Oi Flowsic600

O p e r at i n g i n s t r u C T I O N S
FLOWSIC600
Ultrasonic Gas Flow Meter

for Custody Transfer and Process Applications II+
MEPAFLOW600 CBM and Firmware V3.3.xx
Operating Instructions FLOWSIC600
Content
About this Document ..........................................................................................................9
1 Safety Instructions............................................................................................................ 13
1.1 Intended Use of the Equipment ....................................................................................... 13
1.2 Authorised Staff..................................................................................................................... 13
1.3 General Safety Instructions and Protective Measures ............................................. 14
1.3.1 Dangers due to hot, corrosive and explosive gases and high pressure .... 14
1.3.2 Dangers due to heavy loads........................................................................................ 15
1.3.3 Environmental information and instructions for disposal.................................. 15
2 Product Description.......................................................................................................... 19
2.1 Features and Applications ................................................................................................. 19
2.1.1 FLOWSIC600 1-path, FLOWSIC600 2-path, FLOWSIC600 4-path .............. 20
2.1.2 FLOWSIC600 2plex (4 + 1 CBM Design)............................................................... 20
2.1.3 FLOWSIC600 Quatro ...................................................................................................... 21
2.2 Conformity, Configuration, Technical Data ................................................................... 22
2.2.1 CE certificate ...................................................................................................................... 22
2.2.2 Standard compatibility and type approval .............................................................. 22
2.2.3 Configuration ...................................................................................................................... 22
2.2.4 Technical data ................................................................................................................... 24
2.3 System Components............................................................................................................ 27
2.3.1 Meter body ......................................................................................................................... 27
2.3.2 Ultrasonic transducers ................................................................................................... 27
2.3.3 Signal processing unit..................................................................................................... 28
2.4 Measuring Principle ............................................................................................................. 29
2.4.1 Determining the gas velocity........................................................................................ 30
2.4.2 Calculating the volumetric flow rate .......................................................................... 31
2.4.3 Calculating the actual volume...................................................................................... 32
2.4.4 Determining the speed of sound ............................................................................... 33
2.5 Operating States and Signal Output ............................................................................... 34
2.5.1 Operation and configuration mode............................................................................ 34
2.5.2 Measurement status....................................................................................................... 35
2.5.3 Check request status ..................................................................................................... 35
2.5.4 Measurement invalid ...................................................................................................... 35
2.5.5 Pulse output and status information......................................................................... 36
2.5.6 Battery .................................................................................................................................. 37
2.6 Self-diagnosis......................................................................................................................... 38
8010125/2008-08 © SICK MAIHAK GmbH · Germany · All rights reserved 3

2.7 Data Handling with MEPAFLOW600 CBM ................................................................... 39

2.7.1 Time Synchronization ...................................................................................................... 42
2.7.2 Integrated Volume Counters ........................................................................................ 43
2.7.3 Logbooks ............................................................................................................................. 44
2.7.4 DataLogs.............................................................................................................................. 47
2.7.5 Data Recorder.................................................................................................................... 51
2.7.6 Backup.................................................................................................................................. 53
2.8 Path Failure Compensation ............................................................................................... 54
2.9 Configuration.......................................................................................................................... 57
2.9.1 Hardware variants and signal outputs (I/O configuration) ................................ 57
2.9.2 System configuration with external electronic volume corrector (EVC)....... 60
2.9.3 System configuration with integrated electronic volume corrector (EVC) .. 61
3 MEPAFLOW600 CBM diagnosis and configuration software.............................71

3.1 Overview .................................................................................................................................. 71
3.2 Software Installation............................................................................................................ 73
3.3 Connecting the FLOWSIC600 to a PC or Laptop ....................................................... 74
3.3.1 Connecting the FLOWSIC600 via RS485 / RS232 cable ................................ 74
3.3.2 Connecting the FLOWSIC600 via USB converter................................................. 75
3.4 Connecting to the FLOWSIC600 with MEPAFLOW600 CBM ................................ 76
3.4.1 Starting MEPAFLOW600 CBM..................................................................................... 76
3.4.2 Establishing a connection to MEPAFLOW600 CBM............................................ 77
3.4.3 Creating a new meter entry in the meter database ............................................ 78
3.4.4 Connection troubleshooting.......................................................................................... 79
4 Flow Calibration ................................................................................................................83

4.1 Short Guide to Flow Calibration ....................................................................................... 84
4.2 General Notes ........................................................................................................................ 86
4.2.1 Calibration (for single or constant adjust factor) .................................................. 86
4.2.2 Recommended test flow rates .................................................................................... 87
4.2.3 Flow calibration at atmospheric pressure ............................................................... 88
4.2.4 Flow calibration at high pressure................................................................................ 89
4.3 Preparation.............................................................................................................................. 90
4.3.1 Identification and visual check..................................................................................... 90
4.3.2 Mechanical installation on the flow test stand ...................................................... 90
4.3.3 Electrical connection........................................................................................................ 91
4.3.4 Connection to the MEPAFLOW600 CBM software.............................................. 91
4.3.5 Open / close the configuration protection switch ................................................ 92
4.3.6 Identification of key data in the meter configuration........................................... 93
4.3.7 Setting the current gas condition ............................................................................... 93
4.3.8 Functional check before flow calibration ................................................................. 94
4.3.9 Adjustment of the ‘‘Zero Phase” parameter........................................................... 97
4.3.10 Data record during flow calibration (optional)........................................................ 99
4 © SICK MAIHAK GmbH · Germany · All rights reserved 8010125/2008-08

4.4 Flow Calibrating the FLOWSIC600 ..............................................................................102

4.4.1 Determining the adjust factors without MEPAFLOW600 CBM wizard ...... 102
4.4.2 Finding the adjust factors using the MEPAFLOW600 CBM software........ 105
4.5 Configuration, Verification and Documentation........................................................109
4.5.1 Configuration and documentation without Calibration wizard ...................... 109
4.5.2 Configuration and documentation with Calibration wizard............................. 109
4.6 Sealing....................................................................................................................................111
4.7 Flow Recalibration ..............................................................................................................112
5 Installation.........................................................................................................................115
5.1 General Notes ......................................................................................................................115
5.1.1 Delivery.............................................................................................................................. 115
5.1.2 Transport and storage................................................................................................. 116
5.2 Installation.............................................................................................................................117
5.2.1 Measuring location ....................................................................................................... 117
5.2.2 Installation configurations........................................................................................... 118
5.3 Mechanical Installation.....................................................................................................120
5.3.1 Choosing flanges, seals and other parts.............................................................. 120
5.3.2 Mounting the FLOWSIC600 in the piping............................................................. 121
5.3.3 SPU alignment ................................................................................................................ 122
5.4 Electrical Installation.........................................................................................................123
5.4.1 General information...................................................................................................... 123
5.4.2 Cable specifications ..................................................................................................... 125
5.4.3 Checking the cable loops........................................................................................... 126
5.4.4 Terminal enclosure on the SPU ............................................................................... 127
5.4.5 Operating the FLOWSIC600 in safe areas .......................................................... 129
5.4.6 Operation in hazardous areas (Directive 94/9/EC (ATEX)) .......................... 130
6 Commissioning ..............................................................................................................137
6.1 General Notes ......................................................................................................................137
6.1.1 Checking identification, operation and design data ......................................... 138
6.1.2 Firmware ........................................................................................................................... 138
6.2 Function Check....................................................................................................................139
6.2.1 FLOWSIC600 with LED front panel ........................................................................ 139
6.2.2 FLOWSIC600 with LCD front panel ........................................................................ 139
6.2.3 Function test ................................................................................................................... 139

6.3 Field Setup ............................................................................................................................140

6.3.1 Location information and unit system (Field setup page 1 of 8) ................ 141
6.3.2 Application data (Field setup page 2 of 8) .......................................................... 142
6.3.3 Integrated electronic volume corrector (EVC) (Field setup page 3 of 8). 143
6.3.4 I / O configuration - Output configuration (Field setup page 4 of 8).......... 144
6.3.5 I / O Configuration - Terminal assignment (Field setup page 5 of 8) ........ 145
6.3.6 LCD Display setup (Field setup page 6 of 8)...................................................... 147
6.3.7 Configuration update (Field setup page 7 of 8) ................................................ 148
6.3.8 Maintenance Report (Field setup page 8 of 8) ................................................. 149
6.4 Activation of Path Compensation ..................................................................................150
6.5 Sealing....................................................................................................................................150
7 Maintenance .................................................................................................................... 153

7.1 General ...................................................................................................................................153
7.2 Routine Checks ...................................................................................................................154
7.2.1 Speed of sound.............................................................................................................. 154
7.2.2 Performance .................................................................................................................... 155
7.2.3 Reception sensitivity (AGC level) ............................................................................. 155
7.2.4 Signal-to-noise ratio ...................................................................................................... 155
7.2.5 Overview of typical values .......................................................................................... 156
7.3 Maintenance Report ..........................................................................................................157
8 Troubleshooting .............................................................................................................. 163

8.1 Generation of a Diagnosis Session ...............................................................................164
9 List of parts....................................................................................................................... 167

9.1 Tools and Accessories ......................................................................................................167
9.2 Spare Parts............................................................................................................................168
10 Appendix............................................................................................................................ 173
10.1 Characteristic Properties and Dimensions of the Meter Body ............................173
10.2 Operation and Menu Structure of the SPU with LCD Display...............................178
10.2.2 Menu structure on the LCD display ........................................................................ 179
10.2.3 Display of measured values ...................................................................................... 187
10.2.4 Data editing in configuration mode......................................................................... 187
10.2.5 Resetting the error volume counters ..................................................................... 188
10.2.6 Acknowledging a battery exchange ........................................................................ 188
10.3 Logbooks ...............................................................................................................................189
10.3.1 Overview of event entries in logbooks and MEPAFLOW600 CBM............. 189
10.3.2 Acknowledging a logbook entry on the LCD display ........................................ 192
10.4 SPU Terminal Assignment................................................................................................193

10.5 Connection Diagrams for Operating the FLOWSIC 600 in Hazardous Areas in
Accordance with North American Guidelines (CSA) ...............................................195
10.6 Reports created with MEPAFLOW600 CBM..............................................................197
10.6.1 Short Parameter Report* .......................................................................................... 198
10.6.2 Calibration Report ........................................................................................................ 199
10.7 Manufacturer Data Record (MDR) ................................................................................200
10.7.1 Table of Contents.......................................................................................................... 200
10.7.2 Inspection certificate.................................................................................................... 201
10.7.3 Instrument Data Sheet ............................................................................................. 202
10.7.4 Final check report ........................................................................................................ 203
10.7.5 Zeropoint test ................................................................................................................ 206
10.7.6 Parameter Report ........................................................................................................ 207
10.7.7 Data Sheet Electronics................................................................................................ 212
10.7.8 Data Sheet Transducer Pairs.................................................................................... 213
10.7.9 EC Declaration of Conformity .................................................................................. 214
10.8 Wiring Examples .................................................................................................................215
10.8.1 Intrinsically safe installation ....................................................................................... 215
10.8.2 Non-intrinsically safe installation.............................................................................. 216
10.9 Sealing Plan ..........................................................................................................................217
10.10 Outline Drawings .................................................................................................................222


Operating Instructions About this Document FLOWSIC600
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:
Option, for trained staff only:
• FLOWSIC600 service manual,
• FLOWSIC600 extraction tool operating instructions,
• FLOWSIC600 Modbus specification document,
• FLOWSIC600 HARTbus specification document.
Scope of Document
This document applies to meters with S/N 08xxxxxx, with firmware version 3.2.00 or higher
and extended memory for the storage of e.g. hourly and daily mean values.

FLOWSIC600 About this Document Operating Instructions
Symbols used in this document

Important information, in particular safety instructions, are highlighted in this document to
facilitate quick access. Such information is provided where necessary within each section of
this manual.
Note: Provides information about special features of the equipment and additional
recommendations.
Indicates a section with data which possibly deviate from the applicable national type
approval. Therefore read the appropriate approval papers when using the FLOWSIC600 for
custody transfer application.
TYPE APPROVAL
Important
Indicates potential risks for the equipment and possible functional impairment.
ATTENTION
Warning
Indicates potential hazards for the operating staff, particularly those caused by electrical
installations and improper use of the equipment. Always observe such warnings, as they aim
DANGER to protect you from serious injuries.
Note: Always read this manual carefully before carrying out any work on the equipment. Always
observe warnings and comply with all safety instructions.
All obligations of SICK are set forth in the relevant purchase agreement. This agreement also
includes the complete and definitive list of valid warranty conditions.

Operating Instructions About this Document FLOWSIC600
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 Diagnosis for FLOWSIC600
MDR Manufacturer Datal Report
NAMUR Normenarbeitsgemeinschaft für Mess- und Regeltechnik in der chemischen
Industrie (now "Interessengemeinschaft Prozessleittechnik der chemischen
und pharmazeutischen Industrie"; ~ Association for Instrumentation and
Control Standards in the Chemical Industry)
norm. normalized/corrected (under standard conditions)
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 Informationstechnik
(~ Association of German Electrical Engineers)

FLOWSIC600 About this Document Operating Instructions
The following terms will be used for measurands:
Basic abbrevations and Abbrevations used at MEPAFLOW600 CBM

Measurand
units for FLOWSIC600 LCD-Display of SPU 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

Operating Instructions Safety Instructions FLOWSIC600
1 Safety Instructions
1.1 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:
‡ A FLOWSIC600 equipped with transducers of type ‘‘S1” may under no circumstances be
ATTENTION flooded with liquids.
‡ The pressure during flooding may not exceed a pressure higher than 1,2 times the
nominal pressure (when transducers are assembled).
1.2 Authorised 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.

FLOWSIC600 Safety Instructions Operating Instructions
1.3 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.
1.3.1 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
DANGER 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).
Note 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.

Operating Instructions Safety Instructions FLOWSIC600
1.3.2 Dangers due to heavy loads

The FLOWSIC600 measuring system must be safely attached to the carrying structure when
being transported and installed.
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.
DANGER ‡ 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.
1.3.3 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.

FLOWSIC600 Safety Instructions Operating Instructions

FLOWSIC600
Product Description
Features and Applications
Conformity, Configuration, Technical Data
System Components
Operating States and Signal Output
Self-diagnosis
Data Handling with MEPAFLOW600 CBM
Path Failure Compensation
Configuration
Operating Instructions Product Description FLOWSIC600
2 Product Description
2.1 Features and Applications
System features
The FLOWSIC600 measuring system is the first compact gas meter used for ultrasonic
volumetric gas flow measurement.
It is available in several different path configurations. The redundand configurations include
a second SPU to allow for independent measurements on the redundand paths (see
Section 2.1.1 to 2.1.3 and Key Code table in Section 2.2.2).
Fig. 2.1: FLOWSIC600
The main features of the FLOWSIC600 are:

• Counters, logbooks and configurable data loggers on board
• Ultrasonic transducers integrated into the meter body
• Direct path design without signal reflection
• No damage from over-ranging
• Measuring range up to 1:120
• Power consumption < 1W
• Intelligent self diagnosis with Condition Based Maintenance (CBM) functionality
• MEPAFLOW600 CBM, a comprehensive user interface which includes meter and data
management
• ‘‘One button” meter diagnosis tool
• Worldwide service support
As a result, this measuring system is extremely robust and provides maximum accuracy,
even under adverse operating conditions. Its compact design and concealed cabling also
provides protection from mechanical damage, thereby ensuring long-term stable
measurement that is insensitive to mechanical or electrical interference.

FLOWSIC600 Product Description Operating Instructions
Applications
The FLOWSIC600 is ideally suited for a wide range of custody transfer and process
measurement applications;
‡ Production, transportation and distribution of natural gas,
‡ Company-internal metering and billing,
‡ Power stations and other gas-consuming installations,
‡ Chemical and petrochemical industries,
‡ Compressed air distribution systems.
2.1.1 FLOWSIC600 1-path, FLOWSIC600 2-path, FLOWSIC600 4-path

These FLOWSIC600 meters can have 1, 2 or 4 ultrasonic measuring paths and are
equipped with one set of electronics (SPU). are mainly used for process control and
company internal billing. Meters with 4 paths can be used for fiscal gas metering in any
segment of the natural gas market like gathering, transportation, distribution and storage.
National pattern approvals exist for several countries. (See outline drawings in Section 10.)
Fig. 2.2: FLOWSIC600 1-path, 2-path and 4-path
2.1.2 FLOWSIC600 2plex (4 + 1 CBM Design)

The FLOWSIC600 2plex combines a fiscal and a check
meter - the fiscal meter with four paths and the check
meter with one path. Both flow meters are incorporated
into the same meter body, but each has its own
electronics and therefore are redundand and
metrologically independent. With their different path-
designs and the resulting difference in sensitivity, to
disturbances such as contamination, pulsation or noise
are identified at an early stage. With this design the
FLOWSIC600 2plex warns you long before the fiscal
measurement will be impacted. The FLOWSIC600 2plex
keeps a check on itself. Should the fiscal meter ever
actually fail, the check meter will continue measuring. (See
outline drawings in Section 10.)
Fig. 2.3: FLOWSIC600 2plex

2.1.3 FLOWSIC600 Quatro

The redundant design of the FLOWSIC600 Quatro provides two 4-path fiscal meters for full
redundancy with equal accuracy within one meter body. Each electronics operats 4 chordal
pairs of tranducers (within the same plane), and each determines the flow independently.
This design significantly reduces costs for installations that traditionally were utilizing two
separate meters with their associated piping.
The primary benefit of this design is that two different
companies can utilize one meter body, but have totally
electrically isolated metering systems. This permits each
company to compute flow with equal accuracy, but be
totally independent of each other. Additionally, should one
of the electronics develop a problem or fail, the secondary
unit will continue to provide accurate measurement data.
As an 8-path meter, the FLOWSIC600 Quatro can be used
at flow test laboratories. (See outline drawings in Section
10.)
Fig. 2.4: FLOWSIC600 Quatro

2.2 Conformity, Configuration, Technical Data
2.2.1 CE certificate
The FLOWSIC600 has been developed, manufactured and tested in accordance with the
following EC directives:
• Pressure Equipment Directive 97/23/EC
• Directive 94/9/EC (ATEX100)
• EMC Directive 89/336/EC
Conformity with above directives has been verified. The equipment has been designated the
CE label.
2.2.2 Standard compatibility and type approval

The FLOWSIC600 was developed, designed and certified according to the following
recommendations:
• OIML R 137-1, 2006, "Gas meters, Part 1: Requirements"
• OIML D 11, 2004, "General requirements for electronic measuring instruments"
• A.G.A Report No. 9, 1998, "Measurement of Gas by Multipath Ultrasonic Meters"*
• API 21.1 ‘‘Flow Measurement Using Electronic Metering Systems” (draft) **
Type approval for commercial or custody transfer has been granted by the relevant
authorities, e.g.:
• Germany: PTB (Physikalisch-Technische Bundesanstalt), code number 7.421 / 03.05
• Netherlands: NMI (Netherlands Meetinstituut), code number B35
• Canada: Measurement Canada, Approval No. AG-0521
• Switzerland: Metrologie und Akkreditierung Switzerland, Appr. No. CH-G4-04404-00
• Europe: MID Approval, DE-08-MI002-PTB005
* In derogation of the AGA9, strength test will be performed as hydrostatic pressure test
with 30 minutes holding time according to the requirements of PED and ASME B31.5
‘‘Process piping”
** The FLOWSIC600 meets or exceeds the new proposed audit logging requirements of
API 21.1 (draft). Specifically the API 21.1 (draft) requires the ultrasonic meter to provide
an internal record of any configuration change, including the original and new parameter,
and date and time the change occurred.
2.2.3 Configuration
All approvals for custody and fiscal metering requiere the FLOWSIC600 to have the following
specifications as a minimum:
• 4 parallel ultrasonic measuring paths
• Power supply 12 .. 28,8 V DC
• Electronics with LCD display and 4 digital outputs

Group 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Key code FL600- - -

1
METER BODY
Path configuration
1-Path 1 P
2-Path 2 P
4-Path 4 P
1+1-Path redundant 1 R
2+2-Path redundant 2 R
4+4-Path (Qatro) 4 R
4+1-Path (2plex) 5 C
2-Path crossed 2 X
4-Path crossed 4 X
2 Overall length
2D (at meters >24") 2 D
3D (standard length) 3 D
5D 5 D
Other size X D
3 Nominal size
2" / DN 50 0 2
3" / DN 80 0 3
4" / DN 100 0 4
6" / DN 150 0 6
8" / DN 200 0 8
10" / DN 250 1 0
12" / DN 300 1 2
16" / DN 400 1 6
Other size X X
4 Connection flange type
ANSI CLASS 150 C L 0 1 5 0
ANSI CLASS ??? C L X X X X
DIN/ISO PN16 P N 0 0 1 6
DIN/ISO PN 64 P N 0 0 6 4
DIN/ISO PN 100 P N 0 1 0 0
DIN/ISO PN ??? P N X X X X
5 Inner diameter
Schedule 40 (ANSI) S C 0 0 4 0
Schedule 80 (ANSI) S C 0 0 8 0
Schedule ??? (ANSI) S C X X X X
Specified in [mm] (DIN) X X X . X X
6 Flange type / sealing face
Raised Face (ANSI B16.5) R F
Ring Type Joint (ANSI B16.5) R J
Glatt Form C (DIN 2526) G C
Glatt Form E (DIN 2526) G E
Form B1 (EN 1092-1) B 1
Form B2 (EN 1092-1) B 2
Special design X X
7 Material
Carbon Steel (1.1120 / ASTM A216 Gr. WCC ) 0
Stainless steel (1.4408 / ASTM A351 Gr. CF8M) 1
LT-CS (1.6220 / ASTM A352 Gr. LCC) 2
Duplex (1.4470 / ASTM A995 Gr. 4A / UNS J92205) 3
Superduplex (1.4469 / ASTM A995 Gr. 5A) 4
Superaustenit (1.4557 / ASTM A351 Gr. CK-3MCuN) 5
8 Connection for Extraction Tool
Yes Y
No N
9 ULTRASONIC TRANSDUCER (Will be selected by SICK MAIHAK on the basis of the technical data ) _ _
10 SIGNAL PROCESSING UNIT

Ex-proof-design
CSA Group D T4 1
CSA Group B, C, D T4 2
ATEX IIA T4, M20x1.5 3
ATEX IIC T4, M20x1.5 4
ATEX IIA T4, 1/2 NPT 5
ATEX IIC T4, 1/2 NPT 6
11 Power supply
12 ... 24V DC D C
85 ... 265V AC A C
12 Data outputs
Hardware variant 1 (4 digital outputs) 1
Hardware variant 2 (1 analog current output and 3 digital outputs) 2
Hardware variant 3 (with integrated volume corrector) 3
Hardware variant 4 (1 analog current output and 2 RS485) 4
13 HART-Protocol (By selection of hardware variant 2 only)
Yes Y
No N
14 Front panel
LED SICK/MAIHAK 0
LCD SICK/MAIHAK 1
15 Custody Transfer design
Yes Y
No N
Fig. 2.5: Common key code used for short description of meter design (indicated on Type Plate* and
Instrument Data Sheet)
* See Section 4.3.1 of this Manual.

** The Instrument Data Sheet is included in the Manufacturer Data Report (MDR), see
Section 10.7 in the Appendix.

2.2.4 Technical data
Actual flow rate Actual flow rate

Max. Velocity
Nominal Size [m³/h] [ft³/h]
Min. Max. Min. Max. [m/sec] [ft/sec]
TYPE APPROVAL DN 50 (NPS 2) 6 400 210 14,000 65 213
DN 80 (NPS 3) 12 1,000 280 35,000 65 213
DN 100 (NPS 4) 20 1,600 460 57,000 60 197
DN 150 (NPS 6) 32 3,000 1,130 106,000 50 164
DN 200 (NPS 8) 40 4,500 1,410 159,000 45 148
DN 250 (NPS 10) 50 7,000 1,770 247,000 40 131
DN 300 (NPS 12) 65 8,000 2,300 283,000 33 108
DN 350 (NPS 14) 80 10,000 2,830 353,000 33 108
DN 400 (NPS 16) 120 14,000 4,240 494,000 33 108
DN 450 (NPS 18) 130 17,000 4,590 600,000 33 108
DN 500 (NPS 20) 200 20,000 7,060 706,000 33 108
DN 600 (NPS 24) 320 32,000 11,300 1,130,000 33 108
DN 700 (NPS 28) 650 40,000 22,950 1,413,000 30 98
DN 750 (NPS 30) 650 45,000 22,950 1,589,000 30 98
DN 800 (NPS 32) 800 50,000 28,250 1,766,000 30 98
DN 900 (NPS 36) 1,000 66,000 35,320 2,331,000 30 98
DN 1000 (NPS 40) 1,200 80,000 42,380 2,825,000 30 98
DN 1050 (NPS 42) 1,300 85,000 45,910 3,002,000 30 98
DN 1100 (NPS 44) 1,400 90,000 49,440 3,178,000 28 92
DN 1200 (NPS 48) 1,600 100,000 56,500 3,531,000 27 89
Tab. 2.6: Common meter sizes and flow rates

Material
Meter body Carbon steel 1.1120/ ASME A216 WCC
Stainless steel 1.4408/ ASME A351 Gr. CF 8M
Low temperature carbon steel 1.6220/ASME A352 L CC
Duplex steel 1.4470/ASME A995 Gr.4A/UNS J92205
Common data
Number of measuring paths 1, 2 or 4
Min. gas velocity 0.3 m/s; 1 ft/s
Turn down (vmin/vmax) Max. 1 : 130
Measured medium
Gases Natural gas, process gases, air, Ethylene, etc.
Pressure range*** 0 bar(g) ... 250 bar(g) (0 psi(g) ... 3600 psi(g)); up to 450 bar(g) (6500 psi(g)) on request
Temperature range -40 °C ... + 180 °C (-40 °F ... 356 °F); -194 °C ... 280 °C (-317 °F ... 536 °F) on request
Measuring uncertainty
Repeatability < 0.1 % of reading
Typical uncertainty * 1 path ± 2.0 %
2 paths ± 1.0 %
4 paths ± 0.5 % (dry calibrated); ± 0.2 % (after flow calibration + adjustment with constant
factor); ± 0.1% (after flow calibration + adjustment with polynomial correction)
Power supply
Operating voltage 12 ... 28.8 V DC (minimum 15 V DC for active current output)
Typ. power consumption <1W
Outputs
Measured variables Flow rate and volume at flowing and base conditions, gas velocity, speed of sound
Analog output 4 .. 20 mA; active / passive; electrically isolated; max load = 250 Ω
Pulse and status outputs Passive, electrically isolated, open collector or acc. NAMUR, fmax = 6 kHz (scalable),
pulse width = 0,05 .. 1 s in accordance with NAMUR (EN50227)
Interfaces
MODBUS ASCII and RTU 2 x RS485 for configuration, measured value output and diagnosis
HART® Configuration, measured value output and diagnosis
Ex approval
Europe (ATEX 94/9/EG) II 1/2G EEx de ib [ia] IIA T4 or II 1/2G EEx de ib [ia] IIC T4
Ultrasonic transducers intrinsically safe "ia"
USA / Canada (CSA) Class I, Division 1, Groups D T4; Class I, Division 2, Groups D T4
Class I, Division 1, Groups B,C, D T4; Class I, Division 2, Groups A, B, C, D T4
Ultrasonic transducers intrinsically safe "ia"**
Ambient conditions
Temperature range (ATEX) -40 °C ... +60 °C (-40 °F .. 140 °F)
Storage temperature -40 °C ... +60 °C (-40 °F .. 140 °F)
IP classification IP 67
Relative humidity < 95 %
Tab. 2.7: Technical Data
* Within Qt to Qmax and with straight inlet/outlet section of 10 D/3 D or 5 D/3 D with flow straightener
** Approval for operation of the ultrasonic transducers within zone 0 only valid under atmospheric
conditions (-20 °C ≤ Tmedium ≤ +60 °C; 0.8 bar(a) ≤ pmedium ≤ 1.1 bar(a))))(-4 F ≤ Tmedium ≤ 140 F;
11.6 psi(a) ≤ pmedium ≤ 16 psi(a))
*** Depending on transducer type and meter size, a minimum operating pressure can be neccessary.
Please consult the manufacturer
Warning
When the FLOWSIC600 is used in hazardous areas, compliance with the required type of
explosion protection must be must be addressed during installation (intrinsically safe or
increased safety)!
ATTENTION

Criteria applicable to meter when used in accordance with German PTB specifications
Meter size Min. flow rate Qmin G-class Max. flow rate Qmax Measuring range Meter factor
[m³/h] [m³/h] [pulses/m³]
13 G160 250 1:20 28800
DN 80 (NPS 3) 13 / 20 G250 400 1:30 / 1:20 18000
13 / 20 / 32 G400 * 650 1:50 / 1:30 / 1:20 11100
20 G250 400 1:20 18000
DN 100 (NPS 4) 20 / 32 G400 650 1:30 / 1:20 11100
20 / 32 / 50 G650 * 1000 1:50 / 1:30 / 1:20 7200
32 G400 650 1:20 11100
32 / 50 G650 1000 1:30 / 1:20 7200
DN 150 (NPS 6) 32 / 50 / 80 G1000 1600 1:50 / 1:30 / 1:20 4500
32 G1000 E 2200 1:70 3272
32 / 50 / 80 / 130 G1600 * 2500 1:80 / 1:50 / 1:30 / 1:20 2880
50 G650 1000 1:20 7200
50 / 80 G1000 1600 1:30 / 1:20 4500
DN 200 (NPS 8) 50 / 80 / 130 G1600 2500 1:50 / 1:30 / 1:20 2880
40 G1600 E 3600 1:80 2000
40 / 80 / 130 / 200 G2500 * 4000 1:100 / 1:50 / 1:30 / 1:20 1800
50 / 80 G1000 1600 1:30 / 1:20 4500
50 / 80 / 130 G1600 2500 1:50 / 1:30 / 1:20 2880
DN 250 (NPS
50 / 80 / 130 / 200 G2500 4000 1:80 / 1:50 / 1:30 / 1:20 1800
10)
50 G2500 E 5600 1:100 1285
50 / 130 / 200 /320 G4000 * 6500 1:130 / 1:50 / 1:30 / 1:20 1110
80 / 130 G1600 2500 1:30 / 1:20 2880
DN 300 (NPS 80 / 130 / 200 G2500 4000 1:50 / 1:30 / 1:20 1800
12) 65 / 130 / 200 / 320 G4000 6500 1:100 / 1:50 / 1:30 / 1:20 1110
65 G4000 E 7800 1:120 920
80 G1600 2500 1:30 2880
DN 350 (NPS 80 / 130 / 200 G2500 4000 1:50 / 1:30 / 1:20 1800
14) 80 / 130 / 200 / 320 G4000 6500 1:80 / 1:50 / 1:30 / 1:20 1110
80 G4000 E 7800 1:100 920
130 / 200 G2500 4000 1:30 / 1:20 1800
DN 400 (NPS 130 / 200 / 320 G4000 6500 1:50 / 1:30 / 1:20 1110
16) 120 / 200 / 320 / 500 G6500 10000 1:80 / 1:50 / 1:30 / 1:20 720
120 G6500 E 12000 1:100 600
130 G2500 4000 1:30 1800
DN 450 (NPS 130 / 200 / 320 G4000 6500 1:50 / 1:30 / 1:20 1110
18) 130 / 200 / 320 / 500 G6500 10000 1:80 / 1:50 / 1:30 / 1:20 720
120 G6500 E 12000 1:100 600
200 / 320 G4000 6500 1:30 / 1:20 1110
DN 500 (NPS 200 / 320 / 500 G6500 10000 1:50 / 1:30 / 1:20 720
20) 200 / 320 / 500 / 800 G10000 16000 1:80 / 1:50 / 1:30 / 1:20 450
200 G10000 E 20000 1:100 360
320 / 500 G6500 10000 1:30 / 1:20 720
DN 600 (NPS 320 / 500 / 800 G10000 16000 1:50 / 1:30 / 1:20 450
24) 320 / 500 / 800 / 1300 G16000 25000 1:80 / 1:50 / 1:30 / 1:20 288
320 G16000 E 32000 1:100 225
Tab. 2.8: Meter sizes according to PTB approval
• Any flow rates given above are also valid in the bidirectional mode.
• G-classes marked with an asterisk (*) must only be used in configuration No. 2 (see
Section 5.2.2).
• G-classes marked with an (E) have an extended max. flow rate (max. flow velocity vmax =
36 m/s) related to commonly established turbine meter G-classes
• The transition flow Qt is based on the flow range the meter is designed for according to
the main plate. It is:
for a flow range of 1:20 Qt = 0.20 Qmax and
for a flow range of 1:30 Qt = 0.15 Qmax and
for a flow range of ≥ 1:50 Qt = 0.10 Qmax.

