SICK FLOWSIC600 User manual

OPERATING INSTRUCTIONS
Applifoto
74 x 45 mm
(150 dpi: 437 x 266 pixel)
x = 136 mm y = 58 mm
Title
Ultrasonic Gas Flow Meter
for Custody Transfer
and Process Applications
MEPAFLOW600 CBM and Firmware V3.4.xx
FLOWSIC600
Ultrasonic Gas Flow Meter

2 FLOWSIC600 · Operating Instructions · 8010458 V2.0 · © SICK MAIHAK GmbH
Document Information
Product
Product name: FLOWSIC600
Document ID
Title: Operating Instructions FLOWSIC600
Order No.: 8010458
Version: 2.0
Release: 2010-01
Publisher
SICK MAIHAK GmbH
Nimburger Str. 11 · D-79276 Reute · Germany
Tel.: [phone]
Fax: [phone]
E-mail: [e-mail]
Trademarks
IBM is a trademark of the International Business Machine
Corporation.
MS-DOS is a trademark of the Microsoft Corporation.
Windows is a trademark of the Microsoft Corporation .
Other product names used in this document may also be trade-
marks and are only used for identification purposes.
Guarantee Information
Specified product characteristics and technical data do not serve
as guarantee declarations.
© SICK MAIHAK GmbH. All rights reserved.
Glossary
Abbreviations used in this manual
act. actual (under operating/flowing conditions)
AGC Automatic Gain Control
ASCII American Standard Code for Information
Interchange
ANSI American National Standards Institute
ASME American Society of Mechanical Engineers
AWG American Wire Gage
CBM Condition Based Maintenance
CSA Canadian Standards Association
DC Direct Current
DIN Deutsches Institut für Normung (German
Standards Institute)
DN Nominal Diameter (internal)
DSP Digital Signal Processor
EC European Community
EN Euro Norm (European Standard)
EVC Electronic Volume Corrector
Ex Potentially explosive atmosphere (hazardous
area)
HART®Communication interface
IEC International Electrotechnical Commission
LCD Liquid Crystal Display
LED Light Emitting Diode
MEPAFLOW Menu-assisted Parameterisation and Diagno-
sis for FLOWSIC600
MDR Manufacturer Datal Record
NAMUR Normenarbeitsgemeinschaft für Mess- und
Regeltechnik in der chemischen Industrie
(now "Interessengemeinschaft Prozessleit-
technik der chemischen und phar-
mazeutischen Industrie"; ~ Association for
Instrumentation and
Control Standards in the Chemical Industry)
norm. normalized/corrected (under standard condi-
tions)
OI Operating Instructions (this document)
OIML Organisation Internationale de Metrologie
Legale
PC Personal Computer
PTB Physikalisch Technische Bundesanstalt
(~ Federal Metrology Office in Germany)
RTU Remote Terminal Unit
SPU Signal Processing Unit
VDE Verband der Elektrotechnik Elektronik Infor-
mationstechnik
(~ Association of German Electrical Engineers)

FLOWSIC600 · Operating Instructions · 8010458 V2.0 · © SICK MAIHAK GmbH 3
Warning Symbols
Warning Levels / Signal Words
DANGER
Risk or hazardous situation which will result in severe personal
injury or death.
WARNING
Risk or hazardous situation which could result in severe personal
injury or death.
CAUTION
Hazard or unsafe practice which could result in personal injury or
property damage.
NOTICE
Hazard which could result in property damage.
Information Symbols
Hazard (general)
Hazard in potentially explosive atmospheres
Hazard by voltage
Information about the use in potentially explosive
atmospheres
Important technical information for this product
Important information on electric or electronic func-
tions
Supplementary information
Link to information at another place

