SICK FLOWSIC600 User manual

MMM
I
MMMOPERATING INSTRUCTIONS
OPERATING INSTRUCTIONS
FLOWSIC600 DRU/DRU-S
Gas Flow Meters
Gas flow meters for applications in natural gas production
Title Page

28026711/V1-0/2021-06 | SICKOPERATING INSTRUCTIONS | FLOWSIC600DRU/DRU-S
Subject to change without notice
Described product
Product name: FLOWSIC600 DRU/DRU-S
Manufacturer
SICK Engineering GmbH
Bergener Ring 27 · D-01458 Ottendorf-Okrilla · Germany
Phone: [phone]
Fax: [phone]
E-mail: [email protected]
Legal information
This work is protected by copyright. Any rights derived from the copyright shall be
reserved for SICK Engineering GmbH. Reproduction of this document or parts of this
document is only permissible within the limits of the legal determination of Copyright
Law.
Any modification, shortening or translation of this document is prohibited without the
express written permission of SICK Engineering GmbH.
The trademarks stated in this document are the property of their respective owner.
© SICK Engineering GmbH. All rights reserved.
Original document
This document is an original document of SICK Engineering GmbH.

CONTENTS
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1 About this document................................................................................. 6
1.1 Function of this document..............................................................................6
1.2 Scope of application .......................................................................................6
1.3 Target groups ..................................................................................................6
1.4 Data integrity...................................................................................................6
1.5 Further information ........................................................................................ 7
1.6 Abbreviations used ........................................................................................7
1.7 Abbreviations for measured variables ..........................................................7
1.8 Symbols and document conventions .............................................................8
1.8.1 Warning symbols.............................................................................8
1.8.2 Warning levels and signal words....................................................8
1.8.3 Information symbols .......................................................................8
2 For your safety............................................................................................ 9
2.1 Basic safety information ................................................................................9
2.1.1 General safety instructions and protective measures ................10
2.1.2 Environmental protection information and disposal
instructions ...................................................................................10
2.2 Intended use .................................................................................................10
2.3 Authorized personnel....................................................................................11
3 Product description .................................................................................12
3.1 FLOWSIC600 DRU overview .........................................................................12
3.1.1 Technical features of the FLOWSIC600 DRU ..............................13
3.1.2 FLOWSIC600 DRU application range...........................................13
3.2 FLOWSIC600 DRU-S overview ......................................................................14
3.2.1 Technical features of the FLOWSIC600 DRU-S ...........................14
3.3 FLOWSIC600 DRU/DRU-S system components ..........................................15
3.3.1 Meter body ....................................................................................15
3.3.2 Ultrasonic sensors ........................................................................15
3.3.3 Signal processing unit (SPU) .......................................................15
3.4 Operating modes, meter states and signal output......................................16
3.4.1 Operation mode and Configuration mode ...................................16
3.4.2 Meter status..................................................................................16
3.4.3 Impulse output and status signaling ..........................................18
3.5 Self-diagnosis with user warnings ................................................................20
3.6 Wet gas detection .........................................................................................21
3.6.1 Activating or deactivating wet gas detection...............................21
3.6.2 Signalization of wet gas detection ...............................................22
3.7 Data processing in FLOWSIC600 DRU/DRU-S.............................................23
3.7.1 Integrated volume counters .........................................................23
3.7.2 Logbooks .......................................................................................24
3.7.3 DataLogs / Archives .....................................................................26
3.7.4 Diagnostics Comparison Log ....................................................27
Contents
Contents