2.3 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 Chapter 3).
SPU
Hoisting eye
Pressure tap
Flange
Cover cap
Position of the ultrasonic transducers

(cover cap taken off)
Marking for direction of
flow (forward) Meter body
Fig. 2.9: FLOWSIC600
2.3.1 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 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 Section 2.2.4).
2.3.2 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 (class "ia").

2.3.3 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 see Section 2.7.3.) 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 (see Fig. 2.10). The values to be
displayed can be selected using a magnetic pen without removal of the front cover (for
details on operation and menu structure see Section 10.2 in the Appendix). The
MEPAFLOW600 CBM software provides a more user-friendly way to display the information.
+V 4 9 9 8 2 0m 3 / h Measured values
- V 0 m3 / h
DATA ENTER STEP C/CE
Control buttons for the magnetic
pen
DATA STEP C/CE

ENTER
Control buttons for manual use
Fig. 2.10: 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 (see Section 5.4.4).
The electronics are mounted in the SPU enclosure certified to EN 50018 or IEC 60079-1
with protection type "d" (flameproof enclosure). The transducer circuits are of an intrinsically
safe design (type "ia").

2.4 Measuring Principle

The FLOWSIC600 operates by measuring the propagation delay of an ultrasonic pulse. It is
equipped with four pairs of identical ultrasonic transducers. The transducer pairs are
integrated in a meter body and arranged opposite one another at a defined angle to the flow
axis, thereby forming a direct measuring path (see Fig. 2.11)
A-A Signal processing unit (SPU)

Meter body
B-B
(Path 1) Ultrasonic transducer
Path 1
Path 2
A
B B
L tAB α
Flow
D
tBA
Path 3 A
Path 4
Ultrasonic transducer B
(standard mounting position)
Fig. 2.11: FLOWSIC600 measuring principle
The ultrasonic pulses cross the meter body from transducer to transducer. With no gas
flowing, the pulses are propagated with the same speed (speed of sound) in both directions.
When a gas is flowing through the meter body, the pulse in the direction of the gas flow is
faster, while the pulse flowing against the flow is slower. This means that the transit time is
shorter in the direction of flow (tAB) and longer against the direction of flow (tBA).
The ultrasonic transducers operate alternately as a transmitter and receiver. Each
transducer is a piezoceramic element that is coupled with a diaphragm. To transmit signals,
an alternating current is applied to the piezoceramic element so that it vibrates mechanically
(piezoelectric effect). These vibrations are then transferred through the diaphragm to the
gas. The vibrations are propagated as acoustic waves in the gas and strike the diaphragm
on the opposite transducer after a propagation time that depends on the speed of sound
and on the gas velocity. The waves are transferred to the piezoceramic element in the form
of mechanical vibrations. They are then converted into an electrical signal by the inverse
piezoelectric effect and used for further signal analysis.
The signals are then processed to calculate the transit times of the acoustic signals through
the flowing medium. The measured values can then be calculated from the transit time thus
determined.

2.4.1 Determining the gas velocity
Measuring cycle
4-path-system → In the operating status ,,Measurement“, the FLOWSIC600 determines the gas velocity on
40 measurements per each path 10 times per second. One measuring cycle consists of a velocity measurement
second per path, the integration of the operating volume, several internal procedures and the
update of the measured value output channels. This cycle takes about 100 ms.
Determining the transit time of the ultrasonic signals

A full analysis of the ultrasonic signals makes it possible to determine the point of time of
signal reception, and thus the delay to the point of time of signal transmission. The signal
propagation times in the flowing gas, tAB and tBA, are determined on the basis of this transit
time.
Sound transit time in the direction of flow tAB:
L
L: Measuring path length tAB =
c: Speed of sound c + vPath · cos α
vPath: Path velocity
Sound transit time against the direction of flow tBA:
α : Angle between the
longitudinal axis of the L
meter body and the path tBA =
c - vPath · cos α
Path velocity
The path velocity (vPath i) is calculated from the difference between the two transit times:
i: Path number 1 ... 4
Li
vPath i:Measuring values vPath i =
2 • cos α i
· ( t1 1
tBA i
)
in the registers AB i
#7507 to #7510
L i: Distance between the two transducer diaphragms.
α i: Register #7101 to
This distance is calculated by subtracting the length of the transducers used (register #7109 to
#7104
#7116 “SensorLength i AB”) from the distance between the transducer seats in the meter body
(register #7105 to #7108 “Length i”).
L i = LMeter body i - (LTransducer A i + LTransducer B i)
Mean path velocity

The most recent 100 measured results (path velocity and measurement status) are stored
in a mean value memory. If no valid path velocity was determined due to a negative
plausibility check, such condition is also stored in the mean value memory. The mean value
memory is organised as a FIFO memory. This means that the most recent entry always
overwrites the oldest one. The mean path velocity vavg i forms the mean value of all valid
measured values stored in the memory.
Σv Path i
all valid values
vavg i =
Nvalid
The percentage of invalid measurements within the last 100 measurements is used as a
quality parameter (register #3008 to #3011 “% Error i”). If the proportion of invalid
measured results exceeds a certain threshold (register #3514 “Limit%Error”, manufacturer
constant = 95 %), the path is not used in the calculation of the flow velocity. In such cases,
a replacement value may be determined for the faulty path in order to compensate for the
failure (see Section 2.8).

Note: In MEPAFLOW600 CBM the reciprocal of the % Error (i.e. % Performance) is displayed.
Flow velocity
The mean value of the weighted sum of all four path velocities is the flowing velocity through
vA: Flow velocity the meter body (register #7004 “AvgVelGas”).
wi: Weighting factor of a:
4
Σw
- measuring path
- Register #7120 to #7123 vA = i · vavg i
“Weight i” i=1
2.4.2 Calculating the volumetric flow rate

The uncorrected volumetric flow rate Qv* is calculated from the flowing velocity vA and the
open cross-sectional area in the meter body‘s measuring section:
D: Internal diameter of the D² · π
meter body, Qv* = vA ·
4
Register #7100
“InnerDiameter” This intermediate result is still dependent on the Reynolds number and the properties of the
flow profile (asymmetry, swirl). It is corrected using the following formula:
Qv = Qv* · (1 + f [Qv* , pabs, CC0...4, PF, K0...5])
Profile factor:
vavg 2 + vavg3
PF =
vavg 1 + vavg4
Fixed gas pressure:

mean pressure in the operating range, register #7041 “Pressure(Fixed)”.
Also see Section 4.2.4 p= pmin · pmax + 1 bar
The sets of factors CC0 to CC4 and K0 to K5 are nominal size-dependent constants which
were determined by the manufacturer and which are related to a particular FLOWSIC600.
Correcting the impact of pressure and temperature on the geometry of the meter body
The geometry parameters of the meter body are based on ambient temperature of 20 °C
and 1 bar(a) and have been optimized to minimize deviations due to the influence of
pressure and temperature. However, there is still an impact of pressure and temperature
on the geometry of the meter body and thus on the measured value. This impact is
corrected as follows:
T: Register #7040 Qv, corr = Qv · (1 + KT · (T – 293.15) + Kp · p)
“Temperature(fixed)“
p: Register #7041
The temperature coefficient KT is material-specific and is 4.12 · 10-5 K-1 for carbon steel
“Pressure(Fixed)“
and 5.23 · 10-5 K-1 for special steel.
KT: Register #7118
“ExpCorrTemperature” The pressure coefficient Kp was determined to be 6 · 10-6 bar-1 .
Kp: Register #7117
“ExpCorrPressure”

Correcting the characteristic ‘‘as found” calibration curve

AFforward: Register #7037 The characteristic ‘‘as found” curve may be corrected using a factor dependent on the
“AdjustFactorForward”; direction of flow (AFforward, AFreverse). In addition, a zero offset (ZO) may be entered.
stand. value 1.0 However, it should have the value 0 on a properly working meter.
AFreverse: Register #7038
“AdjustFactorReverse”; Qv, cal = Qv, corr · AFforward + ZO for a positive direction of flow
stand. value 1.0
ZO: Register #7039
“ZeroFlowOffset”; Qv, cal = Qv, corr · AFreverse + ZO for a negative direction of flow
stand. value 0.0[m³/h]
The calculation of the factors is based on the weighted mean error (WME, equivalent to
OIML recommendation no. 32).
Qi: Checked flow rate n
Σk
Qi
Qmax: Checked maximum i · fi with ki = for Qi ≤ 0.7 Qmax
flow rate Qmax
i=1
fi: Error in % WME =
n
Σk
determined for the Qi
checked flow rate i and ki = 1.4 - for 0.7 Qmax < Qi ≤ Qmax
i=1
Qmax
The corresponding factor is then calculated as follows:

1
AF =
WME
1+
100 %
The result of the volumetric flow calculation is stored in register #7001 “VolumeFlow”.
2.4.3 Calculating the actual volume

The operating volume is calculated from the operating volumetric flow rate Qv, cal by
integration over time of the measuring intervals.
Ts: Measuring interval between Vi = Qv, cal · Ts
two measurements
The total aggregated volume is stored in the operating volume counters for both directions
of flow. The operating volume counters can be reset if the hardware write protections switch
(HW lock) is OFF.
#5010 "ForwardVolume"
#5012 "ReverseVolume"
While the system is in “Error” status, the volumes determined are stored in separate error
volume counters. These counters can be reset. Such a reset is recorded in the Custody
logbook [1] together with date and time stamp.
#5011 "ForwardVolumeErr"
#5013 "ReverseVolumeErr"
The resolution of aggregated volumes per volume unit [m3 or ft3]is defined in register
#5014 “TotalizerResolution”. When reading the volume counters (#5010 to #5013), the
corresponding resolution (see table below) must be considered.
Counter resolution
V = Volume register value · [m³]
1000

Counter resolution (defaults)
Metric Units Imperial Units

Nominal pipe size Register #5014 Resolution Register #5014 Resolution
[1/m³] [m³] [1/ft³] [ft³]
DN 60 (NPS 2)
DN 80 (NPS 3) 10 0.01 100 0.1
DN 100 (NPS 4)
DN 150 (NPS 6)
DN 200 (NPS 8)
1,000 1.0
DN 250 (NPS 10)
100 0.1
DN 300 (NPS 12)
DN 350 (NPS 14)
DN 400 (NPS 16)
DN 450 (NPS 18)
10,000 10
DN 500 (NPS 20) 1,000 1.0
DN 600 (NPS 24)
NPS28 - NPS48 10,000 10
Low flow suppression

If the current flow rate falls below a preset threshold (register #7036 “LowFlowCutOff”), the
calculated volumetric flow is set to zero. The current calculated flow velocity is not affected
by this. The threshold is set to 0.25 Qmin at the factory.
2.4.4 Determining the speed of sound

The actual speed of sound c in the gas at current operating conditions is calculated from the
sum of the two measured propagation times tAB i and tBA i of a path.
L
ci = i •
2
( t1 +
1
tBA i
)
AB i
Σc
1
c= i
4
i=1
A theoretical speed of sound can be derived from the gas composition, pressure and
temperature values. This theoretical speed of sound and the measured speed of sound
should be identical. The speed of sound thus provides an excellent diagnostic measure for
system operation.

2.5 Operating States and Signal Output

The FLOWSIC600 has two operating modes:
• Operation
• Configuration
In the Operation mode the meter can have the following Meter states:
• Measurement
• Check request
• Measurement invalid
2.5.1 Operation and configuration mode

The meter can be operated by the user in two modes: Operation or Configuration. In the
Operation mode, the meter runs in one of the aforementioned three Meter states,
depending on the measuring conditions.
The “Configuration” mode is used to modify parameters and to test the system and output
signals. The digital output “Measurement valid” is deactivated in this 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.
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” screen 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.

2.5.2 Measurement status

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 sign 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.
2.5.3 Check request status

This status becomes active if one measuring path has failed and the adaptive path failure
compensation has been activated (see Section 2.8). 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 warnings 2002, 2003, or
2004 become active (see table under Section 10.3.1 in Appendix).
2.5.4 Measurement invalid

If the quality of received signals is deficient in more than one measuring path, the SPU must
mark the measured value 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” or “Check
request” state.

2.5.5 Pulse output and status information
Pulse output signals can be customized as shown in the following table.
TYPE APPROVAL
Signal behavior
Output signal / LCD / port
Measurement state Check request state Configuration mode Measurement invalid
Pulse Inverted with error
output signal *
signals
Phase Positive
shift 90 ° flow rate
**
Negative
flow rate
Separate Positive
outputs flow rate
for each
direction
**
Negative
flow rate
Single pulse output **
Tab. 2.12: Pulse output
* Default setting on delivery

** Optional setting on customer request
**** 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” screen, also see Section 6.3.4 of this Manual).
The default setting for ‘‘Check request”, ‘‘Configuration” and ‘‘Measurement invalid” is “normally
closed”.

Signal behavior
Output signal / LCD / port
Measurement state Check request state Configuration mode Measurement invalid
“Check request” Status Status “undefined” “undefined”
Status signal “active / inactive” *** “active / inactive” ***
Measurement valid Compensation of path
failure
“Direction of flow” Status Status “undefined” “undefined”
Status signal “active / inactive” *** “active / inactive” ***
Positive or negative Positive or negative
direction of flow direction of flow
“Warning” Status Status “undefined” “undefined”
“active / inactive” *** “active / inactive” ***
LCD display
+V 123456 m³ 1234 m³ FLOWSIC600 +V 123456 m³
-V 1234 m³ Configuration -V 1234 m³
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)
Tab. 2.13: Status output
The output signal designation is described in Section 2.9.1 of this Chapter.

The LCD display is capable of displaying measured values, parameters, messages and other
information (see Section 10.2 of the Appendix in this Manual).
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 Section
10.2.
2.5.6 Battery
The Real Time Clock (RTC) of the FLOWSIC600 is buffered by a battery with a guaranteed
life span of 10 years. Because the FLOWSIC600 has no regular maintenance cycle, after
8.5 years a message will be generated automatically, which forces the operator to change
the battery (see Fig. 2.14). The procedure to change the battery is decribed in the Service
Manual.
Information 1030
LifeSpan Battery
Fig. 2.14: Flashing message, prompts to change the battery
The acknowledging of the message ‘‘LifeSpan Battery” on the LCD display and the reset of
the battery lifetime cycle is described in Section 10.2.6 in the Appendix.
The remaining battery capacity can be viewed on the LCD in the first menu level (see Section
10.2.2 in the Appendix).

2.6 Self-diagnosis
During normal operation, the ratios of sound and path velocities, amplification settings,
performance, and signal-to-noise ratios are continuously monitored. If these values exceed
set thresholds (customized warnings) , a warning signal will be generated. This allows
immediate measures to be taken to address a problem which could potentially impact
measurement quality.
During commissioning or operation, the signal thresholds can be adapted to suit individual
application requirements. This allows the status warning system to be optimized (see
Section 6.3.5.)
Note: The "Warning" status signal does not affect the functionality of the meter.
Warning
Parameter Threshold Notes
message
Speed of 1.5 % Warning SOS This message will be produced if the current measured path sound velocity
sound (at Deviation deviates from the average value of the mean sound velocities calculated for all the
VOG > 1m/s paths by more than the specified threshold value.
respectively The current flowing gas velocity is used as a weighting factor, so that temperature
VOG > 3.28 ft/s) stratification is disregarded at very low flow velocities.
Used to indicate whether or not the path is measuring the correct transit time.
Note:
When setting the parameter, take into account plausible conditions for normal
operation (in particular temperature stratification).
Signal 9 dB Warning AGC The absolute difference between both path gain factors is evaluated and must
amplification Deviation remain below the threshold value.
Caution
High flow velocities may also increase the difference in gain.
93 dB Warning AGC The absolute value of the reception gain is monitored.
Limit Caution
The current reception sensitivity largely depends on the current process pressure
(inversely proportional in initial approximation, that is, if the pressure doubles, the
required reception sensitivity will be halved).
If one of the alarms is triggered by a path, this can indicate a malfunction in the
ultrasonic transducers, electronic modules, transducer cables or parameter
settings (signal models, control thresholds).
Signal-to-noise 15 dB Warning SNR This alarm will be activated if the signal-to-noise ratio becomes too small.
ratio Possible causes for this include interfering noise caused by fittings in the pipeline,
valves that are not fully open, sources of noise near the measuring location, or
defective ultrasonic transducers.
Additional signal and system diagnostic functions monitor the reliability of the measured
values, by checking the plausibility of the ultrasonic signals received and the transit times
calculated from them.
Important diagnostic information with respect to flow profile is given by the following values:
v2 + v3
Profile = -------------------
⎫ v1 + v4
v1 ⎪
v2 ⎪ v1 + v2
⎬PathVelocities Symmetry = -------------------
v3 ⎪ v3 + v4
v4 ⎪
⎭ v1 + v3
Swirl = -------------------
v2 + v4
2
δ ( V pathi )
Disturbance = ------------------------------
V avgi

2.7 Data Handling with MEPAFLOW600 CBM

Most data provided by the FLOWSIC600 (like readings, logbook entries and parameters)
can be accessed via the LCD display of the meter (see Section 10.2 in the Appendix of this
Manual). However, the MEPAFLOW600 CBM software provides a more user friendly access
to diagnostic, configuration and measurement data of the flow meter (overview of software
features in Section 3.1. of this Manual).
Meter database
MEPAFLOW600 CBM stores all relevant changes to parameters, and all records and reports
generated for the individual meter in a meter database. The meter database can be
accessed from MEPAFLOW600 CBM via the ‘‘Connect / Disconnect” screen, and then the
‘‘Meter explorer” (see Fig. 2.15) or the ‘‘Report manager”.
The ‘‘Meter explorer” allows the import and export of meter database files and sessions
(see below) as well as the creation of database entries for new meters.
Meter data
Meter data are data that are stored in relation to the meters which are to be monitored with
MEPAFLOW600 CBM. For each meter, a meter data set and an entry is created in the meter
database. A meter data set consists of a master data set and an unlimited number of
session entries and event entries.
Master data set

The master data set is the set of data that identifies a particular meter in the meter
database. This master data set can be created offline, which makes it possible to prepare
for the commissioning of a meter before actually connecting with it.
Session
A session is the period of activity between connecting to and disconnecting from a meter.
Sessions can pertain to online or offline connections. A session is opened upon connecting
(online or offline) to a meter. When the connection is closed, the session ends and the user
has the opportunity to write a short description to explain what happend during the session.
This description is saved in the session entry in the meter database together with the start
and end time stamp of the session as well as the connection type (online / offline).
Session entry
To document all relevant changes pertaining to the meters in the meter database, session
entries are written and stored in a table in relation to the meter to which they apply. All
session entries can be accessed and organized via the ‘‘Meter explorer” screen. Session
entries can be imported and exported to a session file via the ‘‘Meter explorer”.
A session entry can contain an unlimited number of event entries and contains at least one
parameter set.
Note: A session entry is saved to the meter database after the end of the session only if any
relevant events (changes or actions) took place during the session.

Session file
When a session is exported, a session file is generated which contains all data pertaining to
the meter with which it was created and all event entries in relation to the session. It can be
saved to the hard disk, transferred (e.g. via e-mail) and imported to another meter database.
Event entry
An event entry is an entry that documents an important event that occurred during a
session. It is saved in relation to this session and can be viewed and accessed via the
‘‘Meter explorer” screen. A session entry can contain the following event entries:
Event entry Description

Time stamp (begin / Time stamps are written at the beginning and end of each session.
end)
Last parameter set The parameter set documents the parameter settings at the end of the
session. This entry is written when the session is opened, is kept up to
date during the session and is closed when the session is ended.
Parameter change Every change of any parameter is documented with the name of the
parameter, its old value and its new value.
Operating mode change Whenever the meter is switched from configuration mode to
measurement mode or vice versa, the change is documented.
Unit switch Imperial Every change made to the unit system settings is documented.
Units / Metric Units
Measurement record Every measurement record created by the user is saved and can be
accessed (played, exported or deleted) from the Meter explorer if the
software is in an online or offline connection with the particular meter.
For more detail see Section 2.7.5 on the Data recorder.
Maintenance report Every maintenance report created by the user is saved and can be
accessed (printed, exported or deleted) from the Meter explorer.
Error volume counter Every reset of the error volume counters is documented.
reset
Event entries contain the event type, the name of the event (relevant for records, reports
and parameter changes), a time stamp and a description of the event.

Event entry in opened session

Session entry of the current session
Meter entries, selected meter is marked
Fig. 2.15: ‘‘Meter explorer” with meter entries, session entries and event entries; one session is
opened

2.7.1 Time Synchronization

All entries in logbooks or datalogs saved in the meter‘s memory (FRAM) are written with a
time stamp containing the meter time. The meter time can be synchronized with a master
clock (e.g. PC clock) via Modbus or with MEPAFLOW600 CBM.
Note: A synchronization causes a logbook entry in the Custody logbook [1] only if the time change
is greater than 3% of the time elapsed since the last synchronization.
Synchronization via Modbus

The date and the time of the FLOWSIC600 can be set separately by an external write. Each
operation for date and time causes a separate entry in the Custody logbook [1].
Alternatively the synchronization function can be used. To use this method, the date register
(#5007) and the time register (#5008) have to be written sequentially within 2 seconds.
The date register (#5007) has to be written first. The write operation can be accomplished
by the Modbus without setting the FLOWSIC600 into configuration mode.
Time synchronization via MEPAFLOW600 CBM

MEPAFLOW600 CBM offers a synchronization function via a button in the "Meter
Information" screen (see Fig. 2.16). The button is marked with a yellow sign calling attention
to the synchronization if the time difference between the meter clock and the PC clock is
greater than 30 seconds.
Fig. 2.16: Synchronization button and meter clock synchronization window

2.7.2 Integrated Volume Counters

The FLOWSIC600 is equipped with integrated volume counters which can be displayed both
on the LCD display and in MEPAFLOW600 CBM.
Integrated volume counters
Volume Counter Abbreviation

Volume at flowing conditions (forward) +Vf
Volume at flowing conditions (reverse) - Vf
Error volume at flowing conditions (forward) +Ef
Error volume at flowing conditions (reverse) -Ef
Total volume at flowing conditions (forward) +Vo
Total volume at flowing conditions (reverse) -Vo
Additional volume counters in meters with integrated electronic volume corrector
Volume Counter Abbreviation

Volume at base conditions (forward) +Vb
Volume at base conditions (reverse) - Vb
Error volume at base conditions (forward) +Eb
Error volume at base conditions (reverse) - Eb
Error volume counters can be reset (User Access Level ‘‘Authorized operator”). See Section
10.2.5 in the Appendix. The value of the error volume counter at the time of reset is stored
in a logbook entry.

2.7.3 Logbooks
Important system events are stored in logbooks in the SPU memory of the meter. Each
logbook entry consists of a running index number, the event, a time stamp and (in Custody
logbook [1] and Warning logbook [2]) the volume counter readings valid at that time, along
with acknowledgement status. The events are logged continuously in order of occurence
into one of the three logbooks:
• Logbook 1 (Custody logbook [1], max. 1000 entries)
• Logbook 2 (Warning logbook [2], max. 500 entries)
• Logbook 3 (Parameter logbook [3], max. 250 entries)
Every logbook has it‘s own index counter. Logbook entries are on the LCD display classified
according to the event type.
Event types in LCD display
Display Event type

E Error
W Warning
I Information
All possible logbook entries are listed in chart ‘Overview of event entries‘ in the Appendix,
see Section 10.3.1

Saving Logbook Entries In MEPAFLOW600 CBM

To prevent an overflow of the logbooks and possible data loss, logbook entries can be
saved to a device database via the MEPAFLOW600 CMB software.
Logbook queries provide information on the number of registered events and the remaining
memory space. The logbook entries are classified as follows:
• Active events
• Inactive acknowledged and unacknowledged events
• Acknowledged events
Fig. 2.17: Logbooks screen in MEPAFLOW600 CBM

Logbook Overflow
If a FLOWSIC600 is configured as a custody meter, the counter stops if Custody logbook [1]
is full. The measured values are now filed in the error volume counter. If the FLOWSIC600
is not configured as a custody meter, the index number in Custody logbook [1] continues
increasing, and every new entry overwrites the oldest entry, as in Warning logbook [2] and
Parameter logbook [3].
Note: If the logbook overflows, the oldest data will be lost. Regular saving of logbook entries to the
database via MEPAFLOW600 CBM and deletion of entries on the meter itself prevents data
loss. If entries are deleted via MEPAFLOW600 CBM, the index counter on the meter is reset.
Index Counter Overflow

The index number displayed in the LCD display runs up to 9999 and then overflows. In
case of an index overflow, all logbook entries are deleted and all index counters reset.
Acknowledging Entries
Each entry can be acknowledged manually on the LCD display as well as in MEPAFLOW600
CBM. It is possible to acknowledge individual entries or all entries at once.
Firmware Update
If the firmware is updated to version 3.2.00 and higher, the old logbook is deleted and three
new logbooks are created. Thus it is recommended to save the session file prior to updating
ATTENTION the firmware.