Contents
4 FLOWSIC600 · Operating Instructions · 8010458 V2.0 · © SICK MAIHAK GmbH
1 Important Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.1 About this Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.2.1 Intended Use of the Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.3 Authorized Staff. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.4 General Safety Instructions and Protective Measures . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.5 Dangers due to hot, corrosive and explosive gases and high pressure . . . . . . . . . . . . 10
1.6 Dangers due to heavy loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.7 Environmental information and instructions for disposal . . . . . . . . . . . . . . . . . . . . . . . . 11
2 Product Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.1 System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.1.1 Meter body. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.1.2 Ultrasonic transducers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.1.3 Signal processing unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.2 Operating Modes, Meter States and Signal Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.2.1 Operation Mode and Configuration Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.2.2 Meter States . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.2.3 Pulse output and status information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.3 MEPAFLOW600 CBM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.3.1 Software Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.3.2 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.1 General Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.1.1 Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.1.2 Transport and storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.2.1 Measuring location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.2.2 Installation configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.3 Mechanical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.3.1 Choosing flanges, seals and other parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.3.2 Mounting the FLOWSIC600 in the piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.3.3 SPU alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.4 Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.4.1 General information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.4.2 Cable specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.4.3 Checking the cable loops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.4.4 Terminal enclosure on the SPU. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.4.5 Operating the FLOWSIC600 in safe areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3.4.6 Operation in hazardous areas (Directive 94/9/EC (ATEX)) . . . . . . . . . . . . . . . . . . . . 39
Contents

Contents
FLOWSIC600 · Operating Instructions · 8010458 V2.0 · © SICK MAIHAK GmbH 5
4 Commissioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4.1 General Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
4.2 Connecting the FLOWSIC600 to a PC or Laptop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4.2.1 Connecting the FLOWSIC600 via RS485 / RS232 cable . . . . . . . . . . . . . . . . . . . . . . 45
4.2.2 Connecting the FLOWSIC600 via RS485/USB converter . . . . . . . . . . . . . . . . . . . . . . 46
4.3 Connecting to the FLOWSIC600 with MEPAFLOW600 CBM . . . . . . . . . . . . . . . . . . . . . . 47
4.3.1 Starting MEPAFLOW600 CBM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
4.3.2 Choosing an User Access Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
4.3.3 Creating a new meter entry in the meter database . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
4.3.4 Online Connection: Direct Serial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
4.3.5 Online Connection: Ethernet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
4.4 Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
4.4.1 Checking identification, operation / design data and firmware version . . . . . . . . . 52
4.5 Field Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
4.5.1 Disconnecting from the Meter and Closing the Session . . . . . . . . . . . . . . . . . . . . . . . 54
4.6 Function Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
4.6.1 Function test on FLOWSIC600 with LCD front panel . . . . . . . . . . . . . . . . . . . . . . . . . . 55
4.6.2 Function test on FLOWSIC600 with LED front panel . . . . . . . . . . . . . . . . . . . . . . . . . . 55
4.6.3 Function test with MEPAFLOW600 CBM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
4.7 Activation of Path Compensation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
4.8 Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
5Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
5.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
5.2 Routine Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
5.2.1 Comparing theoretical and measured Speed of Sound (SOS) . . . . . . . . . . . . . . . . . . 63
5.2.2 Checking the Meter Health . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
5.2.3 Time Synchronization. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
5.2.4 Battery Lifetime / Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
5.3 Maintenance Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
5.4 Optional Data Download . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
5.4.1 Logbook Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
6 Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
6.1 General Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
6.2 Indication of Meter States, System Alarms and Warnings . . . . . . . . . . . . . . . . . . . . . . . . 72
6.2.1 Checking the “Meter Status“ Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
6.2.2 Checking the User Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
6.2.3 Battery Lifetime / Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
6.3 Generation of a Diagnosis Session . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
6.4 Meter Connection Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Contents
6 FLOWSIC600 · Operating Instructions · 8010458 V2.0 · © SICK MAIHAK GmbH
7 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
7.1 Conformities and Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
7.1.1 CE certificate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
7.1.2 Standard compatibility and type approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
7.1.3 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
7.2 Logbooks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
7.2.1 Overview of event entries in logbooks and MEPAFLOW600 CBM . . . . . . . . . . . . . . 86
7.3 Connection Diagrams for Operating the FLOWSIC 600 in Hazardous Areas in
Accordance with North American Guidelines (CSA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
7.4 Wiring Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
7.4.1 Intrinsically safe installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
7.4.2 Non-intrinsically safe installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
7.5 Sealing Plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

