
– FLOWgateTM Software Manual
– Certificates
– Instructions/information for accessories
– 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.

Important information
FLOWSIC500 · Operating Instructions · 8025733/1GMJ/V4-2/2022-07 · © SICK Engineering GmbH 15
Subject to change without notice
1.6 Information on cybersecruity threats
Protection against cybersecurity threats requires a comprehensive cybersecurity concept
that must be continuously reviewed and maintained. A suitable concept consists of organi-
zational, technical, procedural, electronic and physical levels of defense and takes into
account appropriate measures for the different types of risk. The measures implemented in
this product can only support protection against cybersecurity threats if the product is used
as part of such a concept.
Visit www.sick.com/psirt for more information, such as:
● General information on cybersecurity
● Contact option for reporting vulnerabilities
● Information on known vulnerabilities (Security Advisories)

16 FLOWSIC500 · Operating Instructions · 8025733/1GMJ/V4-2/2022-07 · © SICK Engineering GmbH
Important information
Subject to change without notice

Product description
FLOWSIC500 · Operating Instructions · 8025733/1GMJ/V4-2/2022-07 · © SICK Engineering GmbH 17
Subject to change without notice
FLOWSIC500
2Product description
Measuring principle
System components
FLOWgateTM operating software
Interfaces
Totalizers
Data processing in
Device option
Parameter protection
Sealing
PowerIn TechnologyTM

18 FLOWSIC500 · Operating Instructions · 8025733/1GMJ/V4-2/2022-07 · © 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. 2 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
sensors or entered as fixed value.
v = Gas velocity
L = Measuring path
 = 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

----------------------
 =
VbC Vm
=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 · 8025733/1GMJ/V4-2/2022-07 · © SICK Engineering GmbH 19
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. 3 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. 155, §9.6.

20 FLOWSIC500 · Operating Instructions · 8025733/1GMJ/V4-2/2022-07 · © 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
sensors also has the calibrated pressure sensor and calibrated temperature sensor fitted
in the gas flow meter.
2.2.3 Meter sizes
Available meter sizes → p. 155, §9.6.