2.7.4 DataLogs
Starting with firmware version 3.2.00, the FLOWSIC600 provides three individually
configurable DataLogs: DataLog 1, DataLog 2 and DataLog 3. The mean measured values
taken over a configurable period, are stored in the DataLogs in the SPU‘s non-volatile
memory (FRAM).
The DataLog‘s functions are determined by five parameters, which have to be configured by
the user:
• DataLog mode
• Type of Dataset
• Number of datasets
• Averaging period
• Storage mode
Parameter ‘DataLog Mode‘

The parameter ‘DataLog Mode‘ can be set to ‘Measuring‘ or ‘Diagnosis‘.
‘Measuring‘
If the DataLog mode is set to ‘Measuring‘, the mean values of the measuring values will be
saved into the DataLog after the configured time (e.g. a period of 30 min., 1 h, 1 day) has
elapsed.
‘Diagnosis‘
The DataLog mode ‘Diagnosis‘ provides a comparison between diagnostic values of the
current meter status (today) with those of a reference status (e.g. at time of commissioning).
In diagnostic mode only the dataset ‘Diagnostic Values‘ can be selected. The diagnostic
values are filed dependent on the gas velocity in five velocity range classes.
Reference values are diagnostic data for example collected at commissioning (start-up) of
the meter. They are filed in the classes 0 to 4. The operation of the measurement facility
has to be adapted, so that the meter is able to fill all classes. If a reference class is filled with
a valid dataset, the next dataset is filed into the same velocity range but in the
corresponding current class (class 5 to 9).
During operation, the classes 5 to 9 are constantly overwritten with new datasets, the
classes 0 to 4 stay unchanged. New reference values can only be filed after the diagnostic
datasets of the reference classes have been deleted. Deletion is done with the
MEPAFLOW600 CBM software.
Reference Classes Current Classes

Metric 1 .. 3 3 .. 7 7 .. 15 15 ..31 31 .. 80 1 .. 3 3 .. 7 7 .. 15 15 .. 31 31 .. 80
Velocity m/s m/s m/s m/s m/s m/s m/s m/s m/s m/s
Range Imperial 3 .. 10 ft/ 10 .. 23 23 .. 49 49 .. 102 102 .. 3 .. 10 ft/ 10 .. 23 23 .. 49 49 .. 102 102 ..
s ft/s ft/s ft/s 262 ft/s s ft/s ft/s ft/s 262 ft/s
Classes 0 1 2 3 4 5 6 7 8 9
Tab. 2.18: Velocity range classes
Note: For the systematic filling of the classes, the following has to be considered: Only valid
diagnostic values can be saved into the classes. Diagnostic values are invalid if just one
individual velocity measurement value within the averaging period oversteps the class range
borders. Therefore the set gas velocities should be well within the class range borders.

Parameter ‘Type of Dataset‘

There are three predefined types of datasets - ‘Diagnostic Values‘, ‘Volume Counters‘ and
‘Standard Volume Counters‘ - which can be stored according to DataLog Mode ‘Measuring‘-
or ‘Diagnostic‘ mode. The dataset type ‘Diagnostic Values‘ is intended for diagnostic
purposes. Nevertheless it can also be saved in measuring mode. The dataset types ‘Volume
Counters‘ and ‘Standard Volume Counters‘ are intended for use in measuring mode.
The meter status is saved in all types of datasets. The meter status message works
cumulative. If a bit became active during the averaging period, it stays active until the end
of the time span, even if the event is not active any more.
Data Set Type ‘Diagnostic Values‘
Metric Imperial
Measurand Unit Range Unit Range
Avg VOG m/s 0..±327.67 ft/s 0..± 1075.03
Avg SOS m/s 0..655.35 ft/s 0..± 2150.09
Profile - 0..65.535 - 0..65.535
Symmetry - 0..65.535 - 0..65.535
Meter Status - - - -
Performance [1..4] % 0..255 % 0..255
Turbulence [1..4] % 0..25.5 % 0..25.5
VOG [1..4] m/s 0..±327.67 ft/s 0..±1075.03
SOS [1..4] m/s 0..655.35 ft/s 0..±2150.09
SNR [1..4] dB 0..255 dB 0..255
AGC [1..4] dB 0..255 dB 0..255
σ VOG (VOG_stdev) m/s 0..25.5 ft/s 83.66
Time Stamp Sec - Sec -
Size of one data set = 48 byte
Data Set Type ‘Volume Counters‘
Metric Imperial
Total Volume +Vo m3 0..999,999,999 ft³ 0..999,999,999
Total Volume -Vo m3 0..999,999,999 ft³ 0..999,999,999
Volume +Vf m3 0..999,999,999 ft³ 0..999,999,999
Volume -Vf m3 0..999,999,999 ft³ 0..999,999,999
Valid Data Time % 0..100.00 % 0..100.00
Avg Performance % 0..100 % 0..100

Data Set Type ‘Standard Volume Counters‘
Metric Imperial
Total Volume +Vo m3 0..999,999,999 ft³ 0..999,999,999
Total Volume -Vo m3 0..999,999,999 ft³ 0..999,999,999
Volume +Vb m3 0..999,999,999 ft³ 0..999,999,999
Volume -Vb m3 0..999,999,999 ft³ 0..999,999,999
Valid Data Time % 0..100 % 0..100
Avg Performance % 0..100 % 0..100
Pressure bar 0..655.35 psi 0..9505.05
Temperature C 0..±327 F 0..±621.81
Compressibility - 0..6 - 0..6
Meter Status
Bit Description
0 System rebooted
1 Reading invalid
2 Configuration mode aktive
3 Maintenance required
4 Error Path 1
5 Error Path 2
6 Error Path 3
7 Error Path 4
8 User warning limit exceeded
9 Limit low battery
10 Max. VOG exceeded
11 Max. pulse frequency exceeded
12 Logbook 1 or 2 full of unacknowledged
entries
13 Logbook 1 or 2 unacknowledged entry
14 not used
15 not used

Parameter ‘Number of Datasets‘

Depending on the intention of the data recording, the number of required datasets in the
DataLogs has to be set in the parameter ‘Number of Datasets‘. When setting the number
of datasets, the resulting memory size of the chosen DataLog has to be considered. All three
DataLogs share a total log memory of 64 kBytes.
Example: DataLog 1 with the dataset type ‘Diagnostic Values‘ in DataLog mode ‘Diagnosis‘ with 10
datasets at 48 byte uses 480 byte of memory (10*48 byte = 480 byte).
DataLog 2 with the dataset type ‘Volume Counters‘ in DataLog mode ‘Measuring‘ and
1,000 datasets at 26 byte uses 26,000 byte of memory (1,000* 26 byte = 26,000 byte).
DataLog 3 with the dataset type ‘Standard Volume Counters‘ in DataLog mode ‘Measuring‘
and 730 datasets at 48 byte uses 35,040 byte of memory (730*48 = 35,040 byte).
If the averaging time of DataLog 2 is set to 1 hour and the averaging time of DataLog 3 is
set to 1 day, then in addition to the diagnostic values in datalog 1, the hourly averaging value
across 41 days and a daily averaging value of the past 2 years can be saved.
This example uses 61,520 byte of total log memory.
Parameter ‘Averaging Period‘

The averaging period determines, across what period of time the measuring values of the
chosen dataset type will be averaged. A reasonable averaging time is e.g. 1 hour or 1 day
for the dataset types ‘Volume Counters‘ or ‘Standard Volume Counters‘ in datalog mode
‘Measuring‘. For diagnostic purposes shorter averaging periods can be reasonable. Data is
collected and averaged accross the given averaging time.
Parameter ‘Storage Mode‘

The parameter ‘Storage Mode‘ can be set to ‘Overflow‘ or ‘Stop‘.
If the number of datasets for the chosen datalog is reached, the storage mode ‘Overflow‘
causes the most recent measuring value to overwrite the oldest dataset. In storage mode
‘Stop‘, the recording of new datasets is stopped. A message is created and written to
Warning logbook [2].

2.7.5 Data Recorder

The Data recorder can be started from any page or wizard of MEPAFLOW600 CBM. After it
is started by selecting ‘‘Data recorder” in the Key navigation, it will float above any other
content (see Fig. 2.19) and can be used to record measured data or playback previously
recorded data anytime.
Fig. 2.19: Data recorder floating above the ‘‘Meter information” page
Recording
The Data recorder can record live data, cached data or a combination of both according to
the user‘s choice of options (see below). It can export or playback the record and offers
playback functionality like stopping, pausing, or going back and forward.
Playback
Setup and start recording
Export record to file
List of all records available for playback and export
Fig. 2.20: Data recorder with details

Recording Options
Options available for recording (see Fig. 2.21)
Option Description
Record name Specify a record name and a record description (optional).
Record description (optional)
Storage cycle Frequency for storing records (1 sec .. 1h, or real time)
Stop after Recording stops after set time or after manual stop.
Multi - Run Log File Valuable setting when running sequential tests. It allows for a
manual ‘stop and go‘ of the recording. Makes sequential logfile
naming simple.
Include data of history (cache) Includes the data stored in the cache (historical data). See "Paths
/ Memory" tab in the "Program settings" to set maximum period,
for which the cache is saved.
Fig. 2.21: Data recorder setup window
Playback
The playback of a recording works similar to a video recorder. To playback a recording,
choose the program page displaying the readings or the graphs you want to observe,
choose a record from the list of available records (see Fig. 2.20) and start the playback.
While the record is played, the charts and graphs show the recorded data.
Notes: • The playback feeds the recorded data to the software‘s framework so that all charts and
graphs display the recorded values, not the live data from a connected meter.
• The ‘‘Data recorder” records all data except for the signal waveforms. If you want to
record the signal waveforms in addition to the other records, go to the "Path diagnosis"
page, where the signal waveforms are displayed and click the ‘‘Record signal” button.
• A diagnosis session with all relevant data recorded (including the signal) can be created
vial the menu ‘‘Tools / Diagnosis Session”.
Export
The recorded data can be exported to a Excel file (.xls) for further handling.

2.7.6 Backup
To ensure that a computer problem will not result in data loss, a frequent backup of the
MEPAFLOW600 CBM database file is highly recommended. This database file includes all
meter data.
The database file ‘‘DATABASE.FDB” is created during the installation process and stored in
the file path you specified for the software installation. Default storage path is:
‘‘C:\programs\SICK\MEPAFLOW600 CBM”.
Note: A copy of this file should be created on a regular basis and should be stored in a safe place
(e.g. a CD-ROM).
To restore a backup after a system crash, repeat the installation routine and then overwrite
the newly created ‘‘DATABASE.FDB” with the backup.

2.8 Path Failure Compensation

A 4-path FLOWSIC600 is able to compensate for the failure of one, to a maximum of two
paths using a static or an adaptive compensation routine. Path failure may be caused by an
invalid signal, the AGC level exceeding the limit and/ or problems in processing received
TYPE APPROVAL signals in the DSP.
The measured value of the failed path is substituted with a calculated replacement value.
This replacement value is calculated on the basis of the current valid values measured in
other paths and the relationship of gas velocities between the individual paths. The
relationship between the paths for valid measurements is defined by the individual flow
profile value in the installation. This relationship is continuously calculated and saved during
undisturbed measurement operation.
Field studies have shown that it makes sense to distinguish between two regions (low
velocity and high velocity). The relationship of gas velocities between the paths is stored
separately for each of these two regions.
It is recommended that teh relationships of the paths be determined during the
commissioning procedure, because they are different in each individual installation
configuration (see Chapter 6 of this Manual).
Determination of path relationships

During normal operation, the individual path relationship PPath is calculated continuously.
vPath i
PPath i = (1)
vA: Mean area vA
velocity
N: Number of measuring The mean area velocity is calculated as follows:
paths N
Σw
1
wi: Weighting factor of a vA = i · vPath i (2)
measuring path N
i=1
These relationships are used in an adaptive mean value calculation routine for each
individual path. Statistical variation caused by turbulence is sufficiently suppressed with the
help of this mean value calculation. This algorithm further allows the measuring system to
adapt to different flow profiles caused by changing operational conditions.
After starting the system, the average path relationship values are calculated on the basis
of at least 10,000 single measurements. To collect that number of data, the FLOWSIC600
needs about 20 minutes of error free measurement at all paths.
Example: The FLOWSIC600 makes 10 readings per second and path, thus 6,000 readings in 10
minutes, and 10,200 in 17 minutes.
Because the path compensation procedure operates in a low (1 to 8 m/s) (3.28 to 26.24
ft/s) and a high (>8 m/s) (>26.25 ft/s) gas velocity band separately, the FLOWSIC600
needs to measure 20 minutes within the low and 20 minutes within high velocity range.
When the average path relationships have been established based on the required
minimum number of single readings, the path relationships are marked valid
(‘‘PathCompValid” register #5009 is set to ‘‘valid”), and the system is now able to
compensate for path failure.

The variable mean value calculation is turned on at the same time. The default attenuation
constant for this self-learning algorithm (Register #7206 “PathCompAverWeight”) ensures
that statistical variation is suppressed.
The mean values for low (1-8 m/s) )(3.28 to 26.25 ft/s) and high flow velocities (> 8 m/s)
(>26.25 ft/s) are determined separately (see table below). This improves the result of the
compensation because the path relationships are more stable at higher flow velocities. The
path relationships are not learned below 1 m/s.
Flow velocity
(absolute Parameter Description Notes
value)
< 1 m/s No path relation adaption
<3.28 ft/s In case of failure, the stored path relations for
low flow velocities (1-8 m/s) are used.
1 ... 8 m/s #7208 PathCompClassLo Continuous calculation and adaption of the
3.28 … 26.25 path relations
ft/s The results are saved in the “low flow”
class registers #7289 - #7292 (path 1-4).
> 8 m/s #7207 PathCompClassHi Continuous calculation and adaption of the
> 26.25 ft/s path relations
The results are saved in the “high flow”
class registers #7285 - #7288 (path 1-4).
Adaptive compensation of one or more path failures

If the self-diagnosis routine implemented in the system detects a path failure, the velocity
value for the failed path will not be used for the calculation of the mean area velocity vA
(Equation 2). If this occurs, the following formula will be used to calculate the mean area
velocity based on the applicable measured values for the remaining paths and the stored
adapted path relations.
Σ
bi: Status bit for path i vPath i
bi · w i ·
bi = O: Path inactive PPath i
i=1
bi = 1: Path active vA =
N
i=1
Σb i· wi
The system indicates that a path failure is being compensated with the "Check request"
signal. An additional measurement uncertainty of up to 0.35 % has to be accepted with four-
path systems when operating in this mode. The volume measured during that time is stored
in the normal volume counters for each flow direction.
Multiple path failure is also compensated using the principle described above, but the
system indicates this status with the "Measurement invalid" signal. The volume measured
during that time is stored in separate error volume counters for each flow direction. This
enables gas quantities transported to be determined despite an increased measurement
uncertainty.

Static compensation of one or more path failures

If the adaptive path compensation routine is turned off, static path relations as shown in the
table below are used for path failure compensation. These static values are based on data
of several installations.
Number of
Path no. 1 Path no. 2 Path no. 3 Path no. 4
paths
2 1.000 1.000
4 0.915 1.030 1.030 0.915
The system indicates this status with the "Measurement invalid" signal. The volume
measured during that time is stored in separate error volume counters for each flow
direction. This enables the gas quantities transported to be determined despite an
increased measurement uncertainty.
Note: In order to ensure that the system is able to compensate for path failure at both high and
low flow velocities, it is recommended to run the FLOWSIC600 meter for 30 minutes at low
gas velocities (< 8 m/s) (< 26.25 ft/s) first and then for 30 minutes at high gas velocities
(> 8 m/s) (> 26.25 ft/s) during commissioning.
Deactivation of the adaptive path failure compensation

If path failure compensation is not required, the calculation of the path relations can be
suppressed by setting the attenuation constant (register #7206) to zero (see Fig. 2.22). In
that case, only the static compensation described for single or multiple path failure will be
active.
Fig. 2.22: MEPAFLOW600 CBM, ‘‘Parameters” page, register #7206 (PathCompAverWeight)

2.9 Configuration
2.9.1 Hardware variants and signal outputs (I/O configuration)

The output channels of the FLOWSIC600 can be configured in several ways. Different output
configurations require different hardware variants of the electronic unit. .
Hardware variant/output configuration

Terminal
1/1 1/2 1/3 2/4 * 2/5 ** 3/6 *** 4/7
31/32 Pulse Pulse Status Analog Analog p, T Sensor HART Analog
33/34 RS485 RS485 RS485 RS485 RS485 RS485 RS485
51/52 Pulse Pulse Pulse Pulse Status Pulse Pulse
41/42 Status Status Status Status Status Status Status
81/82 Status RS485 Status Status Status Status RS485
Tab. 2.23: Hardware variant / output configuration
* Can be used for HART® communication. Can be used for operation with integrated EVC
when P and T transmitters are powered externally. (For more detail consult the
‘‘HART®specification”.)
** Can be used for HART® communication. (For more detail consult the
‘‘HART®specification”.)
*** Can be used for operation with integrated EVC when P and T transmitters are powered
by FLOWSIC600
Fig. 2.24: Terminals in the FLOWSIC600 signal processing unit (cover opened)

The following settings can be assigned to the four available physical outputs (the pure
RS485 MODBUS communication port 33/34 is not considered as an output). The settings
can be configured on the ‘‘Parameters” page and in the ‘‘Field setup” wizard of the
Digital Output Possible Settings

Output DO0 (31/32) Pulse, error, warning, flow direction, check request
AO output 4 .. 20mA or 4 .. 20mA with serial HART ®
(33/34) RS485 (fixed)*
Output DO1 (51/52) Pulse, error, warning, flow direction, check request
Output DO2 (41/42) Error, warning, flow direction, check request
Output DO3 (81/82) Communication port RS485 MODBUS
Error, warning, flow direction, check request, encoder**
* For more detail on RS485, see document ‘‘Modbus specification”.

** For more detail on the encoder option, see document ‘‘ENCODER specification”.
Wiring of digital outputs

The digital output (terminals 31/32, 51/52, 41/42, 81/82) can be wired as Open Collector
or as NAMUR contact for connection to a NAMUR amplifier.
The outputs are wired to “NAMUR” on delivery, unless “Open Collector” was specified in the
purchase order.
Open Collector
US Imax = 100 mA
US - 2 V US - 2 V
RL ≤ RL ≤
0.1 A 0.01 A
NAMUR
1k +8.2 V DC
10 k
1k 0V
Fig. 2.25: Wiring of digital outputs

ENCODER output
This output is configured to transmit:
• the total volume Vo according to the data protocol of the german DSfG-work group
‘‘Primärgeräte mit digitaler Schnittstelle”
• identification of the flow meter
• status information of the flow meter.
Therefore there are two protocols: The ‘‘Counter” and the ‘‘Type sign” protocol (see
document ‘‘ENCODER specification”). The ‘‘Counter” protocol ist transmitted every 0.5
seconds, the ‘‘Type sign” protocol after every 100 transmitted ‘‘Counter” protocols (every
50 seconds).
The digital outputs DO3 can become ENCODER outputs (Register 5101).
Note: The number of significant digits can be configured within a range of 1 .. 14 (Register 3033).
The total volume counter is transmitted every half second as ASCII string as follows:
Baud rate 2400
Data bits 7
Parity even
Stop bits 1
The electrical connection of the ENCODER output can only be implemented according to the
NAMUR regulation EN60947-5-5 (Fig. 2.25).
For more detail on the ENCODER protocol consult the document ‘‘ENCODER specification”.

2.9.2 System configuration with external electronic volume corrector (EVC)

Depending on individual requirements exists a wide range of variants to integrate the
FLOWSIC600 into a gas facility. Fig. 2.26 shows a basic configuration.
Gas volume at
Real gas factor Z Electronic Volume base conditions
Corrector (EVC) / Energy content
Flow computer (FC)
Calorific value Hs
Gas volume at flowing conditions Pressure Temperature
RS485 / MODBUS
Service PC / higher-
level control system
12 ... 24 V DC (Ex i isolating transformer only required
for intrinsically safe installation)
Safe area
Hazardous area
FLOWSIC600
Fig. 2.26: FLOWSIC600 connection diagram

2.9.3 System configuration with integrated electronic volume corrector (EVC)
2.9.3.1 General
Application description
The functions utilized by the integrated electronic volume corrector have been incorporated
into the FLOWSIC60 firmware as software function modules. The EVC calculates a corrected
or base volume (Vb reference conditions) from the measured actual flow, pressure and tem-
perature. The output of the corrected volume (Vb) is available as a displayed value on the
LCD display, as a MODBUS register value and as a pulse output.
The calculation methodology for determination of the compressibility is based on the SGERG
method and is applicable up to a pressure of 100 bar (1450 psi).
Limitation of use
When using the FLOWSIC600 with the integrated EVC, the flow computer normally required
to standardize the volumetric flow, may in same cases not be required.
The integrated EVC is not intended or approved for custody applications (fiscal metering).
Requirements
The use of the FLOWSIC600 with integrated EVC requires the following software and firm-
ware releases:
• Firmware: 3.0.00 or higher
• MEPAFLOW600: 3.X.XX or higher
• MEPAFLOW600 CBM: All versions

Calculation schematic
Fig. 2.27: Schematic diagram
The following formula is used to calculate the normalized volume:
Vb Volume at base conditions (normalized)

Pf ⋅ T∅ 1 Vf Volume at flowing conditions
Vb =Vf ⋅ P∅ Reference pressure
P ∅ ⋅ Tf K Pf Actual pressure
T∅ Reference temperature
Tf Actual temperature
K Compressibility according to DVGW G486 SGERG
2.9.3.2 Assembly / Installation

The meter is installed in the same way as a standard FLOWSIC600 without the EVC (see
Chapter 5). To facilitate the added functionality of the EVC, pressure and temperature trans-
mitters will need to be installed and wired to the SPU.

2.9.3.3 Measurement of pressure and temperature

The analog output of the meter is used as an input of the pressure and temperature signals.
The HART protocol is modulated onto this analog signal so that the measured values may
be queried by the gas flow meter (with EVC) in a fixed cycle. In order to realize pressure and
temperature sensing, HART®-capable transmitters must be used.
Electrical connection
There are two different wiring variants for the use of the integrated EVC. In wiring variant 1
the power for the pressure- and temperature transmitters is supplied by the FLOWSIC600
(see Fig. 2.28). Therefor the FLOWSIC600 has to be equipped with the I/O configuration
‘3/6‘ (see Tab. 2.23:Hardware variant / output configuration).
In wiring variant 2 pressure- and temperature transmitters are supplied by an external power
supply (see Fig. 2.29). Here the I/O configuration ‘2/4‘ has to be chosen.
Important
If meter and transmitter are operated in hazardous area, the corresponding Ex-relevant
safety regulations and the Ex-approval of the used devices have to be regarded. Notably
ATTENTION may - in case of a failure - the short circuit current of the FLOWSIC600 exceed the maximal
accepted current of the transmitter.

1 (+)
Power supply FLOWSIC600 2 (-)
FLOWSIC600
31 I/O Configuration : 3/6
AO0 : active
32
+ +
Terminal strip, 10 pole

Temperature Pressure 33
RS485
Transmitter Transmitter 34
- -
51
Pulse
52
41
Status
42
81
Status
82
Fig. 2.28: Wiring variant 1: FLOWSIC600 with integrated EVC, internally powered P and T transmitter
Note: Only the listed transmitters may be used for wiring variant 1.
1 (+)
Power supply FLOWSIC600 2 (-)
FLOWSIC600
31 I/O Configuration : 2/4
AO0 : passive
32
+ + +
Terminal strip, 10 pole

Power Sypply for Temperature Pressure 33
RS485
P & T transmitters Transmitter Transmitter 34
- - -
51
Pulse
52
41
Status
42
81
Status
82
Fig. 2.29: Wiring variant 2: FLOWSIC600 with integrated EVC, externally powered P and T transmitter
Note: The Rosemount and ABB transducers listed below may be used for wiring variant 2.
Important
In this configuration with EVC, the analog I/O is used as input for the pressure and
temperature transmitters. As such the analog I/O is not available as a standard output. To
ATTENTION obtain an analog output signal, an additional module may be used for frequency/analog
conversion (Pepperl & Fuchs - KFD3 - UFC- Ex1.D), with internal Ex-barriers, analog and
frequency output.
The design and wiring of the transmitters can be intrinsically safe, Ex i as well as with in-
creased safety, Ex e. When Ex i transmitters are connected, all other wiring in the terminal
compartment must also be done according to EEx i.
The cable used between power supply and transducers (wiring variant 2) must be a shielded
and twisted pair type. The shield may only be grounded on one cable side. The loop
resistance must be ≤ 250Ω

Tested pressure transmitters for variant 1 and 2

• Manufacturer: Fisher Rosemount
Type: 3051 CA, HART®‚ capable
3051 T, HART® capable
• Manufacturer: ABB
Type: 264 GS, HART® capable
26565, HART® capable
Tested temperature transmitters for variant 1 and 2

• Manufacturer: Fisher Rosemount
Type: 644H A, HART® capable
648H , HART® capable
Tested temperature transmitters for variant 2 only

• Manufacturer: ABB
Type: TH01 - Ex, HART® capable
TTH300, HART® capable
Tested power supplies for P & T transmitters

• Manufacturer: Turck
Type: IM33- 11 ExHi / 24 VDC
Tested analog / frequency transmitter

• Manufacturer: Pepperl & Fuchs
Type: KDF3 - UFC - Ex1.D
Important:
If a customer wants to use other transducers, it is recommended to test these transmitters
at SICK together with the FLOWSIC600 before shipment (additional costs have to be
ATTENTION expected).

2.9.3.4 Configuration of the EVC

The MEPAFLOW600 CBM software supplied with the meter is used for the set-up and con-
figuration of the EVC. The software should be operated in user access level ’’Service’’ with
the password ‘‘expert” (Menu File/Password). Basic settings are done whithin the ‘‘Field set-
up” wizard. The pressure and temperature transmitters supplied by SICK have the address-
es 1 and 2. After start-up of the configured system, the meter can analyze the transmitters‘
actual long address which is then used to communicate the measured values. The recom-
mended read cycle for the pressure and temperature is 30 s (register #3542). See next
figures for the corresponding setup menus.
Fig. 2.30: Setup menu for optional P and T reading via Hartbus (Field setup, page 2/8)
Fig. 2.31: Setup menu for the integrated electronic volume corrector (Field setup, page 3/8)

Although the EVC can be configured with the MEPAFLOW600 CBM Field setup wizard, the
following table lists all EVC-relevant parameters..
Register
Name Description
number
#3026, See Tab.2.1 See Tab.2.1
#3542,
#3545
#3540 P_Address Communication address of the pressure transmitter, must be
identical in the transmitter and gas flow meter
#3541 T_Address Communication address of the temperature transmitter, must
be identical in the transmitter and gas flow meter
#7024 TemperatureBase Base condition for temperature to which the measured volume
is corrected
#7025 PressureBase Base condition for pressure to which the measured volume is
corrected
#7750 Heating Value Average heating value of the gas
#7751 H2 Average hydrogen concentration
#7752 CO2 Average carbon dioxide concentration
#7753 Mass Density at Base Average density of the gas at base conditions
#7754 PressureTransmOffset Mean local atmospheric pressure as an offset when gauge
transmitters are used.
When absolute-pressure transmitters are used, the parameter
remains 0.
#7040 TemperatureFix Is used for volume correction, when no current values provided
by transmitter (e.g. at HART_ReadIntervall = 0)
#7041 PressureFix Is used for volume correction, when no current values provided
by transmitter (e.g. at HART_ReadIntervall = 0)
#7042 Compressibility Is used for volume correction, when the feature ‘calculation of
compressibility’ is not activated (e.g. at GergCalcIntervallMax =
0)
#7755 GergKorr_K0 Correction factor for high-pressure polynomial adjustment
(>100 bars, for natural gas only)
Tab. 2.32: Parameters for the volume correction calculation


FLOWSIC600
MEPAFLOW600 CBM
Overview
Software Installation
Connecting the FLOWSIC600 to a PC or Laptop
Connecting to the FLOWSIC600

with MEPAFLOW600 CBM
Operating Instructions MEPAFLOW600 CBM FLOWSIC600
3 MEPAFLOW600 CBM diagnosis and configuration software

This chapter provides a general overview of the diagnosis and configuration software for the
FLOWSIC600: MEPAFLOW600 CBM. It describes the software installation (including the
system requirements), the procedure for connecting the FLOWSIC600 to a PC or laptop and
the procedure of establishing a connection between FLOWSIC600 and MEPAFLOW600
CBM. Further information on functionalities of MEPAFLOW600 CBM and its use in certain
important procedures like commissioning or calibration are given in the corresponding
Sections of the Operating Instructions. Information on data handling with MEPAFLOW600
CBM is given in Section 2.7 .
3.1 Overview
The MEPAFLOW600 CBM software supplies a menu-based user interface with many
features for the diagnosis of the FLOWSIC600 system. It allows the access of all system
parameters, displays diagnostic information in charts and graphs, generates reports (i.e.
Maintenance reports) and data files which can be exported and can be used for data
recording (logging). It‘s meter database allows online and offline management of
parameters, reports, session files and logbooks.
Main readings
Key navigation
Software features -
(see next page)
Status bar
Fig. 3.1: MEPAFLOW600 CBM graphical user interface

FLOWSIC600 MEPAFLOW600 CBM Operating Instructions
Software Features
Key navigation Description
Connect/Disconnect Menu for establishing online and offline connections between
MEPAFLOW600 CBM meter database and FLOWSIC600
Diagnosis Session Quick creation of session files for diagnostic purposes
Data recorder Tool for the recording and playback of current (or cached) readings
Meter logbook Access to meter logbook and logbook entries saved to meter database
Information Overview of some higher level meter information: Counter readings,
identification and location of meter and display of readings (e.g. flowrate) in
graph
Meter values Detailed diagnostic screen with graphs for velocity of gas, speed of sound
(SOS), path performance, AGC, signal-to-noise-ratio (SNR), turbulence,
profile symmetry and user selectable readings (e.g. flowrate). Summary of
device status
Maintenance report Assistant for the creation of Maintenance reports
Meter explorer Overview, access and management of the meter database saved on the PC.
Includes all meter data and sessions with entries for all changes of
parameters, changes of the operating mode, measurement records
(including diagnosis sessions) and maintenance reports. Functions for
export, import, creating and deleting of meter data.
Go to Operation Operation mode switches. ‘‘Operation Mode‘‘ for normal operation or
Mode / Go to ‘‘Configuration Mode” for writing information (i.e. parameters) to the meter
Configuration Mode
Meter calibration The calibration wizard guides the user through the calibration procedure with
automated processes to write the information to the meter and generate
reports
Field setup The field setup wizard guides the user through the commissioning procedure
Firmware update Assistant for installing firmware updates
I/O check The I/O check wizard guides the user through a test of all meter outputs
Program settings Access to program settings for the individual adjustment of the program
appearance and setup (e.g. settings for file path, memory, unit system and
layout).
Path diagnosis Access to path diagnosis and graphs of received signals
Parameters Access to all meter parameters. Assistant for comparing current parameter
settings with previous ones
Report manager Overview, access and management of all reports stored in the meter
database
Tab. 3.2: MEPAFLOW600 CBM software features

3.2 Software Installation

• System requirements
• Microsoft Windows 2000/XP or higher
• Microsoft .NET Framework 2.0 (Free download available at http://www.microsoft.com)
• 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. If connected to
a FLOWSIC600 with a firmware version older than V3.2.00, not all features of the software
are available.
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.