FLOWSIC600 · Operating Instructions · 8010458 V2.0 · © SICK MAIHAK GmbH 7
Important Information
FLOWSIC600
1Important Information
About this Document
Safety Instructions
Authorized staff
General Safety Instructions and Protective Measures
Dangers Due to Hot, Corrosive and Explosive Gases and High Pressure
Dangers Due to Heavy Loads
Environmental Information and Instructions for Disposal

Important Information
8 FLOWSIC600 · Operating Instructions · 8010458 V2.0 · © SICK MAIHAK GmbH
1.1 About this Document
This manual describes the FLOWSIC600 measuring system, which is used to determine the
volumetric flow rate, volume and the speed of sound in gases transported in pipelines. It
provides general information on the measuring method employed, design and function of
the entire system and its components, and on planning, assembly, installation, calibration
commissioning, maintenance and troubleshooting. Also included is a detailed description
of the various system capabilities, options and settings which will assist in optimizing the
meter configuration for a specific application.
This manual covers standard applications which conform with the technical data specified.
Additional information and assistance for special applications are available from your SICK
representative. However, it is generally recommended to take advantage of qualified
consulting services provided by SICK experts for your specific application.
This operating manual is a part of the FLOWSIC600 device documentation. Which also
includes the following (optional, for trained staff only):
●FLOWSIC600 service manual,
●FLOWSIC600 extraction tool operating instructions,
●FLOWSIC600 MODBUS specification document,
●FLOWSIC600 HARTbus specification document.
●FLOWSIC600 Technical Bulletin ENCODER Output
All documentation is available on www.flowsic600.com or from your local representative.
The following terms will be used for measurands:
Scope of Document
This document applies to meters with S/N 10xxxxxx, with firmware version
3.4.00 or higher and extended memory for the storage of e.g. hourly and daily
mean values.
The software describtion in this document applies to MEPAFLOW600 CBM
V1.1.13.
Measurand Basic abbrevations and
units for FLOWSIC600
Abbrevations used at
LCD-Display of SPU
MEPAFLOW600 CBM
software
Volume at flowing conditions Vf m³ acf Vf m³ cf Vf m³ acf
Volume at base conditions Vb Nm³ scf Vb m³ cf Vb Nm³ scf
Error volume at flowing conditions Ef m³ acf Ef m³ cf Ef m³ acf
Error volume at base conditions Eb Nm³ scf Eb m³ cf Eb Nm³ scf
Total volume at flowing conditions Vo m³ acf Vo m³ cf Vo m³ acf
Volume flow at flowing conditions Qf m³/h acf/h Qf m³/h cf/h Qf m³/h acfh
Volume flow at base conditions Qb Nm³/h scf/h Qb m³/h cf/h Qb Nm³/h scfh

FLOWSIC600 · Operating Instructions · 8010458 V2.0 · © SICK MAIHAK GmbH 9
Important Information
1.2 Safety Instructions
1.2.1 Intended Use of the Equipment
The FLOWSIC600 measuring system is used for measuring the actual volumetric flow rate
of gases transported in pipelines. It can be used for measuring the actual corrected
volume and the velocity of sound in gases.
The measuring system shall only be used as specified by the manufacturer and as set forth
below. Always observe the following information:
●Make sure the use of the equipment complies with the technical data, information
about the permitted use, assembly and installation specifications and ambient as well
as operating conditions. Relevant information is provided in the order documentation,
type plate, certification documents and this manual.
●Any actions for the purpose of maintaining the value of the equipment, e.g. service and
inspection, transport and storage etc., shall be performed as specified.
●Do not expose the equipment to mechanical stress, such as pigging.
●The flooding of the FLOWSIC600 with any liquid (e.g. for pressure or leakage tests) is an
improper use. The consequences of such activities can not be foreseen or estimated.
The result can be a failure of the ultrasonic transducers and consequently a failure of
the entire flow meter.
If a flooding is necessary nevertheless, please contact the manufacturer beforehand and
additionaly strictly respect the following instructions:
1.3 Authorized Staff
Persons responsible for safety issues shall ensure the following:
●Any work on the measuring system shall only be carried out by qualified persons and
must be approved by responsible skilled persons.
Due to their professional training, knowledge and vocational experience, as well as their
knowledge of the relevant standards, regulations, health and safety regulations and
equipment conditions, qualified persons shall be assigned by the person responsible
for personal and plant safety to carry out such work. Qualified persons must be able to
identify possible dangers and to take preventive action in due time.
Skilled persons are defined in DIN VDE 0105 and IEC 364, or comparable standards.
●Skilled persons shall have precise knowledge of process-specific dangers, e.g. due to
the effects of hot, toxic and pressurised gases, gas-liquid mixtures and other process
media, and of the design and working principle of the measuring system and shall have
received and be able to document appropriate training.
●In hazardous areas, wiring and installation shall only be carried out by staff trained
according to EN 60079-14 and according to national regulations.
WARNING:
b A FLOWSIC600 equipped with transducers of type “S1” may under no
circumstances be flooded with liquids.
b The pressure during flooding may not exceed a pressure higher than 1,2
times the nominal pressure (when transducers are assembled).