CONTENTS
48026711/V1-0/2021-06 | SICKO P E R A T I N G I N S T R U C T I O N S | FLOWSIC600 DRU/DRU-S
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3.8 FLOWgateTM ................................................................................................. 28
3.8.1 Overview ....................................................................................... 28
3.8.2 System requirements ................................................................... 28
3.8.3 Installation.................................................................................... 29
3.8.4 Access rights ................................................................................ 29
4 Installation................................................................................................ 30
4.1 General information ..................................................................................... 30
4.1.1 Delivery ......................................................................................... 30
4.1.2 Transport and storage.................................................................. 31
4.2 Installation .................................................................................................... 32
4.2.1 Measuring port ............................................................................. 32
4.2.2 Installation configurations ........................................................... 33
4.3 Mechanical installation ................................................................................ 35
4.3.1 Choosing flanges, gaskets and other components .................... 35
4.3.2 Fitting the FLOWSIC600 DRU/DRU-S in the pipeline ................. 35
4.3.3 SPU alignment .............................................................................. 36
4.4 Electrical installation ................................................................................... 37
4.4.1 General information ..................................................................... 37
4.4.2 Cable specifications .................................................................... 38
4.4.3 Checking the cable loops ............................................................ 39
4.4.4 Terminal compartment on the SPU ............................................. 40
4.4.5 Operation in Non-Ex areas: .......................................................... 42
4.4.6 Operation in Ex zones .................................................................. 43
5 Commissioning ........................................................................................ 50
5.1 General information .................................................................................... 50
5.2 Connecting to the device.............................................................................. 51
5.2.1 Connecting the FLOWSIC600 DRU/DRU-S via an
RS485/USB converter ................................................................. 51
5.2.2 Connecting devices with FLOWgateTM for commissioning ......... 51
5.3 Identification ................................................................................................. 53
5.4 Field Setup wizard ....................................................................................... 54
5.4.1 System + LCD ............................................................................... 54
5.4.2 Operating parameters .................................................................. 54
5.4.3 I/O setup....................................................................................... 54
5.4.4 I/O configuration .......................................................................... 55
5.4.5 Archive/Logbooks......................................................................... 55
5.4.6 Finish ............................................................................................ 55
5.5 Functional test on the device....................................................................... 56
5.5.1 Function test FLOWSIC600 DRU/DRU-S with LCD front panel .. 56
5.6 Function check with FLOWgateTM................................................................ 57
5.7 Activating path compensation ..................................................................... 61
5.8 Documentation ............................................................................................. 61

CONTENTS
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6 Maintenance.............................................................................................62
6.1 General information .....................................................................................62
6.2 Routine checks with FLOWgateTM .................................................................................63
6.2.1 Function check (device status) ...................................................63
6.2.2 Time synchronization....................................................................64
6.2.3 Status report .................................................................................64
6.2.4 Optional data backup ...................................................................65
7 Troubleshooting .......................................................................................66
7.1 General troubleshooting ...............................................................................66
7.2 Displaying meter status, system alarms and warnings..............................66
7.3 Creating a diagnostic session with FLOWgateTM ....................................................67
7.4 Troubleshooting when connecting meters...................................................68
8 Annex.........................................................................................................69
8.1 Conformities and technical data ..................................................................69
8.1.1 Standards conformity and type approvals...................................69
8.1.2 WELMEC conformity .....................................................................69
8.2 Type code .....................................................................................................70
8.3 Technical data FLOWSIC600 DRU................................................................71
8.4 Technical data FLOWSIC600 DRU-S ............................................................73
8.5 Dimensional drawings...................................................................................74
8.5.1 Dimensional drawing FLOWSIC600 DRU 3 and 4 inch...............74
8.5.2 Dimensional drawing FLOWSIC600 DRU 6 inch..........................75
8.5.3 Dimensional drawing FLOWSIC600 DRU-S..................................75
8.6 Operation and menu structure of the meter body with LCD display...........76
8.6.1 Operation ......................................................................................76
8.6.2 Displaying measured values ........................................................84
8.6.3 Data editing in Configuration mode .............................................85
8.6.4 Resetting the error volume counters ...........................................86
8.6.5 Acknowledging a battery replacement.........................................86
8.7 Logbooks .......................................................................................................87
8.7.1 Overview of event entries in Meter logbooks .............................88
8.8 SPU terminal assignment .............................................................................92
8.9 Connection diagram for operation of the FLOWSIC600 DRU/DRU-S
in Ex-zones acc. to North American Directives (NEC, CEC) .........................93
8.10 Wiring example..............................................................................................99
8.10.1 Intrinsically safe installation ........................................................99
8.10.2 Non-intrinsically safe installation.............................................. 100