3.3 Connecting the FLOWSIC600 to a PC or Laptop
3.3.1 Connecting the FLOWSIC600 via RS485 / RS232 cable

Interface sets for the The FLOWSIC600 serial interface conforms with the RS485 standard. An RS485 /RS232
connection of the cable and a 1:1 interface cable (pin 2 – pin 2 and pin 3 – pin 3) are required for data
FLOWSIC600 with a PC transfer to PC or laptop (see Fig. 3.3). Because MEPAFLOW600 CBM, the operation and
via serial- or USB- diagnosis software for the FLOWSIC600, does not support RTS/CTS data transfer, the
interface can be ordered adapter must be able to distinguish between transmission and reception mode
from SICK. See Tab. 3.6: automatically. We, therefore, recommend the use of a serial interface set available from
Interface sets available SICK.
from SICK.
Terminals COM
port
1:1 (9-pole)
Connection cable
Fig. 3.3: Wiring example of ‘‘MEPA interface set RS485 / RS232” (ADAM, power supply, cable) non-
intrinsically safe
Terminals COM
RS232 port
1:1 (9-pole)
Fieldbus Isolating
Repeater Type 9185
(Company "Stahl") Connection Cable
18 .. 31 VDC
Fig. 3.4: Wiring example of ‘‘MEPA interface set RS485 / RS232” intrinsically safe for DIN rail
mounting (also see Fig. 10.28 in the Appendix of the Operating Instructions)

3.3.2 Connecting the FLOWSIC600 via USB converter

If the PC/laptop does not offer a RS232 serial interface, a USB interface can be used. An
appropriate USB converter is necessary to transform the signal for the RS485 device
interface. The USB converter available through SICK contains a CD-ROM with a software
driver which must be installed before an online connection between the FLOWSIC600 and
the MEPAFLOW600 CBM software can be established.
Terminals
A / RxD USB USB
B / TxD
USB
Connection Cable
Fig. 3.5: Wiring example of ‘‘MEPA interface set RS485/USB” (Converter, Cable, Terminal plug, CD-
ROM with software driver), non-intrinsically safe
Description Part Number

‘‘MEPA interface set RS485 / RS232” (ADAM, power supply, cable) non- 7041773
intrinsically safe
‘‘MEPA interface set RS485 / RS232” intrinsically safe for DIN rail mounting 6029957
‘‘MEPA interface set RS485/USB” (Converter, cable, terminal plug, CD-ROM with 6030669
software driver), non-intrinsically safe
Tab. 3.6: Interface sets available from SICK

3.4 Connecting to the FLOWSIC600 with MEPAFLOW600 CBM
3.4.1 Starting MEPAFLOW600 CBM
‡ After successful installation, start the MEPAFLOW600 CBM by selecting the

‘‘MEPAFLOW600 CBM” entry in the program group created during installation, or by
double-clicking on the desktop icon.
Program Group Desktop Icon
Fig. 3.7: MEPAFLOW600 CBM program group and desktop icon

3.4.2 Establishing a connection to MEPAFLOW600 CBM
‡ After starting MEPAFLOW600 CBM, the Connect / Disconnect Screen appears with the
Password dialog window. (Fig. 3.8)
‡ Choose a User access level, activate the corresponding radio button, enter the password
and click the ‘‘OK” button.
User access level Password

Operator No password required
Authorized operator ‘‘sickoptic”
Service See Service Manual
Fig. 3.8: MEPAFLOW600 CBM Connect / Disconnect screen with Password dialog window
‡ The Password dialog disappears and the Connect / Disconnect screen with a list of all
meters in the meter database appears. (If the meter database contains no meters (as is
the case after the first installation of MEPAFLOW600 CBM), or if a new meter is to be
connected, follow the instructions in Section 3.4.3. of this Chapter.)
‡ Choose a meter and click the ‘‘Direct serial” button to establish a serial connection to a
meter which is connected to the PC, or click the ‘‘Offline” button to establish an offline
connection.
‡ The option ‘‘Ethernet” will be supported from release 1.1 of MEPAFLOW600 CBM. The
option will facilitate the connection via ethernet with external device e.g. ‘‘B&B Electronics
Model MES1B TCPtoASCII Converter”.

‡ If a direct serial connection is to be established, the Connection settings window appears

(Fig. 3.9). Specify the appropriate connection settings. and click the ‘‘Connect” button to
establish an online connection to the meter. If the connection fails, follow the instructions
in Section 3.4.4 of this Chapter.
Fig. 3.9: Connection settings*
* The parameters shown in Fig. 3.9 are default values - except for the serial com port
which has to be individually configured.
‡ After the connection (online or offline) has been established, MEPAFLOW600 CBM
displays the start page which can be specifed in the Program settings.
‡ If an online connection has been established, the current readings from the meter will be
displayed.
3.4.3 Creating a new meter entry in the meter database

Note: New meter entries can be created, whether the corresponding meter is connected to the
PC or not. If the meter is connected, MEPAFLOW600 CBM loads all available parameters
from the meter. If the meter is not connected, an initial master data set is created from the
information the user enters.
‡ If the meter database contains no meters (as is the case after the first installation of
MEPAFLOW600 CBM), or if a new meter is to be connected, create a new meter entry in
the meter database by clicking the ‘‘New” button. Then follow the instructions on screen.
‡ After the meter entry has been created in the meter database, the meter is available for
connection in the Connect / Disconnect screen. To connect to the meter follow the
instructions in Section 3.4.2 of this Chapter.

3.4.4 Connection troubleshooting
Meter not found at initial connection
‡ Check all cabeling and hardware including the correct installation of the adapters (see
Section 3.3.1 and 3.3.2 of this Chapter).
‡ Use the options in the displayed window to make MEPAFLOW600 CBM search with wider
options (see Fig. 3.10).
Fig. 3.10: ‘Meter not found” dialog for the specification of wider search options
Connection lost during session
‡ Check all cabling and hardware.
‡ Use the options in the displayed window to make MEPAFLOW600 CBM search with wider
options (see Fig. 3.10), especially If parameters (e.g. the baudrate) may have changed.


FLOWSIC600
Flow Calibration
Short Guide to Flow Calibration
General Notes
Preparation
Flow Calibrating the FLOWSIC600
Configuration, Verification and

Documentation
Sealing
Flow Recalibration
Operating Instructions Flow Calibration FLOWSIC600
4 Flow Calibration
This chapter is a summary of the procedure for calibrating the FLOWSIC60. It can also be
used as a single document to support the staff of flow test facilities when calibrating the
meter. Experienced staff may use the Short Guide in Section 4.1.
The information below relates to FLOWSIC600 devices marked ‘II+’ and the MEPAFLOW600
CBM software version 1.x.

FLOWSIC600 Flow Calibration Operating Instructions
4.1 Short Guide to Flow Calibration
Verification and Installation
‡ Check the meter for possible damages due to delivery.
‡ Cross-check the serial number on the main plate with the serial number in the
Manufacturer Data Report (MDR) as well as the size. design pressure, design
temperature, flow range and meter factor.
‡ Install the flow meter on the flow test facility (Section 4.3.2 of this Chapter).
‡ Cable the FLOWSIC600 (power supply, pulse outputs and RS485 Modbus) (Section
4.3.3 of this Chapter).
‡ Remove the front cap and open the configuration protection switch (Section 4.3.5 of this
Chapter).
‡ Close the front cap and switch on the power supply.
Parameter setup
‡ Establish an online connection between FLOWSIC600 and MEPAFLOW600 CBM

software (Section 3.4 of this Manual). Use the ‘‘Service level” and password ‘‘expert”.
‡ Verify the key data at the ‘‘Meter information” screen of MEPAFLOW600 CBM with the
data of the Parameter report of the MDR (Section 4.3.6 of this Chapter).
‡ Switch the meter into Configuration mode.
‡ Activate the ‘‘Meter calibration” wizard in MEPAFLOW600 CBM.
‡ Enter the pressure and temperature values into the wizard page 1 of 4 (Section 4.3.7 of
this Chapter).
‡ Check, if the Meter factor is proper for the calibration (Section 4.3.8 of this Chapter).
‡ Click the ‘‘Write to meter” button.
Determination of adjust factors
‡ Provide a gas flow rate within the valid flow range in the test line.
‡ Check the performance of the meter and check the ‘‘Meter status” table (Section 4.3.8
of this Chapter).
‡ Adjust the zero phase if necessary (Section 4.3.9 of this Chapter).
‡ When desired, prepare MEPAFLOW600 CBM data recording (Section 4.3.10 of this
Chapter).
‡ Carry out the flow verification. When finished, calculate the WME and the adjust factor(s)
and enter them into the meter (Section 4.4.1 of this Chapter).
Note: The MEPAFLOW600 CBM Calibration wizard supports the determination and setting of
factors and coefficients (Section 4.4.2 of this Chapter).

Verification
‡ Switch the meter into Measurement mode.
‡ Verify the adjustment at some preset flowrates. Deviation between reference meter and
meter under test should be within ±0,1% of the reference value.
‡ Switch the flow meter into Configuration mode.
‡ Set the pressure, temperature and meter factor back to your customized values and
store them to the meter.
‡ Switch the flow meter into Measurement mode, then switch off the power.
‡ Remove the front cap and close the configuration protection switch (position: enabled).
‡ Close the front cap and switch on the power.
Documentation
‡ Reestablish the online connection between flow meter and MEPAFLOW600 CBM.
‡ Check in MEPAFLOW600 CBM that temperature, pressure and meter factor are at your
customized values. Also compare the Meter factor with the value on the main plate.
‡ Check the ‘‘Meter status” table, whether the configuration protection switch (Hardware
write lock, Bit 4 of the System status register) is set and no errors or warnings are active.
‡ Create and print out a parameter report. When the Calibration wizard was used, also print
out the calibration report.
Sealing
‡ Carry out the sealing (Section 4.6 and 10.9 of the Operating Instructions).

4.2 General Notes

The FLOWSIC600 can be calibrated at a certified flow test stand (certified calibration facility),
at ambient or high pressure, to reduce the measurement uncertainty and to reference it to
the national standards.
The following conditions must be fulfilled before the FLOWSIC600 can be calibrated:
• To use a FLOWSIC600 in fiscal metering applications, a national pattern approval
certificate (where required) must exist. The FLOWSIC600 must meet the requirements
set out in the pattern approval documents.
• The meter body must be approved for the maximum gas pressure it will be subjected to.
• The FLOWSIC600 must be installed according to Chapter 5.
• The FLOWSIC600 must be commissioned according to Chapter 6.
4.2.1 Calibration (for single or constant adjust factor)

Generally, a calibration involves the following steps:
1. Flow rate measurement at the

defined test points to determine
the error or deviation relative to
Deviation in %
the test facility reference

meter(s).
Flow rate
2. Flow-rate-weighted calculation of
the error (WME) over the entire
measuring range in % (blue
Deviation in %
arrow)
Flow rate
3. Calculation of the adjust factor

and entering it as a parameter in
the FLOWSIC600
Deviation in %
Flow rate
Verifikation point after the correction
The black line is the calculated characteristic meter error line, i.e. the product of the
previously measured points and the adjust factor.
Then, the flow rate is determined again at a (verification) point in order to determine whether
the error by the meter under test is in agreement to the calculated error value.

4.2.2 Recommended test flow rates

Flow rate calibration aims to find the deviation of the meter under test from a standard or
norm. It is conducted on a calibration facility. The recommended number and position of test
points are provided in OIML and AGA documents and are summarized to the table below,
but may alternatively be defined individually by the customer.
OIML test points A.G.A. test

Measuring range (turn down) points
1:20 1:30 1:50 > 1:50 All ranges
- - - Qmin
- - 2% - 2.5 %
- 3% - 3% -
5% 5% 5% 5% 5%
10 % 10 % - - 10 %
- - 15 % 15 % -
25 % 25 % 25 % 25 % 25 %
40 % 40 % 40 % 40 % 50 %
70 % 70 % 70 % 70 % 75 %
100 % 100 % 100 % 100 % 100 %
% values in table relate to Qmax

4.2.3 Flow calibration at atmospheric pressure

The flow calibration should be performed according to PTB Testing Specification vol. 29
“Gas volume flow meter testing using air at atmospheric pressure”.
For a further increase in the measuring accuracy, the FLOWSIC600 provides Reynolds-
number- and velocity-related impact correction routines. These nominal size-dependent
parameters were determined prior to the verification procedure and are set as
manufacturer constants at the factory. The assignment of the Reynolds number range is
carried out with the help of the “PressureFix” parameter.
For calibration with air at atmospheric pressure, call up the “Calibration” function on the LC
display. This will reset the “PressureFix” parameter to 1.0 bar (a). The word “Calibration” will
appear on the display while the device is being calibrated.
After calibration and adjustment, the FLOWSIC600 must be set to one of the following
operating pressure ranges by setting the “PressureFix” parameter (see Fig. 4.8).
Rated pressure range

PressureFix pe, min pe, max
1 bar(a) 0 bar 0.1 bar
1.5 bar(a) 0.1 bar 1.0 bar
3.2 bar(a) 1.0 bar 4.0 bar
Warning
The maximum permitted operating pressure of a gas flow meter verified at atmospheric
pressure must not exceed 4 bar(g).
ATTENTION

4.2.4 Flow calibration at high pressure

The flow calibration should be performed according to PTB Testing Specification vol. 30
“High pressure testing of gas meters”. The FLOWSIC600 should be tested under the same
conditions and using the same type of gas which will be used during normal operation.
Determining the test pressure

The minimum (pe, min) and maximum (pe, max) operating pressure must be representative of
the operating pressure range.
Warning
The maximum operating pressure must, however, not exceed the maximum pressure rating
of the meter body. (Design Pressure PS, compare with the type plate on the meter body.)
ATTENTION
The maximum permitted operating pressure (design pressure) is specified as PS on the type
plate of the meter body. The permitted working pressure range of the meter is derived from
the “PressureFix” parameter (pfix). Prior to the verification procedure, this parameter must
be set to the average pressure applied during testing. If the final working pressure exceeds
50 bar, testing at 50 bar will be sufficient.
The maximum ratio of minimum and maximum operating pressure is:
pe, max
=≤4
pe, min
Generally,
pfix = pe, min * pe, max + 1 bar
where
pe, min = 0,5 * pfix
pe, max = 2 * pfix if pfix ≤ 0.5 PS; otherwise PS
The corresponding operating pressure range is displayed on the FLOWSIC600 as calculated
in accordance with these equations. If the calibration is based on several test pressures, the
“PressureFix” parameter must be reset to the applicable test pressure before each test.
The test pressure which comes closest to the average at the application working pressure
shall be entered as the “PressureFix” parameter. The meter shall then be adjusted with the
weighted mean error established at this test pressure.
Note Enter the absolute pressure value of the average working pressure when setting the
“PressureFix” parameter.

4.3 Preparation
4.3.1 Identification and visual check

The FLOWSIC600 is delivered in a pre-assembled condition in a sturdy package. When
unpacking the device, check for possible damage in transit. Pay particular attention to the
interior of the meter body, any visible transducer components and the sealing surfaces of
the flanges. Any damage must be documented and reported to the manufacturer
immediately.
For identification use the information on the main type plate (Fig. 4.1, example see Fig.
10.34 in the Appendix). Cross-check the meter‘s serial number and the other information
on the main plate with the data in the Manufacturer Data Record (MDR).
Information on nominal size (DN/NPS), design temperature (TS), design pressure (PS) and
test pressure (PT) can be found on the type plate at the meter body (Fig. 4.1, example see
Fig. 10.35 in the Appendix).
Main type plate

on the SPU
Type plate on the meter body
Fig. 4.1: FLOWSIC600 type plates
4.3.2 Mechanical installation on the flow test stand
Pressure transmitter Temperature transmitter
Signal processing unit
FLOWSIC600
Inlet pipe Outlet pipe
Fig. 4.2: Installation of the FLOWSIC600 in the test pipeline
Detailed information about the installation in the pipeline and about necessary inlet and
outlet pipes can be found in the Operating Instruction, Section 5.2 and Section 5.3.
Note: The FLOWSIC600 can be calibrated without the inlet/outlet section used at the customer
site. A PTB flow conditioner, which may be used at the customer site, has no influence on
the measuring accuracy and the calibration result. Therefore it is not neccessary, to use a
flow conditioner during the calibration.

4.3.3 Electrical connection

After having removed the back cover, the FLOWSIC600 must be connected electrically as
shown in the Figure below. The default configuration is indicated in the terminal assignment
plan inside the back cover of the housing
12.0 ... 28.8 V DC

Caution
Negative is connected with the + power supply 1(+) Entity Parameters
housing of the signal processing alimentation

2 (-)
Vmax = 16V, Imax = 200mA
unit.
_ UB = 12..24V DC
EEx e Um=253V EEx ib [ia] IIA

4 ...20 mA
Ci = 4nF, Li = 0,075mH
Uo = 22,1V Ui = 30V
active
++ 31 Io = 155mA Ii = 100mA
digital out 0 (Hf2) passive Po = 857mW Pi = 750mW
sortie digital 0
- 32 Fmax = 6 kHz
HART/ Co = 4100nF
- NAMUR Lo = 7mH RL<250R
+ RS 485 Uo=5,88V Io=313mA Po=460mW Co=1000µF
33
Pulse output DO 0 - 34 PROFIBUS PA
Ui=10V Ii=275mA Pi=1420mW Lo=1,5mH
Vo=30V Io=100mA Pi=750mW
+ Usat < 2V 2mA < IL <

51 digital out 1 (Hf1)
sortie digital 1
passive 20mA
NAMUR Ui = 30V Ii = 100mA
- 52 Fmax = 6 kHz
Pi = 750mW
+ digital output 2 passive

Usat < 2V 2mA < IL <
41 sortie digital 2
20mA
NAMUR Ui = 30V Ii = 100mA

- 42 Pi = 750mW
+ digital output 3 passive Usat < 2V 2mA < IL < 20mA
Ui = 30V Ii = 100mA
+
81 sortie digital 3 NAMUR Pi = 750mW
RS485 interface -
-
82 RS 485
Uo=5,88V Io=313mA Po=460mW Co=1000µF
Ui=10V Ii=275mA Pi=1420mW Lo=1,5mH
For further details see user manual

and EC Typ-Examination Certificate
TÜV 01 ATEX 1766 X
Pulse output DO 1
Back cover of the housing with

terminal plan
Fig. 4.3: Electrical connections in the signal processing unit
4.3.4 Connection to the MEPAFLOW600 CBM software

See Section 3.4 of the Operating Instructions for details.
Note: Use user access level ‘‘Service” with password ‘‘expert”.

4.3.5 Open / close the configuration protection switch

To calibrate the FLOWSIC600, the configuration protection has to be disabled. To check the
settings, call up the ‘‘Meter status” table (see Fig. 4.5) by clicking the „System state” button
in the top right corner of the MEPAFLOW600 CBM screen (see Fig. 4.4).
Fig. 4.4: ‘System state button
Lamp on:
Configuration
protection is active
Lamp off:
Configuration
protection is disabled
Fig. 4.5: ‘‘Meter status” window
If the configuration protection is active (light on), the switch must be turned to its ‘open‘
position to enable parameter changes (see Fig. 4.6)
Configuration protection
enabled
Configuration
protection switch
Configuration protection
disabled
Fig. 4.6: Configuration protection switch
‡ Disconnect the FLOWSIC600 from the power supply.
‡ Take off the front cap of the signal processing unit.
‡ Move the switch to the desired position.
‡ Mount the front cap again.
‡ Reconnect the power supply.

4.3.6 Identification of key data in the meter configuration

To ensure the validity of the flow meter configuration, the following data of the Parameters
Report in the Manufacturers Data Report (MDR) has to be consistent with the information
on the ‘‘Meter information” screen (Fig. 4.7) in MEPAFLOW600 CBM:
• Serial number of the meter
• Meter factor
• Firmware version
• Firmware CRC
Fig. 4.7: Identification information on the ‘‘Meter information” screen in MEPAFLOW600 CBM
4.3.7 Setting the current gas condition

Before you can start the calibration, the process parameters “TemperatureFix” (register
#7040) and “PressureFix” (register #7041) must be set to the average conditions during
the calibration. These parameters can be edited in the ‘‘Meter calibration” wizard.
‡ Start MEPAFLOW600 CBM and the ‘‘Meter calibration” wizard.

4.3.8 Functional check before flow calibration

Once the test facility is flowing at the initial flow rate, check the performance of the meter.
The performance value should be at least 75% on all paths. If the velocity of gas is greater
than 30 m/s (100 ft/s), the performance values may be significantly lower.
‡ Check the ‘‘Meter Status” table for error messages and warnings (see Fig. 4.5).
If during the calibration the pulse output supplies the readings for the meter under test, the
meter factor has to be checked for the maximum output frequency at Qmax and for the
necessary resolution regarding Qmin. If necessary the meter factor has to be changed.
Example: If Qmin = 20 m3/h and the meter factor is set to 10 Imp./m3 the FLOWSIC600 would
provide a pulse only 3 pulses per minute. Apart from the insufficient resolution, it would take
too long, to collect a representative number of pulses (compare Chapter 6 of the Operating
Instructions).
‡ After entering the correct values to the appropriate fields, press the button ‘‘Write to
meter”.
Fig. 4.8: ‘‘Meter Calibration” wizard in MEPAFLOW600 CBM
‡ Now use the ‘‘Path Diagnosis” wizard (see Fig. 4.9) to check the ‘‘Zero Phase”
parameters of both transducers on each path (path 1, 2, 3, 4). Properly adjusted zero
phases of the individual paths are the basis for accurate transit time measurement of the
ultrasonic signals. The ‘‘Zero Phase” parameter of a path is properly adjusted, when the
green cursor in the signal window is symmetrically within the two dotted red limit lines and
the red asterisk is positioned exactly on the second positive zero crossing of the received
ultrasonic signal

Fig. 4.9: ‘‘Path Diagnosis” wizard in MEPAFLOW600 CBM

If the zero phase values do not meet the aforementioned criteria, the zero phase needs to
be adjusted according to Section 4.3.9.
Fig. 4.10: Signal window displaying ultrasonic signal in the ‘‘Path Diagnosis” screen
Additional the validity of the settings can be verified by:

a. Checking the ‘‘Meter status” table (Fig. 4.5). If the lamp of Bit 13 (‘‘Time plausibility”) is
on, it indicates an incorrect zero phase.
b. Checking that the measured SOS values are almost the same at all paths of the
FLOWSIC600, and that they differ by less then 0,1% (see Fig. 4.11 and Fig. 4.12, switch
between display of absolute and difference SOS by clicking the right mouse button on the
SOS graph and using the context-menu).
Note: In the case of very low gas velocities (< 1 m/s or 3 ft/s), there may be more significant
differences between the paths due to thermal stratification. In this case, the SOS on the
upper paths (1 and 2) will be higher than the lower paths.
c. Checking that the measured SOS deviates no more than 0,3% from a theoretical SOS,
which is calculated from gas composition, pressure and temperature.
Fig. 4.11: Absolute SOS on ‘‘Meter Fig. 4.12: Difference to average SOS
values” screen on ‘‘Meter values” screen

4.3.9 Adjustment of the ‘‘Zero Phase” parameter

The zero phase should only be changed when the meter is at operating conditions.
‡ Activate the ‘‘Path Diagnosis” wizard (Fig. 4.9) in MEPAFLOW600 CBM.
‡ First check the ultrasonic signals shown for both transducers for compliance with the
following criteria:
– Symmetric signal shape with a signal-to-noise ration (SNR) >20 dB
– No signal deformation or bias in the region where the amplitude converges to zero
– Adaptation mean square error (MSE) < 0.008.
Properly adjusted zero phases of the individual paths are the basis for accurate
measurement of the ultrasonic signals‘ transit time.
The ‘‘Zero Phase” parameter of a path is properly adjusted, when the green cursor in the
signal window is within the two dotted red limit lines and the red asterisk is positioned exactly
on the second positive zero crossing of the received ultrasonic signal (see Fig. 4.10).
If the zero phase values do not meet the aforementioned criteria, the zero phase needs to
be adjusted.
Diagnosis paths Green zero phase cursor Zero phase parameter
Fig. 4.13: ‘‘Path Diagnosis” screen in MEPAFLOW600 CBM

Note: The meter must be in the Configuration mode with the Configuration lock switch in the open
position.
To shift the zero phase cursor to the proper position, the parameter ‘‘Zerophase[rad]” in the
parameter table on the right hand needs to be adjusted.
‡ Click the arrows to raise the zero phase in steps of 0.5 rad or type in a value.
‡ Begin by changing the zero phase value in steps of 0.5 rad.
‡ Then click the ‘‘Write to device” button and check the reaction in the signal window.
‡ Continue until the cursor is positioned near or exactly on the red asterisk. (The asterisk
marks the second positive zero passage.)
The proper value of the zero phase can be calculated or determined empirically.
Examples for the effect on the phase lag:
– Zero phase + 6.28 rad (=2Π): Shifts the ZeroPhase BA (or AB) line by about one
period to the right
– Zero phase - 3.14 rad (=-Π): Shifts about half a period to the left
‡ After having adjusted the zero phase, check the SOS again according to Section 4.3.7 of
this Chapter.

4.3.10 Data record during flow calibration (optional)

It is recommended that the measured values and diagnostic information are recorded
during the flow calibration for documentation purposes and later use. The MEPAFLOW600
CBM software has an integrated data recorder for this task. The data recorder collects all
important information and stores it into the meter database.
Note: The meter database is a file which is created by the MEPAFLOW600 CBM software when a
flow meter goes online with the software for the first time. The database with all relevant
data (serial number, meter configuration, parameters, records etc.) is stored on the PC‘s
harddisk.
The following procedure is recommended to store the data during a flow calibration:
‡ Activate the data recorder via the key navigation (Fig. 4.14).
Fig. 4.14: Data recorder
‡ Click on the red button at the data recorder. The ‘‘Data recorder setup” window will
appear (Fig. 4.15).
‡ Specify a record name and a record description. During the flow calibration, the record
name should remain the same while the record description changes (e.g. ‘‘Measuring
point Qmin”, ‘‘Measuring point 0.1 Qmax” or specify the gas velocity etc.). This will make
future reference to the calibration data much simpler.
‡ Refer to Fig. 4.15 for setup of the Data recorder.
‡ The ‘‘Storage cycle” should be set to ‘‘Real time (each measuring).
‡ The ‘‘Stop after” setting should be set to a sufficient duration to capture teh required
number of readings. The period can be selected from the list.
‡ Check Multi-Run Log File. This will allow changes to the Record description while retaining
the same Record name for each file.
‡ Do not check the ‘‘Include historical data from cache” box.