Important Information
10 FLOWSIC600 · Operating Instructions · 8010458 V2.0 · © SICK MAIHAK GmbH
1.4 General Safety Instructions and Protective Measures
Using the equipment for any purpose other than intended, or improper operation may
result in injuries and damage to the equipment. Read this section and the notes and
warnings in the individual sections of this manual carefully and observe the instructions
given therein when carrying out any work on the FLOWSIC600 measuring system.
Generally:
●Always comply with the statutory provisions and the associated technical rules and
regulations relevant to the equipment when preparing for and carrying out any work on
the measuring system. Pay particular attention to potentially hazardous aspects of the
equipment, such as pressurized piping and explosion protection zones. Always observe
the relevant regulations.
●Always consider local and equipment-specific conditions and process-specific dangers
when carrying out any work on the equipment.
●Operating and service instructions and equipment documentation shall always be
available on site. Always observe the safety instructions and notes on the prevention of
injuries and damage given in these manuals.
●Make sure appropriate protective accessories are available in sufficient supply. Always
use such protective accessories. Check that appropriate safety devices are fitted and
working correctly.
1.5 Dangers due to hot, corrosive and explosive gases and high pressure
The FLOWSIC600 measuring system is directly integrated into gas-carrying pipelines.
The operating company is responsible for safe operation and for complying with additional
national and company-specific regulations.
WARNING:
In plants with toxic and explosive gases, high pressure or high temperatures,
the FLOWSIC600 measuring system shall only be installed or removed after
the associated piping has been isolated and depresurrized (i.e. vented to
atomsphere).
The same applies to repair and service work which involves opening any
pressurized component or the explosion-proof signal processing unit (SPU).
NOTICE:
Design, manufacture and inspection of the FLOWSIC600 measuring system
are performed in compliance with the safety requirements set forth in the
European Pressure Equipment Directive 97/23/EC. All relevant information for
the particular application (as specified in the technical information
questionnaire filled out by the customer) has been taken into account before
commencing order processing.

FLOWSIC600 · Operating Instructions · 8010458 V2.0 · © SICK MAIHAK GmbH 11
Important Information
1.6 Dangers due to heavy loads
The FLOWSIC600 measuring system must be safely attached to the carrying structure
when being transported and installed.
1.7 Environmental information and instructions for disposal
The FLOWSIC600 components are easily disassembled and do not contain toxic,
radioactive or any other enviromentally hazardous materials. The instrument consists
primarily of steel, stainless steel, plastic and aluminium, and consequently there are few
restrictions for disposal. Only the printed-circuit boards must be disposed of as electronic
scrap.
WARNING:
●Only use lifting gear and equipment (e.g. lifting straps) which is suitable for
the weight to be lifted. Max. load information can be found on the type plate
of the lifting gear.
●The eye bolts attached to the meter body are suitable for the transport of
the measuring device. However, additional loads (e.g. blind covers, filling
for pressure tests or associated piping) must not be lifted and transported
together with the measuring system without the use of additional support
from the lifting gear.
●Never attach lifting gear to the signal processing unit or its mounting
bracket and avoid contact between these parts and the lifting gear.