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1ABOUT THIS DOCUMENT
1 About this document
1.1 Function of this document
These Operating Instructions describe the FLOWSIC600 DRU/DRU-S measuring system to
measure the volumetric flow a.c., volume a.c. and the sound velocity of gases in pipelines.
They contain basic information on the measuring method used, the layout and function of
the overall system and its components, as well as planning, assembly, installation,
commissioning, maintenance, troubleshooting and fault clearance. The comparison of
characteristic properties of the available system variants is intended to facilitate the
decision in the planning phase for a configuration optimally adapted to the measurement
task.
These Operating Instructions cover standard applications conforming with the technical
data specified. Additional information and assistance for special applications are available
from your SICK representative. Consultation with SICK specialists for your specific
application is recommended in all cases.
1.2 Scope of application
These Operating Instructions apply exclusively to the following firmware and software
versions:
It does not apply to other measuring devices from SICK.
The standards specified in the Operating Instructions must be observed in their currently
valid version.
1.3 Target groups
This Manual is intended for persons who install, operate and maintain the device.
Operation
The device may only be operated by authorized persons who, based on their training on,
and knowledge of the specific device, as well as knowledge of the relevant regulations can
assess the tasks given and recognize the hazards involved.
Installation and maintenance
Skilled persons are required for installation and maintenance.
Observe the information at the beginning of the respective Sections.
1.4 Data integrity
SICK Engineering GmbH uses standardized data interfaces, such as standard IP
technology, in its products. The focus here is on product availability and features. SICK
Engineering GmbH always assumes the customer ensures the integrity and confidentiality
of data and rights affected in connection with the use of the products. In all cases, the
customer is responsible for the implementation of safety measures suitable for the
respective situation, e.g., network separation, firewalls, virus protection and patch
management.
Device / software Firmware or software version
FLOWSIC600 DRU/DRU-S 3.6.84 or higher
FLOWgateTM 1.17.00 or higher

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ABOUT THIS DOCUMENT 1
1.5 Further information
1.6 Abbreviations used
1.7 Abbreviations for measured variables
Document Part No.
FLOWSIC600 DRU Short Manual MODBUS E134768
FLOWSIC600 Technical Bulletin ENCODER Output E_40492
FLOWSIC600 DRU Service Manual 8023840
Abbreviation Significance
s.c. In standard condition
a.c. In operating condition
SOS Speed of sound, sound velocity
VOG Velocity of gas, gas velocity
SPU Signal processing unit
DRU Differential replacement Unit
DRU-S Differential replacement Unit - short
FRAM Ferroelectric random access memory, non - volatile memory
LVF Liquid volume fraction
FLASH PROM Flash programmable read - only memory
Measured variables Abbreviations and units for
FLOWSIC600 DRU/DRU-S
Abbreviations used on the LCD
signal processing unit
Volume in operating
conditions Vf m³ acf Vf m³ cf
Volume in standard
conditions Vb Nm³ scf Vb m³ cf
Error volume in operating
conditions Ef m³ acf Ef m³ cf
Error volume in standard
conditions Eb Nm³ scf Eb m³ cf
Total volume, original Vo m³ acf Vo m³ cf
Operating volume flow Qf m³/h acf/h Qf m³/h cf/h
Volume flow rate in
standard state Qb Nm³/h scf/h Qb m³/h cf/h
Mass counters M t lbs M t lbs
Error mass Me t lbs M t lbs
Mass flow rate s.c. Mf t/h lbs/h M t/h lbs/h
Table 1: Abbreviations for measured variables

88026711/2021-06| SICKO P E R A T I N G I N S T R U C T I O N S | FLOWSIC600 DRU/DRU-S
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1ABOUT THIS DOCUMENT
1.8 Symbols and document conventions
1.8.1 Warning symbols
1.8.2 Warning levels and signal words
DANGER:
Risk or hazardous situation which will result in severe personal injury or death.
WARNING:
Risk or hazardous situation which could result in severe personal injury or death.
CAUTION:
Hazard or unsafe practice which could result in less severe or minor injuries.
NOTICE:
Hazard which could result in property damage.
NOTICE:
Hints.
1.8.3 Information symbols
Symbol Significance
Hazard (general)
Hazard by electrical voltage
Hazard in potentially explosive atmospheres
Symbol Significance
Information on product design with regard to protection against explosions (general)
Important technical information for this product
Important information on electrical or electronic functions