Fig. 4.15: ‘‘Data recorder setup” window
‡ Wait for stabilization of the first stable flow rate at which the meter will be calibrated.
‡ Click the ‘‘Start” button. Now the Data recorder window will appear again (Fig. 4.16). In
the lower right box you will see red text, indicating the record count, remaining countdown
time, and end time for the log file. The text will change to say ‘Ready‘ when the countdown
time is over and the recording is finished.)
Fig. 4.16: Data recording
‡ When the message window with the question ‘Create next recording now?‘ appears,
respond by clicking on the ‘‘Yes” command button to set up the Data recorder for the
next flow rate.
‡ Stabilize the second stable flow rate at which the meter will be calibrated and click on the
‘‘Start” button. The second record will be generated.
‡ Complete the same procedure for all other records required.
‡ After collecting all the data at all the calibration points, the test results will need to be
entered into MEPAFLOW600 CBM in order to adjust the meter‘s output. The flow
laboratory will calculate the WME and the adjust factors. This is described in the following
paragraphs.

‡ The data recorded during the calibration are stored in the meter‘s database. Open the
‘‘Meter explorer” to see the ‘‘Measurement records” collected (Fig. 4.17).
Fig. 4.17: Meter explorer with stored calibration point records

4.4 Flow Calibrating the FLOWSIC600
4.4.1 Determining the adjust factors without MEPAFLOW600 CBM wizard

Now the test facility runs the flow tests and determines the deviations and uncertainties of
the meter under test at at least 6 flow sample rates against the reference meter.
In general the ‘‘standard” calibration is carried out by calculating an adjust factor.
See Section 2.4.2 of Determining the single adjust factors is based on the weighted mean error (WME) of the flow
Operating Instructions rates Qi. The WME is calculated by the test labs according to the equation:
n
Σk
i=1
i • fi
where ki =
Qi
Qmax
for Qi ≤ 0.7 Qmax
WME =
n
Σ
i=1
ki
and ki = 1.4 -
Qi
Qmax
for 0.7 Qmax < Qi ≤ Qmax
Q: Tested flow rate

Q:max: Tested maximum flow rate
fi: Mean error in % established at the tested flow rate
If the meter is calibrated for bidirectional use, the weighted mean error (WME) is determined
using the values established separately for each direction of flow.
Adjustment with constant The new adjust factor is calculated as follows:
factor 1
AF =
WME
1+
100 %
Note: The actual weighting of the error at higher flow rates may be different based on
recommendations, (i.e. AGA9) or national regulations and/or type approvals.

The new adjust factors (AdjustFactorForward and - if relevant - AdjustFactorReverse) must

now be entered in the FLOWSIC600 as follows:
‡ Open the ‘‘Parameters” screen in the MEPAFLOW600 CBM software (Fig. 4.18). (Switch
to Configuration mode first!)
Fig. 4.18: ‘‘Parameters” screen
‡ Enter the new adjust factors into the ‘‘Register value” box.
‡ Click on the ‘‘Write to meter” button to write the value to the meter.
‡ Change back to the Measurement mode.
‡ Then verify the adjustment by repeating a flow test at some preset flowrate(s), and repeat
the steps above if necessary. The error at this verification point should be within 0.1% of
the reference value.
‡ Finally, in the parameters “PressureFix”, meter factor and “TemperatureFix” (see Fig.
4.20), enter the values that apply to the original installation of the meter, if known. (Switch
to Configuration mode first.)
After completion of the steps above, reactivate the Configuration protection:
‡ Disconnect the FLOWSIC600 from the power supply.
‡ Take off the front panel of the signal processing unit.
‡ Move the switch to the desired position (see Fig. 4.6).
‡ Mount the front cap again.
‡ Reconnect the power supply.

‡ Print a parameter report by using the ‘‘Report manager”(Fig. 4.19).
Fig. 4.19: ‘‘Report manager”
After compilation of the documentation the ‘‘standard“ calibration is finished.

The following sections describe how calibration is supported by the Calibration wizard in the

4.4.2 Finding the adjust factors using the MEPAFLOW600 CBM software
The following methods are implemented in the FLOWSIC600 firmware:
• Adjustment with constant factor
• Adjustment using a polynomial correction
• Adjustment with piece wise linear interpolation correction
The method ’’correction with piece wise linear error interpolation’’ is not approved in every
country for use in custody transfer applications. Cross-check with the type approval of the
FLOWSIC600 for your country.
TYPE APPROVAL
‡ Open the ‘‘Meter calibration” wizard of the MEPAFLOW600 CBM software (Fig. 4.8.
‡ Switch the FLOWSIC600 into Configuration mode. If performance, pressure, temperature

and meter factor are already checked or set (as described in previous Sections of this
Chapter), use the ‘‘Next” button to enter the flow rates and the deviation values into the
‘‘Average point table” (Fig. 4.20). Select the flow direction for which the meter is to be
tested. With help of the ‘‘Single point table” the results of numerous measurements of
each test point can be averaged and transferred to the ‘‘Average point table”.
In the tables, the Qact values are the flow rates of the test (facility). ‘‘Deviation %” is the
difference of the test meter relative to the reference (test stand). The Qact and Deviation
must be entered for each flow rate applicable to the calibration procedure.
Fig. 4.20: ‘‘Meter calibration” wizard, page 2 of 4

‡ On completion of the calibration testing, and after all the applicable data has been
entered in the ‘‘Average point table”, click the ‘‘Next” button again.
‡ Select the Adjustment method and, if polynomial correction is used, the degree of
freedom of the polynomial. Click the ‘‘Calculate adjustment” button. Now the WME
(Weighted Mean Error) and the adjust factor (or polynomial coefficients) are calculated
and displayed on the adjusted Error curve chart.
Adjustment with a constant factor

The Adjust factor is calculated from the weighted mean error (WME) as described in Section
4.4. The error curve ‘‘as found” shows the deviation of the tested meter (FLOWSIC600)
relative to the test stand (Reference meter(s)) without any correction of the FLOWSIC600
output behavior (Fig. 4.21).
Fig. 4.21: ‘‘Meter calibration” wizard, page 3 of 4 (linear adjustment)
The error curve ‘‘as left” shows the deviation of the FLOWSIC600 after correction with the
Adjust factor.

Adjustment using a polynomial

Polynomial correction improves the linearity of the error curve and corrects the WME to a
lower value. (Fig. 4.22).
Fig. 4.22: ‘‘Meter calibration” wizard, page 3 of 4 (polynomial adjustment)
The curve defined by the polynomial equation should be very close to the error curve for the
meter under test (MUT) at each of the test flow rates. If not, use the dropdown list
‘‘Polynomial type” to choose one of the three available polynomial types (see below). The
difference between the polynomial curve and the test flow rates ‘‘as found” is the remaining
error after adjustment, represented in the error curve (as left). Through the calculation
procedure, the polynomial is mathematically shifted to the zero line. The following
polynomials are implemented in the firmware:
E’(Q) = a-2Q-2 + a-1Q-1 +a0 +a1Q +a2Q2(1) 7 test flow rates
-1 2
E’(Q) = a-1Q +a0 +a1Q +a2Q (2) 6 test flow rates
-1
E’(Q) = a-1Q +a0 +a1Q(3) 5 test flow rates
Notes: • The adjustment using a polynomial must only be used if the above given minimum
number of test flow rates have been determined.
• To display the red polynomial curve, position the mouse cursor at the error curve window
(Fig. 4.22) and click on the right mouse button.

Adjustment using piece wise linear error interpolation

In this method, the error is corrected exactly to zero at the individual calibration points. Then
a linear interpolation and error correction is carried out between the individual calibration
points.
Fig. 4.23: ‘‘Meter calibration” wizard, page 3 of 4 (piece wise linear interpolation)

4.5 Configuration, Verification and Documentation
4.5.1 Configuration and documentation without Calibration wizard

If the adjust factor(s) or polynomial coefficients were determined without the use of the
MEPAFLOW600 CBM Calibration wizard, all neccessary procedures are described in Section
4.4.1. If all operations have been carried out according to 4.4.1, the sealing procedure
(Section 4.6) completes the calibration.
4.5.2 Configuration and documentation with Calibration wizard

If the adjust factor(s) or polynomial coefficients were determined with the use of the
MEPAFLOW600 CBM Calibration wizard, follow this Section to complete the calibration.
‡ After calculating the adjust parameters, click the ‘‘Next” button again. On page 4 of the
‘‘Meter calibration” wizard, click the ‘‘Write parameters” button (Fig. 4.24).
‡ Switch the meter back to Measurement mode.
‡ The verification can now be run at the verification test flow rate. (If the calibration method
‘‘Constant factor” is used, the verification must be carried out at one test flow rate. The
two other calibration methods need two test flow rates.)
‡ The volume measured by the meter should be within ±0.1% of the reference value
Fig. 4.24: “‘‘Meter calibration” wizard, page 4 of 4 (finish)

If the meter has been adjusted by using another adjustment method than adjust factor, then
the meter has to be verified at two different test flow rates. The verification rates used
should be chosen between two flow rates the meter was tested at. For example, if the errors
at Qmax and 0,7*Qmax have already been found, the polynomial correction should be
tested at e.g. 0,8*Qmax.
‡ After the verification has been carried out successfully, go back to the first page of the
calibration wizard (Fig. 4.8)
‡ Set the pressure, temperature and meter factor values back to your customized values
(see 4.3.8).
‡ Switch the meter into Operation Mode.
‡ Activate the configuration protection switch.
‡ Go back to page four of the ‘‘Calibration wizard”
‡ Click the buttons ‘‘Print calibration report” and ‘‘Print parameter report”. (See examples
of a calibration report and a parameter report in the Appendix of the Operating
Instructions.)

4.6 Sealing
Carry out the following securing measures in accordance with the sealing plan (see Section
10.9) after completion of the calibration:
‡ Close the front cover of the SPU and seal it using the securing bracket and wire lead.
‡ Seal all transducer cover caps with at least two stickers.
‡ Attach the main lead to the main type plate on the SPU..

4.7 Flow Recalibration

To recalibrate the FLOWSIC600 at a flow test facility, apply the procedure as described in
Section 4.3 to 4.4 by using the ‘‘Meter calibration” wizard in MEPAFLOW600 CBM.
‡ Check the remaining battery capacity and replace the battery if neccessary (see Section
2.5.6).
‡ Set the current gas conditions at page 1 of 4 according to Section 4.3.7. of this Chapter.
‡ Perform the functional check according to Section 4.3.8 of this Chapter.
‡ Go to page 3 of 4 of the ‘‘Meter calibration” wizard. (See Fig. 4.25.)
‡ Select ‘‘None” as adjustment method. Now the flow meter does not use the diplayed
linear or polynomial adjust factors at the right hand. The factors are still displayed and not
deleted so that they can be reactivated (see Note below).
Fig. 4.25: ‘‘Meter calibration” wizard page 3 of 4, calibration factors ‘‘as found” (non flow calibrated
flow meter)
‡ Now proceed with Section 4.3.1 of this Chapter.
Note: If after the flowtests it becomes apparent, that the adjust factors do not have to be changed,
do not write the parameter to the meter (as described in Section 4.5.2), but reactivate the
previous adjust factors on page 3 of 4 in the wizard, by selecting the previously used
adjustment method (other than ‘‘None”).

FLOWSIC600
Installation
General Notes
Installation
Mechanical Installation
Electrical Installation
Operating Instructions Installation FLOWSIC600
5 Installation
5.1 General Notes
5.1.1 Delivery
The FLOWSIC600 is delivered in a pre-assembled condition in a sturdy package. When
unpacking the device, check for possible damage in transit. Pay particular attention to the
interior of the meter body, any visible transducer components and the sealing surfaces on
the flanges. Any damage must be documented and reported to the manufacturer
immediately.
Also check the shipment to ensure all components are included. The standard meter
shipment is comprised of:
‡ FLOWSIC600 measuring system (meter body with signal-processing unit and
transducers)
‡ MEPAFLOW600 CBM control and configuration software
‡ Operating instructions
‡ Manufacturer Data Report (MDR)
Important
To guarantee safe and reliable operation of the measuring equipment, make sure the actual
site conditions match the information provided on the labels on the meter body and SPU
ATTENTION (see Fig. 5.1).
Main type plate, see Main type plate

Drawing no. 902153 on the SPU
and no. 902147 on
product CD
Flange dimensions
Type plate on the meter body
Fig. 5.1: FLOWSIC600 labels and marks

FLOWSIC600 Installation Operating Instructions
5.1.2 Transport and storage
Important
Only use lifting gear and load handling equipment (e.g. lifting straps) which are suitable for
the weight to be lifted. Max. load information can be found on the type plate of the lifting
ATTENTION
gear. It is strongly recommended to use only the eye bolts when lifting the meter by itself.
To lift the FLOWSIC600 please pay attention to Fig. 5.2.
During FLOWSIC600 transport and storage operations, make sure that:

‡ The meter is firmly secured at all times
‡ Measures are taken to avoid mechanical damage
‡ Humidity and ambient temperature are within specified limits (see Section 2.2.4).
If the device is to be stored outside for more than one day, sealing surfaces of the flanges
and the interior of the meter body must be protected from corrosion, e.g. with Anticorit spray
(not required for stainless steel meter bodies). The same measure shall be taken if the
meter is to be stored in dry condition, but for more than a week.
Note Due to natural temperature fluctuation in the course of a day, or if the meter is transported
to a place with different temperature and humidity conditions, moisture may condense on
any material. Carbon steel surfaces may corrode if left unprotected.
max.
45 °
Fig. 5.2: Lifting requirements

5.2 Installation
Generally, the installation arrangement is specified during the project planning phase, before
installation of the system. Nominal size, material and type of flange should therefore be in
accordance with the design of the measurement facility. It is particularly important that the
meter inlet and outlet is of the same internal diameter as the adjacent piping.
Fastening bolts, nuts and flange seals used must be suited to the operational conditions,
and comply with legal regulations and relevant standards.
Note: Any deviation from the planned design of the FLOWSIC600 and installation arrangement
shall be agreed upon with the supplier and documented prior to installing the meter.
5.2.1 Measuring location

General requirements:
• The FLOWSIC600 can be installed in customary straight inlet and outlet pipes. The
adjacent pipes must have the same nominal size as the meter body. The internal
diameter can be obtained from the table (Appendix, Table 10.3) based on the flange
rating and Standard. The max. variation of the internal diameter of the inlet pipe from that
of the meter body is 1%. Any welding beads and burs on the flanges of the inlet pipe shall
be removed.
• The meter body may be installed in a horizontal or vertical position. In case of horizontal
installation, the meter body shall be aligned so that the planes formed by the measuring
paths are in a horizontal position. This minimizes dirt in the pipeline from entering the
transducer ports. Vertical installation is only possible if the measuring system is used for
dry, non-condensing gases. The gas flow must be free from any foreign material, dust and
liquids. Otherwise, filters and traps shall be used.
• Do not mount equipment or fittings which may adversely affect the gas flow directly
upstream the FLOWSIC600.
• Seals at the flange connections between meter body and pipeline must not protrude into
the pipeline. Any protrusion into the flowing gas stream may change the flow profile and
thus the measuring accuracy may be adversely affected.
• Pressure transmitter shall be connected to the pressure tap provided (see Fig. 2.3). The
pressure tap is a 1/4 in NPT (female) port, for all meters greater than NPS 2 (DN50). The
NPS 2 (DN 50) meter has a 1/8 in NPT (female) port pressure tap.
• For the leak-proof connection on the pressure line, thread sealing agent (e.g. PTFE tape)
must be used when the pressure connection adapter is screwed in.
• Temperature probes shall be arranged as shown in Fig. 5.3 and Fig. 5.4.

5.2.2 Installation configurations

The choice of the installation configuration (see Fig. 5.3 and Fig. 5.4) depends on type and
extent of the flow disturbance at the installation position (according to TR G13).
Type of disturbance (distance upstream < 20 DN) Possible installation configuration

None
Elbow, reducer Configuration 1 or 2
Double elbow out of plane, T piece
Gas pressure controller with/ without noise abatement
trim
Configuration 2
Diffuser
Diffuser with swirling flow
Unidirectional use
FLOWSIC600 ≥ 3 DN
≥ 10 DN 1.5 .. 5 DN
Configuration 1
DN
≥ 5 DN ≥ 3 DN
min. 2 DN min. 2 DN 1.5 .. 5 DN
Configuration 2
Flow conditioner Temperature measuring point
Fig. 5.3: FLOWSIC600 installation in the pipeline for unidirectional use

Bidirectional use
Two straight pipes shall be installed in the inlet and outlet sections if the meter is to be used
bidirectionally. The temperature measuring point shall be disposed downstream the
FLOWSIC600, seen in the direction of predominant use (position 1 or 2 in Fig. 5.4).
Configuration 1 ≥ 10 DN FLOWSIC600 ≥ 10 DN
5 ..8 DN 5 .. 8 DN
DN
≥ 5 DN ≥ 5 DN
Configuration 2a min. 2 DN min. 2 DN min. 2 DN min. 2 DN
Applicable for meters 1.5 .. 5 DN 1.5 ..5 DN
marked with an asterisk
(*) in Tab. 2.8:Meter
sizes according to PTB
approval, in section
2.2.4
Flow conditioner
Temperature measuring point
Configuration 2b ≥ 10 DN ≥ 10 DN
Applicable for meters min. 2 DN min. 7 DN min. 7 DN min. 2 DN
marked with an asterisk min. 5 DN min. 5 DN
(*) in Tab. 2.8:Meter
sizes according to PTB
approval,
in section 2.2.4
Temperature measuring point
Flow conditioner
Fig. 5.4: FLOWSIC600 installation in the pipeline for bidirectional use

5.3 Mechanical Installation

Work on the pipelines to prepare for the installation of the gas flow meter is not included in
the scope of delivery.
It is recommended to use the following tools, equipment and supplies for installation of the
FLOWSIC600:
• Lifting gear or fork lift (with sufficient capacity to lift meter or meter-piping assembly)
• Wrenches for tightening flanges and other fittings
• Thread seal (e.g. PTFE tape) and flange gaskets
• Bolt lubricant
• Leak detection spray
Warning
• Always observe the general safety regulations and safety instructions given in Section 1
when carrying out any installation work.
DANGER • The FLOWSIC600 must only be mounted on depressurised and vented pipelines.
• Take all necessary precautions to avoid local or plant-specific dangers.
5.3.1 Choosing flanges, seals and other parts

Use pipeline flanges, bolts, nuts, and seals that withstand the maximum operational
pressure and temperature, as well as ambient and operational conditions (external and
internal corrosion) for the flange connections. For installation lengths and flange dimensions,
see Section 10.1).
Warning
• Always strictly observe the safety instructions for the installation of pressure equipment
including the connection of several pressure components set forth in the local or national
DANGER relations and standards or Pressure Equipment Directive 97/23/EC.
• Installation staff must be familiar with the directives and standards applicable for pipeline
construction.

5.3.2 Mounting the FLOWSIC600 in the piping

An arrow on the meter body indicates the main direction of flow. It is recommended to install
the FLOWSIC600 as indicated by this arrow if the meter is to be used for unidirectional flow
applications. If the meter is to be used in the bidirectional mode, the arrow indicates the
positive direction of flow.
Installation work to be carried out
Important
• The lifting eyes are designed for transporting the meter only. Do not lift the FLOWSIC600
using these eyes when additional loads (such as blind covers, filling for pressure tests or
ATTENTION piping) are attached (see also Section 5.1.2)
• Never attach lifting gear to the signal processing unit or its mounting bracket and avoid
contact between these parts and the lifting gear.
• The FLOWSIC600 must not turn over or start to swing while being transported. Flange
sealing surfaces, SPU housing and transducer cover caps may be damaged when the
lifting gear is not attached properly.
• Take suitable measures to prevent damage to the meter when carrying out any other
work (welding, painting) near the FLOWSIC600.
‡ Position the FLOWSIC600 at the desired place of the pipeline using the lifting gear. Only
use the lifting eyes provided to lift and transport the device. If lifting straps are used, wrap
them around the meter body.
‡ Check for correct seating and alignment of the flange gasket after installing the flange
bolts, but prior to tightening.
‡ Align the FLOWSIC600 such that the offsets between inlet pipe, meter body and outlet
pipe are minimized.
‡ Insert the remaining fastening bolts and tighten the nuts cross-wise. The tightening torque
applied must not be lower than specified in the project planning.
‡ Mount the pressure sensing line between pressure tap and pressure transmitter.
‡ Fill the pipeline and check the installed FLOWSIC600 and piping connections for leaks.
Note: It is recommended to perform a leak test in accordance with the relevant regulations and
standards after completion of the mechanical installation.

5.3.3 SPU alignment

The signal processing unit (SPU) can be turned so that the display can be easily read and
that cable routing is facilitated (see Fig. 5.5). A stop on the housing prevents the SPU from
being turned by more than 330° to prevent damage to the cables that come from the meter
body.
Signal processing unit

1. 2. 3.
Tool required for

loosening and
tightening the hexagon
socket head screw:
3 mm Allen key
Loosen the hexagon Position the SPU Tighten the hexagon

socket head screw socket head screw
Fig. 5.5: Positioning the SPU
Note: Do not forget to tighten the hexagon socket head screw after positioning the SPU.

5.4 Electrical Installation
5.4.1 General information
Pre-requisites
Wiring work (routing and connecting the power supply and signal cables), which is necessary
when installing the FLOWSIC600, is not included in the scope of delivery. The mechanical
installation described in Section 5.3 must be completed first. Comply with the minimum
cable specification requirements set out in Section 5.4.2.
Cable routing
‡ Keep cables in conduits or laid on cable trays to provide protection from mechanical
damage.
‡ Observe the permitted bending radiuses (generally, min. six times the cable diameter for
multi-conductor cables).
‡ Keep all connections outside of conduits as short as possible.
Warning
‡ Always observe the general safety regulations and safety instructions given in Section 1
when carrying out any installation work.
DANGER
‡ Installation work shall only be carried out by trained staff and in accordance with the
relevant regulations issued by the operating company.
‡ Take all necessary precautions to avoid local or plant-specific dangers.

General connection of the FLOWSIC600
Gas Volume at base

Compressibility factor Z Electronic Volume
conditions
Corrector (EVC) /
Heating value Hs Flow Computer (FC)
Energy content
Installation examples
Gas volume at flowing conditions Pressure Temperature
see Section 10.8
RS485 / MODBUS
Service PC / higher-
level control system (Ex i isolating transformer only required
for intrinsically safe installation)
12 ... 24 V DC
Safe area
Hazardous area
FLOWSIC600
Fig. 5.6: FLOWSIC600 connection diagram

5.4.2 Cable specifications
Warning
The cables must fulfill the requirements for use in hazardous areas (e.g set forth in EN
60079-14 or other relevant standards).
ATTENTION
Power supply 12 … 28.8 V DC

Specification Notes
Type of cable Two conductors Connect shielding (if present) to
ground terminal
Min./ max. cross- 0.5 mm² / 1.5 mm² (16 to 20 AWG)
sectional area
Maximum cable length Depending on loop resistance; Peak current 150 mA
Minimum input voltage on the
FLOWSIC600 12 V
Cable diameter 6 ... 12 mm (1/4 to 1/2 inch) Fixing range of the cable glands
Digital output / current output

Specification Notes
Type of cable Twisted pair, shielded Connect shielding at other end to
ground terminal
Min./ max. cross- 2 x 0.5 mm2 (2 x 20 AWG) Do not connect unused
sectional area conductor pairs and prevent
them from accidental short-circuit
Maximum cable length Loop resistance under load ≤ 250 Ω
Serial port (RS485)

Specification Notes
Type of cable Twisted pair, shielded, Connect shielding at other end to
impedance approx. 120Ω ground terminal
Min./ max. cross- 2 x 0.5 mm2 (2 x 20 AWG)
sectional area
Maximum cable length* 500 m at 0.5 mm² Do not connect unused lead
1000 m at 0,75 mm² (1500 ft for 20 pairs and prevent them from
AWG) accidental short-circuit.
* In case of difficult conditions or cable length longer as specified, we recommend to use a data
repeater (Part No. 7042042).

5.4.3 Checking the cable loops

Check the cable loops to verify that the cables are connected correctly. Proceed as follows:
‡ Disconnect both ends of the cable of the loop to be tested. This is to prevent connected
devices from interfering with the measurement.
‡ Test the entire cable loop between SPU and terminal device by measuring the loop
resistance.
‡ If you want to test the insulation resistance as well, the cables must be disconnected
from the electronic module before using the insulation resistance tester.
Important
The test voltage applied would seriously damage the electronic module!
ATTENTION ‡ Reconnect all cables after the loop resistance test.
Important
• In non-intrinsically safe installations, the EExe terminal boxes and connect/ disconnect
cables must only be opened if the system is disconnected from the power supply.
ATTENTION • The front cap (with display panel) must only be opened if the system is disconnected from
the power supply and only 10 minutes or more after the system has been switched off.
• Incorrect cabling may cause failure of the FLOWSIC600. This will invalidate warranty
claims. The manufacturer assumes no liability for consequential damage.

5.4.4 Terminal enclosure on the SPU
Opening the rear housing cover

‡ Loosen the securing clip using a 3 mm Allen key.
‡ Turn the rear housing cover counter-clockwise and take it off.
A schematic wiring diagram is provided on the inside of the rear housing cover (see also
Appendix, Section 10.4).
Open the cover
Cover
Securing clip
Fig. 5.7: SPU housing
HSK-K type cable glands,

M 20 x 1.5 plastic (EU)
or ½ in NPT (North America) Bridge
Cover for power
supply terminals
Power supply
2 x 1.5 mm2 1
2
(LiYCY or equivalent)
Digital output / current

output Cable entry for internal 10-
4 x 2 x 0.5 mm2 core cable
(Li2YCY [TP] or equivalent)
Modbus 10-pole terminal block

for signal inputs and outputs
4 x 2 x 0.5 mm2
(Li2YCY [TP] or equivalent)
Fig. 5.8: Terminal box on the rear of the SPU ((see Section 5.4.2for North American wiring
specification equivalents)

Terminal box
Power supply Field connections (10-pole terminal block)
Fig. 5.9: Terminal assignment for use in safe areas
Note: Terminals 2 and PE are bridged internally, i.e. there is no insulation between PE and negative
potential (see Fig. 5.8).

5.4.5 Operating the FLOWSIC600 in safe areas

Assign the terminals in the SPU terminal box (see Fig. 5.9) in accordance with the following
table.
No. Connection for Function Terminal Value Notes

1 Power supply 1+, 2- 12 ... 24 (+20 %) V DC
2 Digital output DO 0 Passive 31, 32 fmax = 6 kHz, pulse duration 0.05 s - 1 s With NAMUR contact
(HF 2) Range: for connection to
Variable number of pulses per volume unit switching amplifier
“closed”: (to DIN 19234)
0 V ≤ UCE L ≤ 2 V, 2 mA ≤ ICE L ≤ 20 mA (L=Low)
“open”:
16 V ≤ UCE H ≤ 30 V, 0 mA ≤ ICE H ≤ 0.2 mA (H=High)
3 Serial port Modbus 33, 34 9600 Baud, 8 data bits, no parity, 1 stop bit Baud rate to be set
(RS485) through software
4 Digital output DO 1 Passive 51, 52 fmax = 6 kHz, pulse duration 0.05 s - 1 s With NAMUR contact
(HF 1) Range: for connection to
Variable number of pulses per volume unit switching amplifier
“closed”: (to DIN 19234)
“open”:
5 Digital output DO 2 Passive 41, 42 “closed”:
“open”:
“Check request” (default)
6 Digital output DO 3 Passive 81, 82 “closed”:
“open”:
“Direction of flow” (default)
(alternative “Warning”)
Alternative assignment with second 9600 Baud, 8 data bits, no parity, 1 stop bit Baud rate to be set
serial port (RS485) through software

5.4.6 Operation in hazardous areas (Directive 94/9/EC (ATEX))

The power supply and field connections are designed with the increased type of protection
("e"). The transducer connections are of an intrinsically safe design ("ia").
All screw-type terminals as well as air gaps and creepage distances of the FLOWSIC600
comply with EN 50019.
Connection characteristics
Power supply connection Field connections

Separate terminal box, separated from the Separate terminal box, separated from the
field connections with partition wall in the power supply connections with partition wall
housing and cover to EN 50020. in the housing and cover to EN 50020.
Cable routing via EExe cable gland, M5 Cable routing via 2x EExe cable gland
ground terminal integrated into housing
section (cast-on part).
Connection options
The protection concept for the FLOWSIC600 permits the following connection options:
• Power supply connection and field connections with increased type of protection ("e")
• Intrinsically safe power supply connection and field connections ("i")
• Power supply connection with increased type of protection ("e"), while the field
connections are intrinsically safe ("i")
The user shall decide which option is to be used, taking into account local / national
regulations and standards or EN 60079-14.
A combination of intrinsically safe and non-intrinsically safe circuits is not permitted in the
terminal box for the field connections.
The rated voltage of non-intrinsically safe circuits is UM = 253 V.