Important Information
12 FLOWSIC600 · Operating Instructions · 8010458 V2.0 · © SICK MAIHAK GmbH

FLOWSIC600 · Operating Instructions · 8010458 V2.0 · © SICK MAIHAK GmbH 13
Product Description
FLOWSIC600
2Product Description
System Components
Operating States and Signal Output
MEPAFLOW600 CBM

Product Description
14 FLOWSIC600 · Operating Instructions · 8010458 V2.0 · © SICK MAIHAK GmbH
2.1 System Components
The FLOWSIC600 measuring system consists of the following hardware components:
●Meter body
●Ultrasonic transducers
●Signal processing unit SPU
The MEPAFLOW600 CBM software is the user interface used to facilitate operation,
configuration and diagnosis (see
→ pg.20, 2.3).
Figure 1 FLOWSIC600
2.1.1 Meter body
The meter body consists of a mid section for mounting the ultrasonic transducers, with
flanges on either end. For meter sizes up to 24“, the body is made of a single-piece casting,
which is machined on precision equipment to ensure high reproducibility of the geometric
parameters. For meters larger than 24“ the body is made of a single-piece casting or
forged or the flanges are welded onto the machined mid section.
The internal diameter, design of the sealing surface, and standard dimensions of the
flanges are in accordance with the specifications in the key code. The meter body material
is chosen to suit customer requirements. Standard meter bodies are available in carbon
steel, Low Temperature Carbon Steel and stainless steel.
The meter bodies can be delivered in several nominal sizes (see
→ pg.82, 7.1.3).
Meter body
Cover cap
Pressure tap
Flange
SPU
Hoisting eye
Position of the ultrasonic transducers
(cover cap taken off)
Marking for direction of
flow (forward)

FLOWSIC600 · Operating Instructions · 8010458 V2.0 · © SICK MAIHAK GmbH 15
Product Description
2.1.2 Ultrasonic transducers
The FLOWSIC600 ultrasonic transducers are optimized to suit the application
requirements. The high quality of the transducer design provides the basis for accurate
and highly stable propagation time measurements with nanosecond precision. These
transducers are of an intrinsically safe design (category “ia“).
2.1.3 Signal processing unit
The SPU contains all the electrical and electronic components for controlling the ultrasonic
transducers. It generates transmission signals and analyzes the received signals to
calculate the measuring values. The SPU also contains several interfaces for
communication with a PC or standardized process control system.
The volume counters, errors, warnings, and system events are stored in a non volatile data
memory (FRAM) together with a time stamp (Logbooks
→ pg.86, 7.2.) On system restart, the
counter readings that were last saved are restored as the start values for the volume
counters. The FRAM backup provides an unlimited number of writing cycles and protects
the saved data for at least 10 years.
The SPU is equipped with a front panel containing a two-line LCD to display current
measured values, diagnostics and logbook information (
→ Figure 2). The values to be
displayed can be selected using a magnetic pen without removal of the front cover . The
MEPAFLOW600 CBM software provides a more user-friendly way to display the information.
Figure 2 FLOWSIC600 front panel LCD
The power supply and interface terminals are located on the back of the SPU in a separate
terminal section of the enclosure (
→ pg.36, 3.4.4).
The electronics are mounted in the SPU enclosure certified to EN 60079-1 or IEC 60079-1
with protection type “d“ (flameproof enclosure). The transducer circuits are of an
intrinsically safe design (category “ia“).
Measured values
Control buttons for the magnetic pen
Control buttons for manual use