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FOR YOUR SAFETY 2
2Foryoursafety
2.1 Basic safety information
WARNING: Hazards through hot, aggressive or explosive gases or high pressure
The FLOWSIC600 DRU/DRU-S is fitted directly in the gas-carrying line.
▸In systems with gases harmful to health, explosion hazard, high pressure, high
temperatures, the FLOWSIC600 DRU/DRU-S may only be installed and removed
when the line is vented or the system is at a standstill.
▸The same requirement applies to carrying out repair and maintenance work that
requires opening the measuring channel and/or the explosion-proof signal
processing unit.
▸The responsibility for safe operation lies with the operator; in particular, additional
applicable national and company regulations must be observed.
WARNING: Danger due to heavy loads
▸The device must be securely fastened to the support structure during transport and
assembly.
▸Only use hoisting equipment and equipment (e.g. lifting straps) suitable for the
weight to be lifted. Maximum load information can be found on the type plate of the
hoisting equipment.
▸The eyebolts attached to the meter body are suitable for transporting the measuring
device. However, additional loads (e.g. dummy covers for closing the device, filling for
pressure tests or associated pipelines) must not be lifted and transported together
with the measuring system without additional support using the hoisting equipment.
▸No hoisting equipment may be attached to or interfere with the signal processing
unit or its mounting.
WARNING: Hazards when flushing the line
If it is necessary to flush the FLOWSIC600 DRU/DRU-S, contact the responsible SICK
subsidiary beforehand and also follow the instructions below exactly:
▸The pressure during flushing must not be higher than 1.2 times the nominal
pressure (with built-in sensors).

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2FOR YOUR SAFETY
2.1.1 General safety instructions and protective measures
Improper use or improper handling can cause damage to health or material damage.
Therefore, please read this Section thoroughly and observe this information for all tasks on
the FLOWSIC600 DRU/DRU-S as well as the caution and warning information in the
individual Sections of these Operating Instructions.
The following is basically applicable:
●When preparing and carrying out tasks, the legal regulations applicable to the respective
plant as well as the technical rules and guidelines implementing these regulations must
be observed. Special care must be taken on plants with increased hazard potential
(pressure lines, explosion protection zones). Particular attention should be paid to the
rules applicable for such plants.
●All work must be carried out in accordance with local, plant-specific conditions and
operational hazards and regulations.
●Operating Instructions and system documentation belonging to the measuring system
must be available on site. The instructions contained therein for the avoidance of
hazards and damage must be observed at all times.
●In accordance with the respective hazard potential, suitable protective devices and
personal safety equipment must be available in sufficient quantity and used by the
personnel.
2.1.2 Environmental protection information and disposal instructions
The FLOWSIC600 DRU/DRU-S components are easy to disassemble and contain no toxic,
radioactive or other environmentally harmful substances. The device is mainly made of
steel, stainless steel, plastic and aluminium, and there are therefore few restrictions on
disposal. Only the circuit boards have to be disposed of as electronic waste.
2.2 Intended use
The FLOWSIC600 DRU/DRU-S serves to measure the volumetric flow rate of gases in
pipelines. The FLOWSIC600 DRU/DRU-S can also be used to determine the sound velocity.
The measuring system may only be used in the manner specified by the manufacturer and
described below. It should be noted in particular that:
●The application complies with the technical data, the information on the permissible use
as well as the assembly, connection, ambient and operating conditions. Relevant
information is provided in the order documentation, type plate, certification documents
and this manual.
●Observe all measures necessary for conservation of value, e.g., for maintenance and
inspection and/or transport and storage.
●The device is not subjected to any unallowed mechanical stress, e.g. through pig
cleaning.
●Flushing the FLOWSIC600 DRU/DRU-S with liquid (e.g. for pressure or leak tests)
constitutes improper use. The consequences of such actions are neither foreseeable nor
can they be assessed. The result of improper use can be the failure of the ultrasonic
sensors and consequently the failure of the entire gas flow meter.