Requirements regarding cabling in hazardous areas (ATEX)

• The cables must fulfill the requirements set forth in EN 60079-14.
• Cables that are subject to exceptional thermal, mechanical, or chemical loads must be
specially protected (e.g. laid in open-ended conduits).
• Cables that are not fire proof must demonstrate fire resistance according to DIN VDE
0472, Part 804, test type B.
• Ferrules must be attached to the wire ends to ensure that they do not split up.
• The applicable requirements regarding air gaps and creepage distances must be
observed in accordance with EN 50019. The available air gaps and creepage distances
in the terminal box must not be reduced when connecting the cables.
• Unused cable glands must be replaced by the EExe plugs included in the delivery.
• The equipotential bonding must be in accordance with EN 60079-14.
• The meter body and SPU housing must be connected to the potential equalizer. In
intrinsically safe circuits, provide equipotential bonding along the wiring runs of the current
outputs.
• The applicable national specifications shall also be observed.
Terminal assignment
The terminal assignment in the SPU terminal box (see Fig. 5.9) is the same as for the
installation of the FLOWSIC600 in non-hazardous areas (see table in Section 5.4.5).
Important
The protective conductor must not be connected within the hazardous area. For
measurement reasons, the equipotential bonding must, as far as possible, be identical to
ATTENTION the pipeline potential. Additional grounding with the protective conductor PE via the
terminals is not permitted!

Notes for safe operation in hazardous areas

Approval of the ultrasonic • Type of explosion protection: II 1/2G EEx de ib [ia] IIC T4 or II 2G EEx de ib [ia] IIA T4
transducers in zone 0 is only • Ambient temperature: -20°C to +60°C
valid for operation under In the extended temperature range from -40 C to +60 C, metal cable glands shall be
atmospheric conditions. used.
• The cable glands included in the delivery are black. If terminals are assigned with
intrinsically safe circuits, it is recommended to replace the black ones with the light-blue
(RAL 5015) cable glands provided.
• For the temperature class according to the ambient temperature and gas temperature,
see the EC Type Approval Certificate.
• The type of protection for the field connections and power supply connection is
determined by the external circuits that are connected (for options see "Connection
options" above).
• Safety-relevant data for intrinsically safe circuits is provided in the EC Type Approval
Certificate.
• Ensure that the cover on the power supply connection is properly sealed. In intrinsically
safe installations, the terminal box can be opened and cables connected and
disconnected while the system is live.
• If the meter body is insulated, the insulation thickness must not exceed 100 mm. The
SPU housing must not be insulated.
Important
Always observe the temperature specifications for use in hazardous areas.
ATTENTION
Aux. power 1+
Power supply 2-
PE
Terminal box “e”, “i”
31 Signal processing
Digital output
32 unit
33
RS485
34
51 Pressure-resistant
Digital output
52 space “d”
Field connections
41
Digital output
42
81
Digital output
82
PA
Meter body
Ultrasonic transducers “ia”
Fig. 5.10: FLOWIC600 components and their type of protection

Safety-relevant data of inputs and outputs
Output circuit Intrinsically safe EEx ia IIA / IIC Non-intrinsically safe

UM = 253 V
Active current output UO = 22.1V UB = 18 V
Terminals 31/32 IB = 35 mA
IO PO EEx ia IIA EEx ia IIC
[mA] [mW] CO [nF] LO [mH] CO [nF] LO [mH]
155 / 155 857 / 857 4100 7 163 1
Characteristic curve: linear
Internal capacity CI = 4 nF, internal inductance LI = 0.075 mH
Only for connection to passive, intrinsically safe circuits or intrinsically safe circuits
with the following maximum values: VI = 30 V
Passive current output UI = 30 V CI = 4 nF UB = 30 V
Terminals 31/32 II = 100 mA LI = 0.075 mH IB = 35 mA
PI = 750 mW
Digital output UI = 30 V CI = 4 nF UB = 30 V
Terminals 31/32, 51/ II = 100 mA LI = 0.075 mH IB = 100 mA
52, 41/42, 81/82 PI = 750 mW
RS485 Characteristic curve: linear UB = 5V
Terminals 33/34 and Uo = 5.88 V Ui = 10 V IB = 175 mA
81/82 Io = 313 mA Ii = 275 mA
Po = 460 mW Pi = 1420 mW
Co = 1000 • F/43 • F
Lo = 1.5/0.2 mH
Ultrasonic transducer EEx ia IIA EEx ia IIC
connections Characteristic curve: linear
(for connecting SICK Max. transmission voltage Uo = 60.8 V Uo = 38.9 V
ultrasonic transducers Short-circuit current Io = 95 mA Io = 60 mA
only) Po = 1444 mW Po = 584 mW
Co = 300 nF Co = 34 nF


FLOWSIC600
Commissioning
General Notes
Function Check
Field Setup
Activation of Path Compensation
Sealing
Operating Instructions Commissioning FLOWSIC600
6 Commissioning
6.1 General Notes
Before commissioning, all activities described in Chapter 5 must be completed. It is
recommended to use a laptop/PC with installed MEPAFLOW600 CBM software be used for
the commissioning (see Section 3.2 of this Manual).
The FLOWSIC600 is ’wet’ or ’dry’ calibrated when delivered to the end user. The ’dry’
calibration contains the 3-D measurement of the meter body, zeroflow and speed of sound
test, and other system specific inspections/tests which belong to the manufacturing and
quality assurance process. The ’wet’ calibration is performed at a flow calibration test stand
(calibration test facility).
All parameters, determined by the aforementioned tests, as well as design specific data are
preset and stored in the FLOWSIC600 in a non-volatile memory before delivery. The design-
specific data which is known before manufacturing the device will not be changed during
commissioning. This is of special importance if the FLOWSIC600 is officially sealed after an
authorized flow calibration. Generally, the parameters are protected by a password.
Additionally a Configuration protection switch in the SPU prevents custody relevant
parameter changes.
If the FLOWSIC600 is to be used for custody transfer applications, each change of

parameters and of the configuration protection switch has to be agreed to by the applicable
national authorities.
TYPE APPROVAL
In all other cases the output parameters of the FLOWSIC600 can be adapted on site by
trained staff.
Commissioning the FLOWSIC600 involves the following steps, no matter whether the device
is installed at a test facility or at the final measuring location:
• Function check (Section 6.2)
• Field setup (Section 6.3)
• Documentation (Section 6.3)
• Activation of path compensation (Section 6.4)
• Sealing (Section 6.5).

FLOWSIC600 Commissioning Operating Instructions
6.1.1 Checking identification, operation and design data

Before commissioning, cross-check the data presenting the flow meter with the data in the
test protocols which are contained in the Manufacturer Data Report (MDR). This can be
done on the LCD display (if available; see Section 10.2 of this Manual) or - much easier -
with MEPAFLOW600 CBM software.
To cross-check the data with MEPAFLOW600 CBM, open the ’’Meter information’’ screen
and compare the data in the ’’Identification’’ section (see Fig. 6.1) with the data in the check
reports of the MDR (see Section 10.7.4) or, when the meter has been calibrated, with the
calibration and parameter report.
Fig. 6.1: ’‘‘Meter Information” screen
6.1.2 Firmware
The FLOWSIC600 firmware is stored on a non-volatile memory (FLASH PROM). The program
code for the signal processor and system micro-controller are identified by a version number
(register#5002) and a check sum (register #5005) and can be verified as mentioned
above.
If the FLOWSIC600 is used for fiscal metering, the approved firmware versions and the
associated check sums are documented in the national pattern approval certificates.
TYPE APPROVAL

6.2 Function Check
6.2.1 FLOWSIC600 with LED front panel

The FLOWSIC600 is functioning correctly when the green status LEDs for each measuring
path installed start flashing periodically approximately 30 seconds after the power supply is
switched on.
If the yellow LED flashes, the FLOWSIC600 works in the operation state ’’Check request’’
with an insignificantly reduced accuracy (e.g. if one path fails).
If the yellow LED lights up permanently, the measurement is invalid. In this case, you must
diagnose the error (see Chapter 8 of this Manual).
6.2.2 FLOWSIC600 with LCD front panel

The FLOWSIC600 is functioning correctly, if the standard display shows two pages of
measurands and current readings and the pages alternate every 5 seconds. (For operation
and menu structure of the SPU with LCD see Section 10.2 of the appendix.) If the logbooks
contain unacknowledged Errors, Warnings or Information, the corresponding letter is
displayed in the upper right hand corner and flashes. If a current error or warning is active,
the display will be interrupted by an error message every 2 seconds. As soon as the cause
of the error has been rectified, the FLOWSIC600 automatically returns to the standard
display. Detailed information on errors is available in the logbook (see Section 2.7.3 and
10.3 of this Manual). The flashing letter disappears, once the message has been
acknowledged in the logbook. See Chapter 7 of this Manual for error diagnosis.
Note: You are advised to check the plausibility of the measured and diagnosis values, even if the
device is functioning properly (see Chapter 6 of this Manual).
6.2.3 Function test

The major system parameters are configured at the factory. The default settings should
allow error free operation of the FLOWSIC600. Nevertheless, correct meter operation
should be verified on site when the meter is installed and is subject to acutal operating
conditions. This verification is to be carried out according to the description in the Sections
4.3.8 and 4.3.9 of this Manual.
Note: Since the check is carried out with the MEPAFLOW600 CBM software, also note Section
5.2.4, which describes the procedure for connecting to the FLOWSIC600 with the

6.3 Field Setup

The MEPAFLOW600 CBM software ‘‘Field setup” wizard guides through the parameter
configuration during the commissioning of the FLOWSIC600. The wizard consists of 8 pages.
For checking and configuration refer to the ‘‘Instrument Data Sheet” of the FLOWSIC600,
which is included in the Manufacturer Data Record (MDR) (example see Fig. 6.2).
Note: The parameter changes performed in the Field setup wizard require the password level
‘‘Authorized operator”.
INSTRUMENT DATA SHEET FOR : ULTRASONIC GAS FLOW METER

0 Typecode FL600-4P3D06CL0600SC0040RF2N-S1-1DC1N1Y
1 GENERAL 54 TRANSMITTER (Integral)

2 56 * Power supply 12 .. 28,8 V DC < 1W
3 Type FL600 57 * Enclosure classification IP 67
4 Meter size 06'' / DN150 58 * Cable entry 1/2'' NPT
5* Article number 1042 247 ° 59 Hazardous Area Class. Class 1, Division 1, Group D, T4
Class 1, Division 2, Group D, T4
6* TAG number 0
Class 1, Zone 1, Group IIA, T4
7* Order number Class 1, Zone 2, Group IIA, T4
8 60 SPU housing material Aluminium
9 METER BODY ° 61 Ambient temperature (range) °F -40 ... 140
10 Pipe diameter inch 6,1 - SC040 62 Display LCD
11 Overal length (A) inch 17,72 63 Display language English
12 Overal height (B) inch 19,29 64 Engineering units Imperial
13 Weight lb 309 65 Output and Signal Configuration - Signal processing unit
14 Flow range cft/h 1130 ... 106000 66 DO0/AO0 Clamp 31/32 (HF-Pulse) Volume a.c. 180° shifted to DO1
15 Number of meas. paths 4 67 Signal configuration Open Collector / normally closed
16 Linearity +/- 0.5% of MV 0.1 .. 1 Qmax 68
17 * Repeatability < 0,1% 69
18 Flange design code ANSI 70
19 Flange class CL0600 71
20 Flange face Raised Face/stock finished 72 MOD Clamp 33/34 (RS 485) Modbus ASCII
21 Body material l.t. c-steel 1.6220/A352LCC 73 DO1 Clamp 51/52 (HF-Pulse) Volume a.c.
22 Transducers exchangeable under pressure No 74 meter factor 1/cft 68
23 * Transducer cover Aluminium 75 Signal configuration Open Collector / normally closed
° 24 Design temperature (range) °F -51 ... 185 76 max. Output 0...30 V / 0...100 mA
° 25 Design pressure psi (g) 1450 77 DO2 Clamp 41/42 (Status) Status Maintenance required
26 Material certificate 3.1 EN 10204 78 Signal configuration Open Collector / normally closed
27 * Enclosure classification IP 67 79 max. Output 0...30 V / 0...100 mA
28 * Surface coating / painting two layers: Epoxy + Acrylic 80 DO3 Clamp 81/82 (RS 485) Modbus ASCII
29 * Pressure tapping 1/4" NPT female 81
30 Sensors 82
31 83 COMMUNICATION
32 * Sensor material Titan 3.7165 84 Interface 2x RS 485
33 85 Protocol Modbus ASCII
34 86
Fig. 6.2: Example of an ‘‘Instrument Data Sheet!” as contained in the MDR

6.3.1 Location information and unit system (Field setup page 1 of 8)
‡ Give information about the measuring site (see Fig. 6.3).
‡ Click the ‘‘Write to device” button.
Fig. 6.3: Field setup wizard page 1 of 8: Location information

6.3.2 Application data (Field setup page 2 of 8)

The pressure and temperature values which have to be entered at this page are stored as
the parameters PressureFix and TemperatureFix.
Fig. 6.4: Field setup page 2 of 8: Application data
These values are used to correct the influence of geometric changes of the meter body due
to temperature and pressure on site (in relation to the conditions during the dry calibration
/ wet calibration). These values are also used when the FLOWSIC600 operates with the
integrated volume corrector using constant temperature and pressure correction of the
volume.
The pressure value is to be determined as described in the Section 4.2.4 of this Manual.
The ‘‘Low flow cut off” is usually set to 25% of Qmin. If the option HART® protocol is ordered,
you can activate the checkbox ‘‘Optional P and T reading via HARTBUS”.

6.3.3 Integrated electronic volume corrector (EVC) (Field setup page 3 of 8)

If the meter was ordered with the option ‘‘Integrated electronic volume corrector (EVC)”, the
integrated electronic volume corrector has to be activated here and the gas characteristics
have to be input.
Fig. 6.5: Field setup page 3 of 8: Integrated electronic volume corrector

6.3.4 I / O configuration - Output configuration (Field setup page 4 of 8)

The output configuration has to be set based on the information provided in the Instrument
Data Sheet.
Fig. 6.6: Field setup page 4 of 8: I / O configuration

6.3.5 I / O Configuration - Terminal assignment (Field setup page 5 of 8)

The terminal assignment contains five tabs for the individual terminals and one for the
overview. In these tabs, the outputs can be specifically configured. For detailed information
on the output signal and for support functions use the information buttons (when displayed).
For the pulse output, use the built in Meter Factor calculator.
Meter factor calculator

Information button
Fig. 6.7: Field setup page 5 of 8: I / O configuration - Terminal assignment, tab for terminals 31/32
Meter factor
The meter factor specified on the main type plate must be identical to the meter factor in
the meter‘s firmware, which is displayed on the terminal assignment page, when a pulse
output is selected (you also find the meter factor on the ‘‘Meter parameter” page at register
#7027). The meter factor is set at the factory according to the customer‘s statement. If this
doesn‘t exist, the meter factor is set to a standard value such that the maximum pulse
output frequency is approximately 2 kHz at the maximum flow rate (see Section 2.2.4 of
these Operating Instructions).
If the meter factor has to be modified to the current application during the commissioning,
any change must be agreed with the authorities, if the meter is used for fiscal purposes. In
this case, the main type plate has to be exchanged with a new one containing the new meter
TYPE APPROVAL factor. Contact your SICK representative to obtain a new type plate.
The new meter factor can be calculated according to the following formula:
fmax • 3600 Pulse

Meter factor =
Qmax Volume unit
fmax : max. pulse frequency[Hz]

Qmax : max. volumetric flow [m³/h], [ft³/h]

For assistance in calculating the meter factor, use the integrated ‘‘Meter factor calculator”
by clicking the button (see Fig. 6.7 and Fig. 6.8).
Fig. 6.8: Meter factor calculator
Warning limits
If there is a status output configured as ‘‘Warning”, the window ‘‘Warning limits” will be
shown. Here the displayed limit warnings can be edited. Factory settings are preset. (If there
is no need to change them, or if you are not sure about consequences of changes, keep
the values as they are and discuss with a SICK|MAIHAK representative.)
Fig. 6.9: Warning limits

Analog output
To adapt the FLOWSIC600 to the different application conditions the analog output has to
be adapted. The adjustment of the analog output requires the change of various
parameters.
The output current Iout is calculated as follows:
Q − AORangeLow
Iout = 4 mA + • 16 mA
(AORangeHigh - AORangeLow)
Q: Actual volumetric flow rate, normalised volumetric flow rate,

mass flow rate, molecular weight
AORangeHigh: Upper range limit (has to be set)
AORangeLow: Lower range limit (has to be set)
6.3.6 LCD Display setup (Field setup page 6 of 8)

Assign the language to be used in the menu of the LCD display. Choose from the dropdown
menu, what measurands and readings are to be displayed on the two page standard
display. See Section 10.2 in the Appendix for more information on the LCD display.
Fig. 6.10: Field setup page 6 of 8: LCD display setup with dropdown menu

6.3.7 Configuration update (Field setup page 7 of 8)
‡ Switch the meter into the Configuration mode.

User Access Level: ‡ To write the configuration and parameter settings specified on page 2 to 6 of the ‘‘Field
‘‘Authorized Operator” or setup” wizard to the meter, use the ‘‘Write to flow meter” button. The summary field
‘‘Service” displays information about the actions just carried out (successful or uncsuccessful
writing of parameters).
‡ To reset the error volume counters and the logbooks - which is recommended after
commissioning the meter - use the ‘‘Reset at flow meter” buttons.
‡ The time synchronization function makes it possible to write your PC time to the meter
and thus synchronize the meter with your local time settings. Be careful with this function
and read Section 2.7.1 of this Manual before using it.
‡ Switch the meter back to the Measurement mode.
‡ Print a parameter report to document any changes made.
‡ Before creating the final maintenance report according to Section 6.3.8, activate the path
compensation according to Section 6.4.
Fig. 6.11: Field setup page 7 of 8: Configuration update

6.3.8 Maintenance Report (Field setup page 8 of 8)

Create the final Maintenance report.
‡ Enter the information (Description, Technician) in the fields provided.
‡ Specify the collection duration, a timespan, over which live meter data is to be collected
to document the meter‘s state after the field setup. (Live data collection starts after you
click the ‘‘Start” button.)
‡ Enter the current pressure, temperature and SOS. If the SOS is unknown, use the Speed
of sound Calculator (SOS calculator) to calculate the SOS for the gas composition. The
gas composition must be current and representative (See Section 7.3 of this Manual for
more details on the SOS calculator).
‡ Click the ‘‘Start” button to start live data collection. Diagnosis data, measured values and
status information will be collected over the specified time span.
‡ Click the ‘‘Create report” button. The Maintenance report will be created and displayed.
Print it and store a copy in the Manufacturer Data Report (MDR) shipped with the meter.
Additionally the data is stored in the MEPAFLOW600 CBM meter database and
accessible via the ‘‘Meter explorer” and the ‘‘Report manager”. The Maintenance report
can also be exported to Excel using the direct link provided when the Maintenance report
is displayed.
Fig. 6.12: Field setup page 8 of 8: Maintenance report

6.4 Activation of Path Compensation

The ‘‘PathCompValid” parameter has to be set ‘‘valid”, so that the FLOWSIC600 is able to
compensate a path failure (see also Section 2.8 of this Manual).
The meter automatically sets this parameter to ‘‘valid” after operating for about 20 minutes
with error free measurement at all paths at a gas velocity between 1 to 8m/s (3 to 25ft/s)
and also about 20 minutes at a gas velocity higher than 8m/s (25ft/s).
The ‘‘PathCompValid‘‘ parameter is valid, when Bit 14 at the ‘‘Meter status” window is
displayed as active (see Fig. 6.13 ).
Fig. 6.13: ‘‘Meter status” window with active ‘‘PathCompValid” parameter
6.5 Sealing
After having completed the commissioning, seal the signal processing unit (if required) in
accordance with the sealing plan (see Section 10.9).

FLOWSIC600
Maintenance
General
Routine Checks
Maintenance Report
Operating Instructions Maintenance FLOWSIC600
7 Maintenance
7.1 General
The FLOWSIC600 does not contain mechanically moving parts. The meter body and
ultrasonic transducers are the only components that come into contact with the gaseous
media. Titanium and high-quality stainless steel ensure that these components are resistant
to corrosion, provided that the meter is installed and operated in accordance with the
relevant specifications. This means that the FLOWSIC600 is a low-maintenance system.
Maintenance is limited mainly to routine checks to determine the plausibility of the
measured values and diagnostic results produced by the system (for details see the
FLOWSIC600 service manual).
It is recommended to create and file maintenance reports on a regular basis (see Section
7.3). This serves to create a basis of comparable data over time and helps when a fault has
to be diagnosed.
Note: The operating conditions (gas composition, pressure, temperature, flow velocity) under
which the maintenance reports to be compared are generated should be similar. If the
operating conditions are not comparable, they should be documented separately and taken
into account when the data is analyzed.

FLOWSIC600 Maintenance Operating Instructions
7.2 Routine Checks

The information displayed on the front panel LCD display of the FLOWSIC600 meter can be
checked to ensure that the system is functioning properly.
The MEPAFLOW600 CBM software provides a more user friendly way for doing routine
checks. The ‘‘Meter status” window displays a detailed overview about the meters
performance, status and operation. Click on the ‘‘System” button in the top right corner of
the MEPAFLOW600 CBM screen (Fig. 7.1) to call up the ‘‘Meter status” window (Fig. 7.2).
For more detailed information call up the ‘‘Meter values” screen (Fig. 7.3) via the Key
navigation.
Fig. 7.1: Meter status bar with ‘‘System” button
Fig. 7.2: ‘‘Meter status” window
The following values are subject to routine checks:
7.2.1 Speed of sound

The measured speed of sound should be stable. Sudden changes in the measured value
may be indicative of signal detection problems, which can affect transit time measurements,
or changes in the gas composition. A theoretical speed of sound value can be calculated
based on the gas composition, pressure and temperature determined during test
measurements. Implausible measurements can then be indicated by comparing theoretical
and measured speed of sound and identifying any marked discrepancies. The speed of
sound in the individual paths should also be approximately identical (see Graph 3 in Fig.
7.3.).
Note: Use the SOS Calculator provided in the ‘‘Maintenance report” wizard (see Fig. 7.4. and
Section 7.3), or in the options list for the SOS chart on the ‘‘Meter values” screen, to
calculate the theoretical SOS.

7.2.2 Performance
The performance is the percentage of valid received ultrasonic signals for each path. That
means, if 5 of 100 transmitted signals do not meet the acceptance criteria for a signal
analysis, then the performance of this path is only 95%. The performance of each path
should be very close to 100% (Fig. 7.3).
Fig. 7.3: ‘‘Meter values” screen with 9 graphs
Due to signal attenuation on the way from the transmitting to the receiving sensor or due to
acoustic noise, also caused by very high gas velocity, the performance can be significantly
lower. The minimum performance at which reliable gas velocity values are supplied is 5%.
When the performance falls below 5 %, the path failes and will be substituted by a
replacement value. (For more detail see Section 2.8. of this Manual).
Significant discrepancies in the values under comparable conditions (pressure,
temperature, flow velocity, gas composition) indicate that changes have occurred in the
device or piping (e.g. disturbance caused by a valve that is not fully open).
7.2.3 Reception sensitivity (AGC level)

The reception sensitivity (AGC level) set by the meter largely depends on the process
pressure. At normal conditions, this value is very stable over time. The difference between
the ultrasonic transducers on each of the measuring paths is small, although it can increase
at higher velocities. Significant fluctuations in the reception sensitivity indicate a low-quality
received signal. A significant increase under comparable process conditions is usually
caused by dirt on the ultrasonic transducers (see the Service Manual for cleaning
instructions).
7.2.4 Signal-to-noise ratio

These values are generally site-specific and do not change as long as the conditions remain
the same. A reduction in the signal-to-noise ratio while the reception sensitivity stays
unchanged, hints at sources of acoustic interference (e.g. pressure regulator) near the point
of measurement.

7.2.5 Overview of typical values
Parameter Typical value Error Comment

Speed of sound Deviation from the Greater than ± 0.3 % When calculating the
theoretical speed of theoretical speed of sound,
sound less than attention has to be paid to
± 0.3 %. ensuring that the gas
composition, pressure and, in
particular, the temperature at
the measuring location are
identical to those when the
test measurements were
conducted.
The differences Greater than Temperature stratification
between the speed of ± 1.5 m/s (5 ft/s) can occur with low flow rates.
sound readings in the
individual paths should
not exceed ± 1.5 m/s.
(5 ft/s)
Signal-to-noise ratio ~20 dB Permanently less than Possible sources of
This depends on the 10 dB interference include electrical
nominal diameter of noise caused by bad contact
the meter body and of the connectors or sources
the current process of acoustic interference, such
pressure. as control valves or very high
flow velocities.
Reception This depends on the Significant deviations The reception sensitivity is
sensitivity / AGC nominal diameter of (greater than 50%) inversely proportional to the
level the meter body and from the historical process pressure: if the
the current process data with comparable pressure doubles, the
pressure. process pressures sensitivity will halve.
Performance > 75% Permanently less than
50%
Deviations from the typical values specified in the table can indicate a malfunction. In
addition to diagnosing the error as described in this Chapter, you can also create a
Diagnosis session and send it to your SICK MAIHAK representative for support (see Section
8.1).
Note: It is recommended that Maintenance reports be filed and printed on a regular basis. See
next Section for details.

7.3 Maintenance Report

It is recommended that Maintenance reports be generated on a regular basis. This serves
to create a basis of comparable data over time and helps when a problem has to be
diagnosed.
To create a maintenance report, follow the described procedure:
‡ Call up the ‘‘Maintenance report” wizard using its entry in the Key navigation (see Fig.
7.4).
Fig. 7.4: ‘‘Maintenance report” wizard
‡ Enter the information (Description, Technician) in the fields provided.
‡ Specify the collection duration, a timespan, over which live meter data is to be collected
to document the meter‘s state.

‡ Enter the current pressure, temperature and SOS. Use the SOS Calculator to calculate
the SOS for the gas composition. The gas composition must be current and
representative.
‡ Click the ‘‘Start” button to start live data collection. Diagnosis data, measured values and
status information will be collected over the specified time span and will be saved in the
meter database
‡ Click the ‘‘Create report” button. The Maintenance report will be generated and displayed.
‡ Print it and file the copy in the Manufacturer Data Report (MDR) shipped with the meter.
Additionally the data is stored in the MEPAFLOW600 CBM meter database and
accessible via the ‘‘Meter explorer” and the ‘‘Report manager”. The Maintenance report
can also be exported to Excel using the direct link provided when the Maintenance report
is displayed.
Note: The operating conditions (gas composition, pressure, temperature, flow velocity) under
which the maintenance reports are created, should be similar. If the operating conditions are
not similar, they should be documented separately and taken into account when the data is
analyzed.

Speed of Sound Calculator (SOS Calculator)

The Speed of Sound Calculator (SOS Calculator) accessible in the ‘‘Maintenance report”
wizard calculates a theoretical speed of sound for a specific gas composition at a specified
temperature and pressure (see Fig. 7.5). The calculation of thermodynamic properties is
based on the ‘‘GERG-2004 Wide-Range Equation of State for Natural Gases and other
Mixtures”. The algorithms that are implemented in the SOS calculator where developed by
the Ruhr-University Bochum (Germany).
Checkbox for advanced options
Fig. 7.5: Speed of Sound Calculator with loaded gas composition file (ekofisk.cmp)
‡ Start the SOS calculator from the maintenance report (see Fig. 7.4).
‡ Load one of the offered files with typical gas compositions (Menu File - Open File) and
modify it, or enter your gas composition.
‡ Specify temperature and pressure.
‡ Click the ‘‘Calculate” button to start the calculation.
‡ The calculated value is automatically copied to the corresponding field in the

‘‘Maintenance report” wizard.
‡ For additional settings, activate the ‘‘Advanced” checkbox.