Product Description
16 FLOWSIC600 · Operating Instructions · 8010458 V2.0 · © SICK MAIHAK GmbH
2.2 Operating Modes, Meter States and Signal Output
The FLOWSIC600 has two operating modes ( → 2.2.1):
●Operation Mode
●Configuration Mode
In the Operation Mode the meter can have the following Meter states (
→ 2.2.2):
●Measurement valid
●Check request
●Measurement invalid
2.2.1 Operation Mode and Configuration Mode
The meter can be operated by the user in two modes: Operation or Configuration.
Operation Mode
In the Operation Mode, the meter runs in one of the aforementioned three Meter states,
depending on the measuring conditions.
Configuration Mode
The Configuration Mode is used to modify parameters that directly influence the
measurement and to test the system and output signals. The Configuration Mode forces
the meter into the status “Measurement invalid”. The digital output “Measurement valid” is
deactivated in Configuration Mode because invalid measured values may be produced.
The system continues operation using the current sample rate and executes all
calculations as in the Operation Mode. Frequency output and analog output may represent
test values and do thus not necessarily indicate measured values. Any parameter
modifications are applied immediately to the running calculations, with the exception of
the sample rate and baud rate of the MODBUS interface/device address.
Test Cycle
The test cycle can be activated for a measuring path by setting the corresponding control
bit in the System Control Register (#3002) (the setting can be carried out on the
“Parameters” page in MEPAFLOW600 CBM). In a test cycle, the transmitted signal is fed to
the receiver signal amplifier of the measuring path through an electric attenuation unit
(transducer simulator). This function can only be activated if the system is in the
“Configuration” mode. It is used to test a path-specific electronic module.
Test cycles are automatically cancelled when leaving the “Configuration” mode.
If the meter is in Configuration Mode and there have been no activities either
on the LCD display or via MEPAFLOW600 CBM for more than 15 minutes, the
meter automatically switches to Operation Mode.

FLOWSIC600 · Operating Instructions · 8010458 V2.0 · © SICK MAIHAK GmbH 17
Product Description
2.2.2 Meter States
2.2.2.1 Status: Measurement valid
The “Measurement” status is the standard Meter state of the FLOWSIC600. Frequency
outputs and current output are updated cyclically and indicate the actual volume and
volumetric flow rate. In addition, the analog signal can indicate the actual flowrate,
corrected volumetric flowrate, SOS (speed of sound) or VOG (velocity of gas) The digital
output “Direction of flow” is updated in accordance with the direction of the volumetric
flow. The digital output “Valid measurement” (active) represents the status of the
measurement. Positive (forward) and negative (reverse) volumetric flow rates are
integrated and saved in separate internal memory sections.
The MODBUS interface allows the query of all parameters and signals at any time without
interfering with the function of the system.
Each measurement initiated by the system controller includes one full transit time
measurement with, and one against the direction of flow on each path. The result of each
measurement is written to a mean value memory to be used in further calculations. The
size of this memory block and thus the device response delay can be modified through the
parameter in register #3502 “AvgBlockSize”. If no result can be calculated due to poor
signal quality, this measurement is registered as an invalid attempt in the mean value
memory. The mean value is formed in a variable averaging process including all valid
measured values in the memory.
If the number of invalid measurements on a path exceeds a predefined limit (register
#3514 “Limit%Error”), the measuring system activates the “Check request” status.
2.2.2.2 Status: Check request
This status becomes active if one measuring path has failed and the adaptive path failure
compensation has been activated. The multi-path FLOWSIC600 system is able to
compensate for this failure. Measurement is continued with reduced accuracy. If a path
fails while the path failure compensation is deactivated, the measuring system will activate
the “Measurement invalid” status.
Moreover the check request status becomes active when the system alarms 2002 (“No
HART communication to temperature transmitter”), 2003 (“No HART communication to
pressure transmitter”), or 2004 (“Maximum pulse output frequency exceeded”) become
active (see table
→ pg.86, 7.2.1).
2.2.2.3 Status: Measurement invalid
If the quality of received signals is deficient in more than one measuring path, the SPU
must mark the measured value invalid and activate the meter status “Measurement
invalid”. However, the SPU will cyclically try to re-establish valid measurements. As soon as
the signal quality and number of valid measurements meet the required criteria, the SPU
will automatically change back to the “Measurement valid” or “Check request” status.