FLOWSIC600
Troubleshooting
Generation of a Diagnosis Session

Operating Instructions Troubleshooting FLOWSIC600
8 Troubleshooting
If the routine tests described in Section 7.2 or the function tests described in Section 6.2.3
indicate that, there may be a measurement problem. The following table may help
determine the cause of the problem. If the cause of the problem cannot be localized, the
MEPAFLOW600 CBM software can be used to record the current parameter set and
diagnosis values in a diagnosis session file (see following page).
Display, parameter Possible cause Corrective action

• No display Faulty power supply • Check the input voltage at terminals 1 and 2
• No pulse frequency • Check cables and terminal connections
• No active status Caution
signal Take the relevant safety precautions!
Defective device Contact the SICK|MAIHAK representative
Warnings and Errors on Transducer(s) are dirty Clean the transducer(s) (see Service Manual,
the LCD display Chapter 8)
Transducer(s) are Replace the transducer(s) (see Service Manual,
defective Chapter 8)
Cables mixed up Check and correct, if necessary
when transducer was
cleaned
Different speed of Faulty transducer or Replace the transducer(s) (see Service Manual,
sound in the individual electronic module Chapter 8)
paths Note
Temperature-induced stratification can result in
differences between the individual paths,
especially with very low flow (higher temperatures
generate higher velocities of sound). Even if the
plant is being filled or if it is shut down, different
velocities of sound may occur in the individual
paths as a result of stratification.
Implausible speed Gas composition,
of sound pressure or
temperature
measurement is
incorrect
• Lower signal-to- Damaged transducer Replace the transducer(s) (see Service manual,
noise ratio and Chapter 8)
reception sensitivity
• Increased number Additional sources of Check the measurement plausibility and number
of rejected noise due to a valve of rejected measurements and, if necessary,
measurements in that is not fully open, eliminate noise sources.
individual paths fittings, noise sources
near the device
Increased reception Different gas No activity required on the device
sensitivity composition or
process pressure
Transducer(s) are dirty Clean the transducer(s) (see service manual,
Chapter 8)
Increased number of Additional noise Eliminate noise sources
rejected sources
measurements in all Gas velocity outside
paths the measuring range

FLOWSIC600 Troubleshooting Operating Instructions
8.1 Generation of a Diagnosis Session

If it becomes necessary to generate a Diagnosis session for remote support, follow the
procedure described below:
‡ Start the MEPAFLOW600 CBM software and establish an online connection to the meter
in question (see Chapter 3 for all necessary preparations).
‡ Click the ‘‘Diagnosis session” item in the Key navigation (see Fig. 8.1)
Abb. 8.1: ‘‘Diagnosis session” generation
‡ Specify a file name. (The file path is set according to the program settings. If necessary,
specify a differing path.)
‡ Click the „Safe” button.
‡ MEPAFLOW600 CBM will now download the logbooks from the meter and generate a
Diagnosis session (entire process takes about 3 minutes) with all relevant data.
‡ Email the Diagnosis session file to your SICK representative for support.

FLOWSIC600
List of Parts
Tools and Accessories
Spare Parts
Operating Instructions List of parts FLOWSIC600
9 List of parts
9.1 Tools and Accessories
Designation Part number

Transducer extraction tool 7041772
Special key for extractable ultrasonic transducers 4047937
Coax connection tool NL200 4047938
LCD control set (magnetic pen, adhesive straps) 2032787
MEPA interface set RS485 / RS232 (Adam, power supply, cable) 7041773
MEPA interface set RS485 / RS232, intrinsically safe 6029957
for DIN mounting rail
MEPA interface set RS485 / USB (converter, cable, plug, software) 6030669
Data repeater RS485 7042042
MEPAFLOW600 CBM

FLOWSIC600 List of parts Operating Instructions
9.2 Spare Parts
SPU housing and electronic module

Power supply terminal box cover with seal 7041671
Set of clips (for SPU housing rear cover and front panel) 2031000
SICK LCD front panel 7041660
Connection block (EMC board and backplane) 2040275
Fuse board with parts needed for assembly 2041502
Electronic block IIA/D 135 kHz (power, SPU, I/O, analogue) 2040382
Electronic block IIC/BCD 135 kHz (analogue board and shunt board) 2040383
Electronic block IIA/D H 135 kHz (analogue board and shunt board) 2040384
Electronic block IIC/BCD H 135 kHz (analogue board and shunt board) 2040385
Electronic block IIA/D 200 kHz (analogue board and shunt board) 2040386
Electronic block IIC/BCD 200 kHz (analogue board and shunt board) 2040387
Electronic block IIA/D H 200 kHz (analogue board and shunt board) 2040388
Electronic block IIC/BCD H 200 kHz (analogue board and shunt board) 2040389
Buffer battery 7048533
Ultrasonic transducers and gaskets

Transducer pair, type S1 (200 kHz, 100 bar, 85 °C, titanium, P18) 7042400
Transducer pair, type 22 (200 kHz, 250 bar, 120 °C, titanium, P18) 2039997
Transducer pair, type M6 (200 kHz, 10 bar, 120 °C, titanium/+layer, P10) 2032592
Transducer pair, type L8 (135 kHz, 100 bar, 280 °C, titanium, P18) 2040394
O ring 15 * 2.0 (Viton, natural gas resistant, -25 ... +200 °C) 7045173
O ring 15 * 2.0 (Viton, LT170-TT, natural gas resistant, -40 ... +200 °C) 5314393
O ring 15 * 2.0 (Celrez, FFKM-900, -15 ...+260 °C) 5315517
O ring 11.5 * 1.5 (Viton, natural gas resistant, -25 ... +200 °C) 5313739
O ring 11.5 * 1.5 (Viton, V747-75, -25 ... +200 °C) 5314241
O ring 11.5 * 1.5 (Celrez, FFKM-900, -15 ...+260 °C) 5314490
O ring 7.5 * 1.5 (Viton, natural gas resistant, -25 ... +200 °C) 7044129
O ring 7 * 2.0 (Viton, LT170-TT, natural gas resistant, -40 ... 200 °C) 5315493

Operating Instructions List of parts FLOWSIC600
Other

Plug 1/4 in NPT 7045206
Plug 1/8 in NPT 2039447
Retaining bolt M27 * 2 7041294
Spring washer B12 7045991
Retaining bolt M22 * 1.5 4040076
Serrated lock washer I 10.5 5313750
Retaining bolt M16 * 1.5 4039880
Serrated lock washer I 8.2 5313705
Sealing cord for cap, 2.0-EPDM (yard ware) 5308767

FLOWSIC600 List of parts Operating Instructions

FLOWSIC600
Appendix
Characteristic Properties and Dimensions of the Meter Body
Operation and Menu Structure of the SPU with LCD Display
Logbooks
SPU Terminal Assignment
Connection Diagrams for Operating the FLOWSIC 600 in

Hazardous Areas in Accordance with North American
Guidelines (CSA)
Maintenance Report
Manufacturer Data Record (MDR)
Wiring Examples
Sealing Plan
Operating Instructions Appendix FLOWSIC600
10 Appendix
10.1 Characteristic Properties and Dimensions of the Meter Body
Standard materials for meter body
Min. application
Material Temp.
Carbon steel 1.1120 (A216 WCC) - 25 C
LT carbon steel 1.6220 (A352 LCC) - 46 C
Stainless steel 1.4408 (A351 Gr. CF8M) - 180 C
Duplex 1.4470 (A995 Gr.4A/UNS J92205) - 46 C
Tab. 10.1: Material
Weights and dimensions
Model for nominal sizes up to 24‘‘
Model for nominal sizes 24’’ up to 48‘‘
* Dimension F must be
specified by the
customer, as it
depends on the internal
pipe diameter at the
installation location.
Adaptation of pipeline diameter to measuring section
Fig. 10.1: Dimensioned drawing

FLOWSIC600 Appendix Operating Instructions
Nominal Connect- Standard Weight Length Height Flange Width of the Internal
pipe size ion flange (A) (B) diameter measuring diameter
(C) section (D) (E)
[kg] mm mm mm mm mm
cl. 150 28 250 330 152.4 49.3
cl. 300 31 250 340 165.1 49.3
2" cl. 600 ANSI B16.5 33 250 340 165.1 160 49.3
cl. 900 50 42.8
300 360 215.9
cl. 1500 55
PN 16 * 15 150 345 - 155 48
DN50 PN 64 DIN EN 1092-1 26 250 345 180 160 49.1
PN 100 35 250 350 195 49..1
cl. 150 37 335.30 190.50
cl. 300 38 240 344.75 209.50
3" ANSI B16.5
cl. 600 42 344.75 209.50
cl. 900 84 400 360.65 241.30 180 73
PN 16 37 340.00 200.00
DN80 PN 64 DIN EN 1092-1 40 240 347.50 215.00
PN 100 43 355.00 230.00
cl. 150 44 389.30 228.60
cl. 300 55 300 402.00 254.00
4" ANSI B16.5
cl. 600 66 411.55 273.10
cl. 900 99 500 421.05 292.10 240 95
PN 16 40 385.00 220.00
DN100 PN 64 DIN EN 1092-1 52 300 400.00 250.00
PN 100 61 407.50 265.00
cl. 150 100 444.70 279.40
cl. 300 110 450 463.75 317.50
6" ANSI B16.5
cl. 600 140 482.80 355.60
cl. 900 220 750 495.50 381.00 300 142
PN 16 90 447.50 285.00
DN150 PN 64 DIN EN 1092-1 110 450 477.50 345.00
PN 100 130 482.50 355.00
cl. 150 150 496.45 342.90
cl. 300 180 515.50 381.00
8" ANSI B16.5
cl. 600 210 534.55 419.10
cl. 900 300 600 559.95 469.90 350 190
PN 16 140 495.00 340.00
DN200 PN 64 DIN EN 1092-1 190 532.50 415.00
PN 100 210 540.00 430.00
cl. 150 240 543.20 406.40
cl. 300 250 562.25 444.50
10" ANSI B16.5
cl. 600 330 594.00 508.00
cl. 900 470 750 613.05 546.10 410 235
PN 16 220 542.50 405.00
DN250 PN 64 DIN EN 1092-1 270 575.00 470.00
PN 100 320 592.50 505.00
cl. 150 350 596.30 482.60
cl. 300 400 615.35 520.70
12" ANSI B16.5
cl. 600 490 634.40 558.80
cl. 900 720 900 659.80 609.60 470 270
PN 16 325 585.00 460.00
DN300 PN 64 DIN EN 1092-1 425 620.00 530.00
PN 100 525 647.50 585.00
*: Sandwich design (without flanges)

Flange Width of the Internal

Nominal Connect- Weight Length Height diameter measuring diameter
Standard (A) (B) (C) section (D) (E)
pipe size ion flange
[kg] mm mm mm mm mm
cl. 150 475 644.20 533.40
cl. 300 600 669.60 584.20
14“ ANSI B16.5
cl. 600 675 679.15 603.30
cl. 900 800 1050 698.15 641.30 540 315
PN 16 475 637.50 520.00
DN350 PN 64 625 677.50 600.00
PN 100 DIN EN 1092-1 750 705.00 655.00
cl. 150 625 699.45 596.90
cl. 300 700 724.85 647.70
16" ANSI B16.5
cl. 600 790 743.90 685.80
570 360
cl. 900 1175 1200 753.40 704.80
PN 16 DIN EN 1092-1 520 691.00 580.00
DN400 PN 64 750 736.00 670.00
PN 100 Dimensions on request
cl. 150 850 768.50 635.00
cl. 300 950 806.60 711.20 620 405
18" ANSI B16.5
cl. 600 1150 822.50 743.00
cl.900 1550 1350 844.70 787.40
PN 16
DN450 PN 64 Dimensions on request
PN 100
cl. 150 1050 800.25 698.50
cl. 300 1225 838.35 774.70
20“ ANSI B16.5
cl. 600 1375 857.40 812.80 670 450
cl. 900 2050 1500 879.60 857.20
PN 16 DIN EN 1092-1 1000 808.50 715.00
DN500 PN 64
Dimensions on request
PN 100
cl. 150 1575 907.40 812.80
cl. 300 1875 958.20 914.40
24" ANSI B16.5
cl. 600 2100 970.90 939.80 760 540
cl. 900 2550 1800 1,021.70 1,041.40
PN 16 DIN EN 1092-1 1500 921.00 840.00
DN600 PN 64
PN 100
cl. 150 1650 947.48 869.95
cl. 300 2000 1,025.28 971.55
26“ ASME B16.47 828 585
cl. 600 2275 1,047.50 1,016.00
cl. 900 2750 1300 1,085.85 1,085.85
PN16
DN650 PN64 Dimensions on request
PN100
cl. 150 2150 1,028.00 927.10
cl. 300 2425 1,081.97 1,035.05
28“ ASME B16.47
cl. 600 2650 1,101.02 1,073.15 862 630
cl. 900 3200 1400 1,168.40 1,168.40
PN16 DIN EN 1092-1 2000 1,019.45 910.00
DN700 PN64
PN100


Nominal Connect- Weight Length Height diameter measuring diameter
pipe size ion flange
[kg] mm mm mm mm mm
cl. 150 2475 1,081.63 984.25
cl. 300 2825 1,135.60 1,092.20
30“ ASME B16.47 902 675
cl. 600 3100 1,154.65 1,130.30
cl. 900 3650 1500 1,231.90 1,231.90
PN16
DN750 PN64 Dimensions on request
PN100
cl. 150 2900 1,144.73 1,060.45
cl. 300 3250 1,189.18 1.149.35
32“ ASME B16.47
cl. 600 3525 1,211.40 1,193.80 979 720
cl. 900 4300 1600 1,314.45 1,314.45
PN 16 DIN EN 1092-1 2700 1,127.00 1,025.00
DN800 PN 64
PN 100
cl. 150 3375 1,195.13 1,111.25
cl. 300 3775 1,242.75 1,206.50
34“ ASME B16.47 1024 765
cl. 600 4100 1,261.80 1,244.60
cl. 900 5300 1700 1,397.00 1,397.00
PN 16
PN 100
cl. 150 3675 1,251.20 1,168.40
cl. 300 4075 1,302.00 1,270.00
36“ ASME B16.47
cl. 600 4400 1,324.26 1,314.45 1082 810
cl. 900 5775 1800 1,460.50 1,460.50
PN 16 DIN EN 1092-1 3025 1,229.50 1,125.00
DN900 PN 64
PN 100
cl. 150 4550 1,308.63 1,238.25
cl. 300 4475 1,273.70 1,168.40
38“ ASME B16.47 1160 855
cl. 600 5050 1,324.50 1,270.00
cl. 900 6600 1900 1,460.50 1,460.50
PN 16
PN 100
cl. 150 4825 1,361.53 1,289.05
cl. 300 5125 1,336.13 1,238.25
40“ ASME B16.47
cl. 600 5675 1,377.40 1,320.80 1213 900
cl. 900 7100 2000 1,511.30 1,511.30
PN 16 DIN EN 1092-1 4850 1,344.50 1,255.00
DN1000 PN 64
PN 100
cl. 150 5675 1,414.54 1,346.20
cl. 300 5650 1,385.97 1,289.05
42“ ASME B16.47 1261 945
cl. 600 6450 1,443.12 1,403.35
cl. 900 7825 2100 1,562.10 1,562.10
PN 16
PN 100


Nominal Connecti- Weight Length Height diameter measuring diameter
pipe size on flange
kg mm mm mm mm mm
cl. 150 6525 1,468.68 1,403.35
cl. 300 6500 1,443.28 1,352.55
44“ ASME B16.47 1310 990
cl. 600 7275 1,494.08 1,454.15
cl. 900 9025 2200 1,647.95 1,647.95
PN 16
DIN1100 PN 64 Dimensions on request
PN 100
cl. 150 7800 1,573.65 1,511.30
cl. 300 7875 1,551.43 1,466.85
48“ ASME B16.47
cl. 600 9250 1,614.96 1,593.85 1416 1080
2400
cl. 900 12100 1,784.35 1,784.35
PN 16 DIN EN 1092-1 7275 1,560.50 1,485.00
DN1200 PN 64
PN 100
Tab. 10.2: Meter dimensions
Note: • Weight indications are to be considered as guide values.
• Weight indications are estimated for carbon steel.
Nominal pipe Pipe dimensions in accordance with ANSI B36.10M - 1985 DIN 2633 DIN 2636 DIN 2637
size SC20 SC30 SC40 SC60 SC80 PN16 PN64 PN100
2" 52.5 49.3
DN 50 54.5 54.5 54.5
3" 77.9 73.7
DN 80 82.5 81.5 80.9
4" 102.3 97.2
DN 100 107.1 106.3 104.3
6" 154.1 146.3
DN 150 159.3 157.1 154.1
8" 206.4 205 202.7 198.5 193.7
DN 200 206.5 204.9 199.1
10" 260.4 257.5 254.5 247.7 242.9
DN 250 260.4 255.4 248.0
12" 311.2 307.1 303.2 295.3 288.9
DN 300 309.7 301.9 295.5
14“ 339.8 336.6 333.3 325.4 317.5
DN 350 339.6 343.0 336.0
16" 390.6 387.4 381.0 373.1 363.5
DN 400 390.4 378
18“ 441.4 434.9 428.7 419.1 409.5
DN 450
20“ 489.0 482.6 477.8 466.8 455.6
DN 500 492.0
24“ 590.6 581.1 574.6 560.4 547.7
DN 600 592.4
Tab. 10.3: Inner pipe diameter

10.2 Operation and Menu Structure of the SPU with LCD Display
10.2.1 Operation
The current measured values, counter readings, and diagnostic information can be
displayed on the two-line LCD display on the front panel of the SPU. The information display
can be navigated by using a magnetic pen, while the front cap is kept closed, or using the
buttons while the front cap is open (see Fig. 10.2).
Important
EMC and protection from accidental contact cannot be guaranteed if the cover is opened.
ATTENTION
LCD display
Measurand
+V 4 9 9 8 2 0m 3 / h Measured value
- V 0 m3 / h
DATA ENTER STEP C/CE Magnet
sensors
Buttons
DATA STEP C/CE
ENTER
Fig. 10.2: Front panel with LCD display
Magnetic
Button sensor Function Description
C/CE C/CE Menu level up Use the C/CE button to return from any menu
to the upper level; continue pressing to return
to the initial display
STEP STEP Step forward Use the STEP button to step forward in the
menu
DATA DATA ENTER Step backward Use the DATA button to step backward in the
menu
STEP + DATA DATA ENTER ENTER Use the ENTER function to select a menu level,
pressed pressed longer acknowledge logbook entries, reset the error
together than 2 volume counters or edit any modifiable
or seconds parameter (after disabling the configuration
DATA pressed protection)
longer than 2
seconds

10.2.2 Menu structure on the LCD display

The menu structure on the LCD display consists of a standard display (displaying readings,
important errors or warnings, the device state and a submenu for the reset of the error
volume counters) and the main menu. The main menu provides topically structured
information and allows operations like changing parameters, acknowledging logged events.
Navigate standard display and main menu using the buttons or the magnetic sensors as
described above.
Note Parameters can be edited in "Configuration” mode only.
Graphical
representation Description
Vertical lines represent connections between menu items on the
same menu level. Use the STEP button to step forward and the
DATA button to step backward
Horizontal lines represent connections between different menu
levels. Use the ENTER function to enter a lower-level menu and the
C/CE button to go back to a higher-level menu
Dashed horizontal or vertical lines represent connections between
alternating displays pages
Boxes with a thick border represent the display of a menu item
Boxes with a grey border represent a flashing display (e.g. if a current

warning or an unacknowledged logbook entry is displayed)
Tab. 10.3: Graphical representation of menu structure
Standard Display Submenu Notes
SOS 430.86m/s The standard display shows two pages with a configurable
VOG 10.8m/s display of measurands and current readings. By default
Speed of Sound (SOS), Velocity of Gas (VOG), the Volume
at Flowing Conditions forward (+Vf) and the Volumetric
+Vf 10366.04m3 Flowrate at Flowing Conditions forward (+Qf) are displayed.
+Qf 1350.20m3/h The pages alternate every 5 seconds. If the logbooks
contain unacknowledged Errors, Warnings or Information,
the corresponding letter is displayed in the upper right
hand corner and flashes.
Error 3003: If a current error or warning is active, the display will flash
Reading invalid and a message will be displayed with a message number in
the upper right corner. For further explanation see Section
10.3.1.
+Vf 34569870m3 Display of the current operating volume counter readings
-Vf 0m3 forward (+Vf) and reverse (-Vf). Volume counter readings
can be displayed for volume at flowing (Vf) or at base (Vb)
conditions.
+Ef 2145m3 Display of the current error volume counter readings

-Ef 0m3 forward (+Ef) and reverse (-Ef). Use the ENTER function to
erase the error counter.
Reset err.count? Confirmation dialog for the erasure of the error counter.
OK Cancel Use the ENTER function to confirm erasure or the C/CE
button to cancel the dialog. This event will be recorded with
a time stamp in Logbook1.

Standard Display Submenu Notes
+Vo 141145m3 Display of the total volume at flowing conditions forward

-Vo 0m3 (+Vo) and reverse (-Vo).
Battery Display of battery charge.

Charge 100%
Device state Display of the current device state. The number of active
E:0 W:1 I:2 Errors, Warnings and Informatio is displayed. To view the
messages enter the menu with the ENTER function.
Error 3003: Currently active error, warning or information. The number

Reading invalid of the message is displayed in the first line
(1xxx=Information, 2xxx=Warning, 3xxx=Error). See table
in Section 10.3.1. Use the STEP and the DATA button to
navigate through the messages.
Use the ENTER function to go from the standard
display to the main menu.
Main Menu Submenu Submenu Notes

The main menu provides menus and submenus for topically
structured information and user operations.
Operation mode Display of the current operating mode (‘‘Operation” or

Operation ‘‘Configuration”). Use the ENTER function to switch the
mode.
Configuration? Confirmation dialog for switching to the indicated operating

OK Cancel mode. Use the ENTER function to confirm or the C/CE
button to cancel the dialog. Event is logged in Logbook1.
FLOWSIC600 ‘‘Parameter change” menu with submenus for editing the

Parameter change system configuration at commissioning and
parameterization. Parameters can only be changed in
‘‘Configuration” mode.
Parameter change Submenu "Calibration” with the basic parameters for the
Calibration calibration of the meter according to the field conditions.
Adjust forward Display of the forward adjustment /correction factor.

1.0000
Adjust reverse Display of the reverse adjustment/correction factor.

1.0000
Pressure fix The parameters pe_min and pe_max are calculated from
20.00 bar the entered average working pressure.
Testmode (1 bar) Turn the ‘‘Calibration” mode ON or OFF.

Airtest OFF

Parameter Change Submenu "Impulse output” with the parameters of the

Impulse output impulse output.
Impulse source Variable to be supplied to pulse output

Flow Rate a.c. Possible sources are:
- Flow Rate s.c.
- Flow Rate a..c.
Depending on the number of available pulse outputs, this
menu can exist once or twice.
Impulse factor Number of pulses to be output per cubic meter

3600/m3 (fmax = 6 kHz).
Impulse update Refresh rate of the frequency output.

0.4s
Impulse mode The following settings may be chosen (see also Section
Flow+direct.n.o. 2.5.5):
- ‘‘Flow+direct.n.o.”
- ‘‘Flow+direct.n.c.”
- ‘‘Flow+error n.o.”
- ‘‘Flow+error n.c.”
- ‘‘Flow +/- n.o.”
- ‘‘Flow +/- n.c.”
- ‘‘Flow+state n.o.”
- ‘‘Flow+state n.c.”
(n.o. = normally open; n.c. = normally closed)
Parameter Change Submenu "Digital output” with the parameters of the digital
Digital output output. Parameters can only be changed in ‘‘Configuration”
mode
DO 0 The following signals can be chosen for all digital outputs
at Warning n.o. default is ‘‘Not active”):
- Error n.o.
DO 2 - Warning n.o.
at Warning n.o. - Direction n.o.
- CheckReq n.o.
DO 3 - Error n.c.
at Warning n.o. - Warning n.c.
- Direction n.c.
DO 4 - CheckReq n.c.
at Warning n.o.
Parameter change Submenu ‘‘Analog output” with the parameters of the

Analog output analog output.
AO source The following sources can be chosen for the analog output:
Flow Rate a.c. - Flow Rate a.c.
- Flow Rate s.c.
- Speed of Sound
- Velocity of Gas
- Molar mass
AO Qv at 20 mA Volumetric flow rate at maximum current.

1000 m3/h

AO Qv at 4 mA Volumetric flow rate at minimum current.

0 m3/h
AO at error Current output in “Error” state.

22 mA
AO damping Averaging period for the current output in order to smooth

0 s peaks.
Parameter Change Submenu "Serial Interface” with the parameters for the
Serial Interface serial interface.
Serial Interface Resetting the parameter serial interface 1 to the default

Reset RS485/1? values. Defaults are: Baudrate 9600, protocol ASCII
(MODBUS ASCII), 8, n, 1. Master burst mode off.
Serial Interface Resetting the parameter of the serial service interface to

Reset Service? the default values (see above).
Serial Interface Resetting the parameter serial interface 2 to the default

Reset RS485/2? values (see above).
Parameter Change Submenu "LCD Display” with language parameter for the
LCD Display LCD display.
Language Set parameter "Language” to

English - English
- German
- French
FLOWSIC600 "Information” menu with submenus for the display of
Information information on system and firmware.
Information Submenu "System”.

System
Device type Nominal width of the meter body and number of measuring
8‘‘, 4-path paths.
Meter serialno. Serial number of the meter.

03138703
Analog serialno. Serial number of the analogue circuit board installed.

00112233
Device date Current system date.

Dec 20 2007
Device time Current system time.

09:10:00
Install. FRAM: Installed FRAM 1 and 2.

1: 64kb 2: 64kB

Sensor type
Pe-min/Pe-max Set working pressure range.

3393/6786 psig
Information Information on the installed firmware and activated

Firmware parameter sets.
Version 3.2.xx Version number and corresponding time stamp.

Dec 4 2007
CRC16 Firmware 16-bit check sum for the entirefirmware code range.
0xFF91
CRC16 Parameters 16-bit check sum for the entire parameter range (different
0x1852 user defined parameters are excluded).
CRC16 Metrology 16-bit check sum for the parameter range whose content is
0x1754 predefined by the manufacturer. This range is a subset of
the entire parameter range. Conformity with the
manufacturer settings can be checked by comparing this
check sum with the original check sum.
Unauthorized modification of these parameters may lead to
failure of the device!

Main Menu Submenu Submenu Submenu Notes
FLOWSIC600 "Logbooks” menu with

Logbooks information on on the current
content of the device logbooks.
FLOWSIC600 Logbook 1 to 3. There are 3

Logbook x logbooks:
• No.1 for errors and warnings
• No.2 for information
• No.3 for parameter changes
Logbook x Submenu for the display of the
Show Entries entries in the chosen logbook.
Logbook x Display of the total number of

unack. 4/5 saved logbook entries and
number of unacknowledged
entries. Example:
5 entries, 4 unacknowledged.
Navigate with STEP and DATA
through the list of entries. The
entries are shown in order of
appearance. Most recent event
first. If an entry is
unacknowledged, the display
flashes.
I Power ON 0082 The first line of every entry

28/12/2007 08:31 displays the event classification
(‘‘I”, ‘‘E” or ‘‘W” and ‘‘+” for a
coming or ‘‘-” for a going event) a
short description of the event
itself (see Section 10.3.1 ), and
an index number. Depending on
the content of the entry, further
information may be displayed in
the second line.
Entry time Use the ENTER function to

28/12/2007 08:31 display the time stamp of the
event. Return to the list of
logbook entries with C/CE.
Acknowl. entry? Use the ENTER function again to

OK Cancel acknowledge the entry and once
more to confirm the dialog.
Logbook 1 Acknowledge all entries in the

Acknowledge all chosen Logbook.

FLOWSIC600 "Diagnosis” menu for the display of diagnostic information

Diagnosis on the meter.
% Error Display of the ratio of incorrect and correct measurements

000 000 000 000 in percent per path.
Diagnosis Display of further information on path x (path 1 to 4).

path x values
VOG 8.9m/s Display of the actual values of flow rate (Velocity of Gas,
SOS 343.2m/s VOG) and Speed of Sound (SOS) in path x.
SNR: 25dB 25dB Display of the actual signal-to-noise ratio (SNR) and
AGC: 50dB 50dB reception sensitivity (automatic gain control, AGC) in path
x. One value for each direction of measurement (left:
forward, right: reverse).
Diagnosis Display of further system information.

System values
Flow Rate a.c. Display of the actual volumetric flow rate together with the
+Qv 1289.3 m3/h direction of flow (positive direction marked by “+Qv“,
negative direction marked by “-Qv”).
VOG 8.9 m/s Display of the actual readings of Velocity of Flow and
SOS 343.2 m/s Speed of Sound.
Act. freq. FO Display of the actual frequency at the frequency output.

1245 Hz
Act. current AO Display of the actual current at the analog output.

14.54 mA
Act.status DOUT Display of the current status of the digital switching output
DO2: c DO3: o (c: closed, o: open).
Act. voltage
21.30V Display of the actual voltage.
FLOWSIC600 "Parameters” menu.

Parameters
Reg.: 3001 Display of all parameters stored in the meter‘s registers.

0000 Navigate through the list of registers with STEP or DATA.

FLOWSIC600 Display of the three DataLogs stored in the meter.

DataLogs Navigate through the DataLogs with STEP or DATA.
DataLog 1: Display of the current filling status of DataLog 1. E.g. 9 of 10

9/ 10 5m possible entries are filled, the DataLog1CycleTime is set to
5 minutes (default).
DataLog 2: Display of the current filling status of DataLog 2. E.g. 504 of
504/ 744 60m 744 possible entries are filled, the DataLog2CycleTime is
set to 60 minutes (default).
DataLog 3: Display of the current filling status of DataLog 3. E.g. 21 of
21/1126 1440m 1126 possible entries are filled, the DataLog3CycleTime is
set to 1440 minutes (default).