Product Description
18 FLOWSIC600 · Operating Instructions · 8010458 V2.0 · © SICK MAIHAK GmbH
2.2.3 Pulse output and status information
* The meter can be configured to put out a fixed frequency at “Measurement invalid“. The
frequency to be put out in this case can be configured in Reg.#3034 “ErrorFreq“ (0-6 kHz).
** Default setting on delivery.
*** Optional setting on customer request.
The default setting for “Check request”, “Configuration” and “Measurement invalid” is
“normally closed”.
NOTICE: TYPE APPROVAL
Pulse output signals can be customized as shown in the following table.
Table 1 Pulse output
Output signal / LCD / port Signal behavior
Measurement state Check request state Configuration Mode Measurement invalid*
Pulse
output
signals
Inverted with error
signal **
Phase
shift
90 ° ***
Positive
flow rate
Negative
flow rate
Separate
outputs
for each
direction
***
Positive
flow rate
Negative
flow rate
Single pulse output
***

FLOWSIC600 · Operating Instructions · 8010458 V2.0 · © SICK MAIHAK GmbH 19
Product Description
****The “active” or “inactive” state can be assigned to the electric switch status
“normally open” or “normally closed” by configuration in the MEPAFLOW600 CBM software
(adjust settings for register #5101 on the “Parameters” page.)
The LCD display is capable of displaying measured values, parameters, messages and
other information.
A flashing letter at the upper right corner of the LCD display indicates that a logbook
contains unacknowledged logbook entries. Depending on the type of entry this will be:
●“I” for Information
●“W” for Warning
●“E” for Error
After acknowledging all new entries, the flashing letter disappears. For details see
→ pg.68,
5.4.1.
Table 2 Status output
Output signal / LCD / port Signal behavior
Measurement state Check request state Configuration Mode Measurement invalid
“Check request”
Status signal
Status
“active / inactive” ***
Measurement valid
Status
“active / inactive” ***
Compensation of path
failure
“undefined” “undefined”
“Direction of flow”
Status signal
Status
“active / inactive” ***
Positive or negative
direction of flow
Status
“active / inactive” ***
Positive or negative
direction of flow
“undefined” “undefined”
“Warning” Status
“active / inactive” ***
Status
“active / inactive” ***
“undefined” “undefined”
LCD display
Display flashing Display flashing
Serial port RS485 ●Measured value, diagnosis information and parameters
●Measuring data logging, diagnosis and configuration through the MEPAFLOW600
CBM software
●Connection with external process control equipment through implemented
MODBUS protocol (data polling)
+V 123456 m³
-V 1234 m³
1234 m³ FLOWSIC600
Configuration
+V 123456 m³
-V 1234 m³

Product Description
20 FLOWSIC600 · Operating Instructions · 8010458 V2.0 · © SICK MAIHAK GmbH
2.3 MEPAFLOW600 CBM
Most data provided by the FLOWSIC600 (like readings, logbook entries and parameters)
can be accessed via the LCD display of the meter. However, the MEPAFLOW600 CBM
software provides a more user friendly access to diagnostic, configuration and
measurement data of the flow meter.
2.3.1 Software Installation
System requirements
●Microsoft Windows 2000/XP/Vista (later MEPAFLOW600 CBM versions will support
Windows 7 or higher)
●Min. 1 GHz CPU
●Min. 512 MB RAM
●USB- or serial interface
●Screen resolution min. 1024 x 768 pixel (optimal display resolution 1280 x 1024 pixel)
Compatibility
MEPAFLOW600 CBM can be used for all firmware and hardware versions of the
FLOWSIC600. The availability of the software features depend on the firmware version of
the connected FLOWSIC600.
Installation
A product CD containing the MEPAFLOW600 CBM software is included with the
FLOWSIC600 when it is delivered. Insert the product CD into your CD-ROM drive to install
the software. Start the file ‘FLOWSIC600_R_CD.exe‘ to install the software.
Download from www.flowsic600.com
MEPAFLOW600 CBM can be downloaded free of charge from the www.flowsic600.com
website. Select the Software tab and follow the download instructions.