10.2.3 Display of measured values

The default values to be displayed on the two line LCD can be assigned using
MEPAFLOW600 CBM. indicated readings can be assigned individually to either line of the
initially displayed standard display. The values can be assigned to the desired page and line
of the standard display. The two display pages alternate every 5 seconds.
10.2.4 Data editing in configuration mode

In configuration parameters which are relevant to the commissioning or operation of the
meter can be modified. If the hardware configuration protection is enabled, the configuration
protection switch must be set to ‘‘open” before parameter modification.
Navigate to the parameter and use the ENTER function to begin editing.
Options depending on the type of data:
• Integer: 0, 1, 2, 3, 4, 5, 6, 7, 8, 9, sign
• Floating point: 0, 1, 2, 3, 4, 5, 6, 7, 8, 9, space, decimal point, sign
• List of registers: List of all registers (which are plausible for this parameter)
Example Switching the meter to configuration mode and editing a parameter, e.g. the impulse factor..
Action Buttons Display
Standard display - +V 34569870 m3

-V 0 m3
Enter menu ENTER Operation mode

Operation
Edit parameter ‘‘Operation mode‘‘ ENTER Configuration?

OKJ Cancel
Confirm change to ‘‘Maintenance ENTER –> Change mode Configuration?

Mode‘‘ Success!
Scroll through the menu structure to (ENTER, STEP, DATA)

the parameter you want to edit
In this example, the impulse factor is Impulse factor

edited 115/m3
Select the parameter ENTER Impulse factor

115J
Move cursor to the digit that you 1 * STEP Impulse factor

want to change 11J
Put in edit mode 2 * DATA Impulse factor

115
Enter desired value x * DATA Impulse factor

110
Confirm new value ENTER Impulse factor

110/m3
Return to standard display 3 x CE/C +V 34569870 m3

-V 0 m3

10.2.5 Resetting the error volume counters

To reset the error volume counters, password level ‘‘authorized operator” is required.
+Ef 70 m³ Select the error volume display. Use the ENTER function to enter the
-Ef 0 m³ dialog for resetting the error volume counters.
<ENTER>
Counter reset Confirm the reset with the ENTER function. The error volume counter
OK Cancel will be reset to zero. The reset will be recorded in the logbook. Press
C/CE to cancel the reset.
<ENTER>
+EV 0 m³
-EV 0 m³
10.2.6 Acknowledging a battery exchange

Description of a battery After a battery exchange the following message flashes on the LCD-display:
exchange see Service INFORMATION 1030
Manual LifeSpan Battery
Since date and time of the FLOWSIC600 are invalid after switching the meter back on, they
have to be set to valid values. We recommend to use the clock synchronization function of
MEPAFLOW600 CBM (click the ‘‘Attention” Icon in the ‘‘Identification” box on the
‘‘Information” page).
After setting date and time, the LCD message can be acknowledged. The acknowledgment
sets the life span cycle of the new battery to zero. Complete the following step at the LCD-
display:
Press DATA. INFORMATION 1030

LifeSpan Battery
Apply the ENTER function two Device state

times E:x W:x I:x
Apply the ENTER function Battery replaced (This message becomes visible for just
OK Cancel one second.)

10.3 Logbooks
1. Classification of logbook entries
The entries are distinguished into three classes and identified by the initial character in the
first line.
• “I” information
• “W” warning
• “E” error/ malfunction
2. Type of occurrence
• “+” point of time identifying the beginning of a status
• “-” point of time identifying the end of a status
10.3.1 Overview of event entries in logbooks and MEPAFLOW600 CBM
No Logbook message in MEPAFLOW600 CBM Logbook LCD-Text

Custody logbook [1]
3002 NO DSP communication 1 E+System 0001
NO DSP-Communic.
E-System 0001
NO DSP-Communic.
3003 Measurement invalid 1 E+DSP 0001
Reading invalid
E-DSP 0001
Reading invalid
3004 Firmware CRC invalid 1 E+Firmware 0001
CRC invalid
E-Firmware 0001
CRC invalid
3005 Parameter CRC invalid 1 E+Parameter 0001
CRC invalid
E-Parameter 0001
CRC invalid
3006 Parameter out of range 1 E+Parameter 0001
Out of range
E-Parameter 0001
Out of range
3007 Failure during storage of path compensation 1 E+PathComp. 0001
parameter Storage error
E-PathComp. 0001
Storage error
3008 Meter clock time invalid 1 E+System 0001
ClockTime inval.
E-System 0001
ClockTime inval.
3009 Custody logbook [1] overflow 1 E+Logbook 1 0001
Overflow
E-Logbook 1 0001
Overflow


3011 CRC volume counter (a.c) invalid 1 E+Count.ac 0001
CRC invalid
E-Count.ac 0001
CRC invalid
3012 CRC volume counter (n.c) invalid 1 E+Count.sc 0001
CRC invalid
E-Count.sc 0001
CRC invalid
3013 Transit time mode activated 1 E+System 0001
TransitTimeMode
E-System 0001
TransitTimeMode
2001 Path failure 1 W+PathError 0001
Path 1 2 3 4
W-PathError 0001
All paths OK
2002 No HART communication to temperature 1 W+HART T 0001
transmitter No communication
W-HART T 0001
No communication
2003 No HART communication to pressure transmitter 1 W+HART P 0001
No communication
W-HART P 0001
No communication
2004 Maximum pulse output frequency exceeded 1 W+PulseOut 0001
(6kHz) 6000 Hz exceeded
W-PulseOut 0001
6000 Hz exceeded
1001 Flow meter power ON 1 I Power ON 0001
dd/mm/yy mm:ss
1002 Meter clock adjusted 1 I Set Time 0001
dd/mm/yy mm:ss
1003 Configuration mode active 1 I+Meas.Mode 0001
Configurat. ON 1
I-Meas.Mode 0001
Measurement ON 1
1004 Firmware changed 1 I Update FW 0001
3104 -> 3200
1007 Custody logbook [1] erased and initialized 1 I Logbook 1 0001
Reset and Init
1014 Overflow volume counter (a.c.) 1 I Count.ac 0001
Overflow
1015 Overflow volume counter (s.c.) 1 I Count.sc 0001
Overflow
1016 Error volume counter cleared 1 I Reset E 0001
01/01/07 10:47
1017 All volume counters cleared 1 I Reset V 0001
01/01/07 10:47
1027 Initialization error → Default parameter loaded 1 I+InitError 0001
DefaultParaLoad
I-InitError 0001
DefaultParaLoad


1029 Air test mode activated 1 I+Airtest 0001
Active
I-Airtest 0001
Not active
Warning logbook [2]
1008 Warning logbook [2] erased and initialized 2 I Logbook 2 0001
Reset and Init
1018 DataLog 1 cleared 2 I DataLog 1 0001
Reset
Reset
Reset
1021 DataLog 1 overflow 2 I+DataLog 1 0001
Overflow
I-DataLog 1 0001
Overflow
Overflow
I-DataLog 2 0001
Overflow
Overflow
I-DataLog 3 0001
Overflow
1024 DatenLog 1 CRC error 2 I+DataLog 1 0001
CRC invalid
I-DataLog 1 0001
CRC invalid
1025 DatenLog 2 CRC error 2 I+DataLog 2 0001
CRC invalid
I-DataLog 2 0001
CRC invalid
1010 Warning logbook [2] overflow 2 I+Logbook 2 0001
Overflow
I-Logbook 2 0001
Overflow
1026 DataLog 3 CRC error 2 I+DataLog 3 0001
CRC invalid
I-DataLog 3 0001
CRC invalid
1028 Customer limit exceeded 2 I+Userlimit 0001
Limit XXXXXXXXXX
I-Userlimit 0001
Limits OK
Parameter logbook [3]
1005 Parameter changed 3 I Parameter 0001
Change Reg3001
1006 All parameters to default (Reset) 3 I Parameter 0001
Reset all


1009 Parameter logbook [3] erased and initialized 3 I Logbook 3 0001
Reset and Init
1011 Parameter logbook [3] overflow 3 I+Logbook 3 0001
Overflow
I-Logbook 3 0001
Overflow
10.3.2 Acknowledging a logbook entry on the LCD display
I Power ON 001 Press STEP or DATA to select an entry which has not yet been
28/12/2007 12:13 acknowledged (display is flashing). Activate the ENTER function to
display the corresponding time stamp of the event. The display is still
<ENTER>
flashing. Activate the ENTER function again in order to acknowledge
Entry time the entry (display will stop flashing). Return to the list of logbook
28/12/2007 12:13 entries by pressing C/CE.

10.4 SPU Terminal Assignment
Connection in accordance with ATEX IIA
Fig. 10.4: Terminal assignment in accordance with ATEX IIA
Connection in accordance with ATEX IIC
Fig. 10.5: Terminal assignment in accordance with ATEX IIC

Connection in accordance with CSA Group B, C, D
1(+)
Entity Parameters
power supply
Vmax=16V, Imax =200mA
alimentation
VB = 12..24V DC 2 (-) Ci = 4nF, Li = 0.075mH
Maximum non-hazardous area voltage not to exeed 125V

4 ...20 mA active Voc=22,1V Vmax=30V
31 digital out 0 (HF2) passive
Isc=155mA Imax=100mA
Ca=163nF Ci=4nF
32 sortie digital 0
f = 6 kHz
m a x
HART/
NAMUR La=1mH Li=0.075mH
RS 485 Voc=5.88V Isc=313mA Ca=43µF La=0.2mH

33 Vmax=10V Imax=275mA Ci=4nF Li=0.075mH
34 PROFIBUS PA Vmax=30V Imax=100mA Ci=4nF Li=0.075mH
passive Vmax=30V
51 digital out 1 (HF1)
Imax=100mA
sortie digital 1 Ci=4nF
52 fmax = 6 kHz NAMUR Li=0.075mH
digital output 2 passive Vmax=30V
41 sortie digital 2 Imax=100mA
Ci=4nF
42 NAMUR Li=0.075mH
digital output 3 passive Vmax=30V Ci=4nF
81 sortie digital 3 NAMUR Imax=100mA Li=0.075mH
82 Voc=5.88V Isc=313mA Ca=43µF La=0.2mH
RS 485 Vmax=10V Imax=275mA Ci=4nF Li=0.075mH
Class1, Division1, Groups B,C and D

Class1, Division 2, Groups A, B, C and D
Class 1, Zone 1 Group IIB + Hydrogene
Class 1, Zone 2, Group IIC
Fig. 10.6: Terminal assignment in accordance with CSA Group B, C, D
Connection in accordance with CSA Group D
1(+)
Entity Parameters
power supply
Vmax=16V, Imax =200mA
alimentation
VB = 12..24V DC 2 (-) Ci = 4nF, Li = 0.075mH
Maximum non-hazardous area voltage not to exeed 125V

4 ...20 mA active Voc=22.1V Vmax=30V
31 digital out 0 (HF2) passive
Isc=155mA Imax=100mA
Ca=4.14µF Ci=4nF
32 sortie digital 0
f = 6 kHz
m a x
HART/
NAMUR La=7mH Li=0.075mH
RS 485 Voc=5.88V Isc=313mA Ca=1000µF La=1.5mH

33 Vmax=10V Imax=275mA Ci=4nF Li=0.075mH
34 PROFIBUS PA Vmax=30V Imax=100mA Ci=4nF Li=0.075mH
passive Vmax=30V
51 digital out 1 (HF1)
Imax=100mA
sortie digital 1 Ci=4nF
52 fmax = 6 kHz NAMUR Li=0.075mH
digital output 2 passive Vmax=30V
41 sortie digital 2 Imax=100mA
Ci=4nF
42 NAMUR Li=0.075mH
digital output 3 passive Vmax=30V Ci=4nF
81 sortie digital 3 NAMUR Imax=100mA Li=0.075mH
82 Voc=5.88V Isc=313mA Ca=1000µF La=1.5mH
RS 485 Vmax=10V Imax=275mA Ci=4nF Li=0.075mH
Class1, Division1, Group D

Class1, Division 2, Group D
Class 1, Zone 1 Group IIA
Class 1, Zone 2, Group IIA
Fig. 10.7: Terminal assignment in accordance with CSA Group D

10.5 Connection Diagrams for Operating the FLOWSIC 600 in Hazardous

Areas in Accordance with North American Guidelines (CSA)
Fig. 10.8: Control drawing CSA 781.00.02 (page 1)

Fig. 10.9: Control drawing CSA 781.00.02 (page 2)

10.6 Reports created with MEPAFLOW600 CBM

Maintenance Report
FLOWSIC600 - Maintenance Report: 080206132934

Meter Name: TestMeter1 Address: Bergener Ring 27 Test Date: 06.02.08 (dd.mm.yy)
Serial Number: 06448799 City/State: Dresden Test Time: 13:28:10 (hh:mm:ss)
Station Name: T1 Zip code: D-01458 Log Length: 43 (Samples)
Technician: Julia Brück Country: Germany Last Test Date: 01.02.08 (dd.mm.yy)
Meter Operating Data Average Pressure: 12.00 bar(a) Average Temp.: 19.99 °C Calculated SOS:
Internal Meter ID: 0.073062 m Firmware Version: 3200 SOS Difference:

Internal Pipe ID: 0.073062 m Program CRC: 0x3700 Profile Factor: 1.003
Path Number: 4 Parameter CRC: 0x0BF4 Symmetry: 0.969
K Factor: 117 1/m³ Metrology CRC: 0x00E9 Flow Rate: 42.15 m³/h
Adjust Method: linear
Meter Diagnostics (Paths & Transducers)

Vel [m/s] Average Maximum Minimum AGC [dB] SNR [dB] Perform Turbulence Velocity ACC Diff.
Path 1 2.532 3.298 1.984 Path 1 AB 57.2 38.3 Avg [%] Avg [%] Ratio AB - BA
Path 2 2.730 3.098 2.221 Path 1 BA 57.3 38.9 Path 1 100 10.1 0.936 -0.047
Path 3 2.623 3.086 2.167 Path 2 AB 63.2 37.8 Path 2 100 8.0 1.010 0.233
Path 4 2.807 3.224 2.320 Path 2 BA 63.0 37.8 Path 3 100 10.3 0.970 0.000
Average 2.704 2.722 2.681 Path 3 AB 64.0 37.3 Path 4 100 8.7 1.038 -0.279
Path 3 BA 64.0 37.6 Average 100 9.3

SOS [m/s] Average Maximum Minimum
Path 1 346.09 346.41 345.80 Path 4 AB 58.3 37.1 Counter Readings
Path 2 346.11 346.41 345.88 Path 4 BA 58.5 36.6 Volume [m³] Normal Error
Path 3 346.01 346.40 345.75 Avg AB 60.7 37.6 Forward 3610.20 10.18
Path 4 345.65 345.96 345.47 Avg BA 60.7 37.7 Reverse 112.57 0.00
Average 345.97 346.30 345.72
Meter Health Device ok ok P1 P2 P3 P4

Warning ok Path error 0 0 0 0 %
Check Request ok Warning SNR limit 0 0 0 0 %
Measurement yes Warning AGC dev 0 0 0 0 %
Configuration no Warning AGC limit 0 0 0 0 %
Write Lock no Warning SOS dev 0 0 0 0 %
Charts of Logged Data
Average SNR [dB] Average AGC [dB]
Comments:
Signatures
Tested By: Witness: Date:
Fig. 10.10: Maintenance report created with MEPAFLOW600 CBM (example)

10.6.1 Short Parameter Report*
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Fig. 10.11: Short parameter report created with MEPAFLOW600 CBM (example)
* Long parameter report see Section 10.7.6

10.6.2 Calibration Report
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Fig. 10.12: Calibration report created with MEPAFLOW600 CBM (example)

10.7 Manufacturer Data Record (MDR)
10.7.1 Table of Contents
FLOWSIC 600 – Documentation – Table of Contents
Manufacturing records
Final check report
Configuration record
Parameterisation record (Dry calibration report, part 1)
Zero flow calibration report (Dry calibration report, part 2 and Factory acceptance test)
Test reports of ultrasonic transducers and analog electronics
Inspection certificates
Sick Maihak Inspection certificate
Materials inspection certificate of flow meter body*
Inspection certificate "Non-destructive testing" of flow meter body*
Conformity declarations
EC-Conformity declaration according NSP 73723/ EWG, EMV 89/336/EWG and 94/9 EWG
EC-Conformity declaration according DRGL 97/23/EG
Type approvals
EC-Type examination certificate TÜV 04 ATEX 2602 X
National type approval certificate for custody transfer
Certificates of quality system approvals
Certificate of quality system approval according PED 97/23/EC
Electronic data carrier
CD FLOWSIC 600 (Application- and diagnostics software, manuals, documentation)
Type: FLOWSI 600 – x CLxxxPx Production number: 1234
Type code: FL600-xPxDxxCLxxxxxxxxxxxxxx-Sx-xDCxxxx Serial number: 2345678
* These documents are meter-specific documents provided by sub-suppliers of SICK Maihak Dresden, therefore they are not
included in the sample standard documentation.
Fig. 10.13: MDR Table of Contents (example)

10.7.2 Inspection certificate
Fig. 10.14: Inspection certificate (example)

10.7.3 Instrument Data Sheet
INSTRUMENT DATA SHEET FOR : ULTRASONIC GAS FLOW METER
0 Typecode FL600-4R3D10CL0600SC0040RF0N-S1-1DC1N1Y
1 GENERAL 54 TRANSMITTER (Integral)

2 56 * Power supply / Power consumption 12 .. 28,8 V DC < 1W
3 Type FL600 57 * Enclosure classification IP 67
4 Meter size 10'' / DN250 58 * Cable entry 1/2'' NPT
5* Article number 104 xxxx ° 59 Hazardous Area Class. Class 1, Division 1, Group D, T4
Class 1, Division 2, Group D, T4
6* TAG number
Class 1, Zone 1, Group IIA, T4
7* Order number Class 1, Zone 2, Group IIA, T4
8 60 SPU housing material Aluminium
9 METER BODY ° 61 Ambient temperature (range) °F -40 ... 140
10 Inner pipe diameter inch 10 - SC040 62 Display LCD
11 Overal length (A) inch 29,53 63 Display language English
12 Overal height (B) inch 23,62 64 Engineering units Imperial
13 Weight lb 727 65 Output and Signal Configuration - Signal processing unit 1
14 Flow range cft/h 1770 ... 247000 66 DO0/AO0 Terminals 31/32 (HF-Pulse) Volume a.c., flow direction by phase shift +/-90°
15 Number of meas. paths 4+4 67 Signal configuration Open Collector / normally closed
16 Linearity +/- 0.5% of MV 0.1 .. 1 Qmax 68
17 * Repeatability < 0,1% 69
18 Flange design code ANSI B16.5 70
19 Flange class CL0600 71
20 Flange face Raised Face/stock finished 72 MOD Terminals 33/34 (RS 485) Modbus ASCII
21 Body material carbon steel 1.1120/A216WCC 73 DO1 Terminals 51/52 (HF-Pulse) Volume a.c.
22 Transducers exchangeable under pressure No 74 meter factor 1/cft 4.078
23 * Transducer cover Aluminium 75 Signal configuration Open Collector / normally closed
° 24 Design temperature °F -51 ... 185 76 max. Output 0...30 V / 0...100 mA
° 25 Design pressure psi (g) 1450 77 DO2 Terminals 41/42 (Status) Status Maintenance required
26 Material certificate 3.1 EN 10204 78 Signal configuration Open Collector / normally closed
27 * Enclosure classification IP 67 79 max. Output 0...30 V / 0...100 mA
28 * Surface coating / painting two layers: Epoxy + Acrylic 80 DO3 Terminals 81/82 (RS 485) Modbus ASCII
29 * Pressure tapping 1/4" NPT female 81
30 Sensors 82
31 83 COMMUNICATION
32 * Sensor material Titan 3.7165 84 Interface 2x RS 485
33 85 Protocol Modbus ASCII
34 86 Output and Signal Configuration - Signal processing unit 2
35 Supplementary Information: Process and operating conditions 87 DO0/AO0 Terminals 31/32 (HF-Pulse) Volume a.c., flow direction by phase shift +/-90°
36 88 Signal configuration Open Collector / normally closed
37 min. norm. max. 89
38 Flow rates cft/h 1.766 70.629 247.203 90
39 Pressure psi (g) 363,0 725,0 1436,0 91
40 Temperature °F 50 68 86 82
41 93 MOD Terminals 33/34 (RS 485) Modbus ASCII
42 Medium natural gas - dry 94 DO1 Terminals 51/52 (HF-Pulse) Volume a.c.
43 Aggressive contents No agents 95 meter factor 1/cft 4.078
44 Liquid content g/cft 0 96 Signal configuration Open Collector / normally closed
45 97 max. Output 0...30 V / 0...100 mA
46 Dry calibrated 98 DO2 Terminals 41/42 (Status) Status Maintenance required
47 98 Signal configuration Open Collector / normally closed
48 100 max. Output 0...30 V / 0...100 mA
49 101 DO3 Terminals 81/82 (RS 485) Modbus ASCII
50 102
51 103
52 National type approval 104 COMMUNICATION
53 105 Interface 2x RS 485
REMARKS 106 Protocol Modbus ASCII
Lines marked by " * " are default values
Lines marked by " ° " are safety relevant features according to 97/23/EC
This data sheet has been created based on the technical details provided with the order . Missing information has been completed by SICK MAIHAK and marked with a *.
Manufacturing period after receipt of approval for this data sheet, is ~14 weeks.
Subsequent changes will require approval by SICK MAIHAK. Effects on date of despatch are the responsibility of the client. Any additional cost involved will be charged.
Engineered By RWI Date 08.02.2008
Customer / Project SMU Part.-No.: 104 xxxx Revision 0
Fig. 10.15: Instrument Data Sheet (example)

10.7.4 Final check report
Fig. 10.16: Final check report, page 1 of 3 (example)



10.7.5 Zeropoint test
Fig. 10.19: Zeropoint test (example)

10.7.6 Parameter Report
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Fig. 10.24: Parameter report created with MEPAFLOW600 CBM, page 5 of 5 (example)

10.7.7 Data Sheet Electronics
Fig. 10.25: Data sheet electronics (example)

10.7.8 Data Sheet Transducer Pairs
Fig. 10.26: Data sheet transducer pairs (example)

10.7.9 EC Declaration of Conformity
Fig. 10.27: EC declaration of conformity (exapmle)

10.8 Wiring Examples
10.8.1 Intrinsically safe installation
Fig. 10.28: FLOWSIC600 intrinsically safe installation

216
FLOWSIC600
L N
<= 24V DC
<= 24V DC
<= 24V DC
<= 24V DC
Flowcomputer
24 VDC
RL RL
RL RL
24 V DC
Appendix
Imax = 100 mA
Imax = 100 mA
Imax = 100 mA
Imax = 100 mA
Fuses for field terminals:
Very fast acting type (FF-Type)
Fuse
Fuse
Fuse
Fuse
Fuse
Fuse
1A 100 mA 100 mA 100 mA 100 mA In case of blow out lock for reason
fast super fast super fast super fast super fast before change.
Additional surge protection is
-X
recommended in case of powerful or
recurrent strokes of lightning.
Non Hazard Area

Remark:
Screen
SICK recommends to install all cable
between device and non hazardous area.
10.8.2 Non-intrinsically safe installation
Non intrinsic installation:

2 x 1,5 mm² 4x2x0,5 mm² (TP) - Twisted pair 2x0,5 mm²
NYY-O Li2YCYv(TP) Li2YCYv(TP) in North America
in accordance with NEC and CEC,
see control drawing 781.00.02
in EU in accordance with EN 60079-14
© SICK MAIHAK GmbH · Germany · All rights reserved

National regulation must be observed.
Fig. 10.29: FLOWSIC600 non-intrinsically safe installation

Volume pulse
Modbus
Volume pulse
Status
Status
or 4 .. 20 mA
WARNING! !
32-
52-
81+
31+
33+
34-
51+
41+
42-
82-
2 (-)
Incorrect cabling can cause
the FLOWSIC 600 to fail!
1 (+)
For further details see
internal
DO 1
DO 2
DO 3
operation manual.
RS 485
AO 0
DO 0
Class1, Division1, Groups B, C and D Attention:
Class1, Division2, Groups A, B, C and D
Explosion Hazard Location

Class1, Zone 1 Group IIB + Hydrogene Cable glands
Class1, Zone 2, Group IIC M20 x 1,5 (EU) or
II 1/2G EEx de ib [ia] IIC T4 or 1/2" NPT (North America)
II 1/2G EEx de ib [ia] IIA T4
FLOWSIC 600 6 - 12 mm cable diameter
RS485 Modbus - approx. impedance 120 Ohm
maximum length: 100 m
FL600
8010125/2008-08
Operating Instructions
10.9 Sealing Plan
Fig. 10.30: Sealing plan, part 1



alternatively

Fig. 10.34: Examples: Main type plates at the signal processing unit
Fig. 10.35: Example: Type plate at the meter body

10.10 Outline Drawings
Arrow defines positive flow direction
Fig. 10.36: Outline drawing FLOWSIC600 1-path

Fig. 10.37: Outline drawing FLOWSIC600 2-path

Tab. 10.38: Outline drawing FLOWSIC600 4-path

Fig. 10.39: Outline drawing FLOWSIC600 2plex

Fig. 10.40: Outline drawing FLOWSIC600 Quatro

FLOWSIC600
SICK worldwide
8010125/2008-08 (V1.0)
You will find our local subsidiary

or agency at:
www.sick.com.
Your local sales and service partner
SICK MAIHAK GmbH | Process Automation

Nimburger Str. 11 | 79276 Reute | Germany | www.sick.com
Phone +49 7641 469-0 | Fax 49 7641 469-11 49 | info.pa@sick.de

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Ultrasonic Gas Flow Meter

Ultrasonic Gas Flow Meter

About this Document ..........................................................................................................9

8010125/2008-08 © SICK MAIHAK GmbH · Germany · All rights reserved 3

Ultrasonic Gas Flow Meter

2.7 Data Handling with MEPAFLOW600 CBM ................................................................... 39

3 MEPAFLOW600 CBM diagnosis and configuration software.............................71

4 Flow Calibration ................................................................................................................83

4 © SICK MAIHAK GmbH · Germany · All rights reserved 8010125/2008-08

Ultrasonic Gas Flow Meter

4.4 Flow Calibrating the FLOWSIC600 ..............................................................................102

8010125/2008-08 © SICK MAIHAK GmbH · Germany · All rights reserved 5

Ultrasonic Gas Flow Meter

6.3 Field Setup ............................................................................................................................140

7 Maintenance .................................................................................................................... 153

8 Troubleshooting .............................................................................................................. 163

9 List of parts....................................................................................................................... 167

6 © SICK MAIHAK GmbH · Germany · All rights reserved 8010125/2008-08

Ultrasonic Gas Flow Meter

8010125/2008-08 © SICK MAIHAK GmbH · Germany · All rights reserved 7

Ultrasonic Gas Flow Meter

8 © SICK MAIHAK GmbH · Germany · All rights reserved 8010125/2008-08

Ultrasonic Gas Flow Meter

About this Document

8010125/2008-08 © SICK MAIHAK GmbH · Germany · All rights reserved 9

Ultrasonic Gas Flow Meter

Symbols used in this document

10 © SICK MAIHAK GmbH · Germany · All rights reserved 8010125/2008-08

Ultrasonic Gas Flow Meter

Abbreviations used in this manual

8010125/2008-08 © SICK MAIHAK GmbH · Germany · All rights reserved 11

Ultrasonic Gas Flow Meter

The following terms will be used for measurands:

Basic abbrevations and Abbrevations used at MEPAFLOW600 CBM

12 © SICK MAIHAK GmbH · Germany · All rights reserved 8010125/2008-08

Ultrasonic Gas Flow Meter

1.1 Intended Use of the Equipment

If a flooding is necessary nevertheless, please contact the manufacturer beforehand and

1.2 Authorised Staff

8010125/2008-08 © SICK MAIHAK GmbH · Germany · All rights reserved 13

Ultrasonic Gas Flow Meter

1.3 General Safety Instructions and Protective Measures

14 © SICK MAIHAK GmbH · Germany · All rights reserved 8010125/2008-08

Ultrasonic Gas Flow Meter

1.3.2 Dangers due to heavy loads

1.3.3 Environmental information and instructions for disposal

8010125/2008-08 © SICK MAIHAK GmbH · Germany · All rights reserved 15

Ultrasonic Gas Flow Meter

16 © SICK MAIHAK GmbH · Germany · All rights reserved 8010125/2008-08

Ultrasonic Gas Flow Meter

Features and Applications

Conformity, Configuration, Technical Data

Operating States and Signal Output

Data Handling with MEPAFLOW600 CBM

Path Failure Compensation

Ultrasonic Gas Flow Meter

2.1 Features and Applications

Fig. 2.1: FLOWSIC600

The main features of the FLOWSIC600 are:

8010125/2008-08 © SICK MAIHAK GmbH · Germany · All rights reserved 19

Ultrasonic Gas Flow Meter

2.1.1 FLOWSIC600 1-path, FLOWSIC600 2-path, FLOWSIC600 4-path