DescriptionInstallationOperation

FLOWSIC150 CARFLOWExhaust Gas Flow Meter

O P E R A T I N G I N S T R U C T I O N S

ContentAbout this Document ..........................................................................................................5

1 Safety Instructions...............................................................................................................6

1.1 Intended Use ............................................................................................................................6

1.2 Authorised Personnel .............................................................................................................6

1.3 Safety Instructions and Protection Measures................................................................61.3.1 General Information ............................................................................................................................ 6

1.3.2 Danger from electrical Equipment ................................................................................................. 7

1.3.3 Preventive Measures for safe Operation .................................................................................... 7

1.3.4 Detecting and Preventing Malfunctions ....................................................................................... 7

2 Product Description.............................................................................................................9

2.1 System Features ................................................................................................................... 11

2.2 System Design ...................................................................................................................... 12

2.3 Measuring Principle Flow Measurement....................................................................... 132.3.1 Determining the Gas Velocity ........................................................................................................ 14

2.3.2 Calculating the Volumetric Flow ................................................................................................... 14

2.3.3 Determining the Velocity of Sound.............................................................................................. 14

2.3.4 Compensating Path Failure............................................................................................................. 15

2.4 Elements for Display, Operation and Communication............................................... 16

2.5 Self-diagnosis......................................................................................................................... 18

2.6 Technical Data ...................................................................................................................... 19

2.7 Dimensions, Part Numbers................................................................................................. 20

3 Installation........................................................................................................................... 21

4 Commissioning and Parameterization........................................................................ 27

4.1 Basics ....................................................................................................................................... 294.1.1 General Notes .................................................................................................................................... 29

4.1.2 Prerequisites ....................................................................................................................................... 29

4.1.3 Preparations ........................................................................................................................................ 30

4.1.4 Basic Settings ..................................................................................................................................... 30FLOWSIC150 Operating Instructions 8010815 V 1.2 SICK MAIHAK GmbH Germany 3

Content4.2 Parameterization .................................................................................................................. 314.2.1 Setting Basic Parameters and Analog Output ......................................................................... 31

4.2.2 Calibration ............................................................................................................................................ 33

4.2.3 Start Standard Measuring Mode ................................................................................................. 33

4.3 MEPA-Carflow Program ...................................................................................................... 344.3.1 Program Interface............................................................................................................................... 34

4.3.2 Menu Descriptions............................................................................................................................. 36

4.3.3 Data Recorder .................................................................................................................................... 40

4.3.4 Data Collection, Data Management, Data Save..................................................................... 42

5 Maintenance .......................................................................................................................51

5.1 General ..................................................................................................................................... 53

5.2 Routine Checks ..................................................................................................................... 545.2.1 Gas temperature Measurement................................................................................................... 54

5.2.2 Velocity of sound ................................................................................................................................ 55

5.2.3 Checking the Measuring Pipe on Depositions ........................................................................ 55

6 Troubleshooting .................................................................................................................57

6.1 Fault Diagnosis ...................................................................................................................... 59

6.2 Warning Messages ............................................................................................................. 60

6.3 Malfunction Messages........................................................................................................ 61

7 Parts Overview....................................................................................................................63

7.1 Standard Components......................................................................................................... 65

7.2 Spare Parts.............................................................................................................................. 66

8 Appendix...............................................................................................................................674 FLOWSIC150 Operating Instructions 8010815 V 1.2 SICK MAIHAK GmbH Germany

About this DocumentAbout this Document

The present Operating Instructions describe the FLOWSIC150 measuring system designed for contactless measurements of flow velocity and air temperature in tunnels.

These Operating Instructions contain general information on the method of measurement used, the design and function of the entire system and its components, as well as instructions for planning, assembly, installation, commissioning, maintenance and troubleshooting.A comparison of the characteristics of the available system variants is provided to help you decide on the configuration that is best suited to your needs in the planning phase.

These operating instructions only cover standard applications that match the technical data listed. Your SICK MAIHAK representative will gladly provide you with additional information and support for special applications. We strongly advise that you contact a SICK MAIHAK specialist for consultation with regard to special applications.

Note Always read these operating instructions carefully before commencing work. The safety instructions and warnings must be followed at all times.

Symbols used in this document

For quick access and reasons of clarity, important safety information is specially highlighted in these operating instructions. These symbols are provided at the points in this documentation where the relevant information is required.

Note Provides information on the features of the device or system, along with additional tips.

ATTENTION

Important

Indicates a risk of damage to the device or system components and potential functional impairments.

DANGER

Warning

Identifies potential danger for personnel, particularly due to electrical equipment or as a result of incorrect handling of the device or system components. These warnings are intended to protect you from (fatal) injuries.

Always read warnings carefully and follow them at all times!FLOWSIC150 CARFLOW Operating Instructions 8010815 V 1.2 SICK MAIHAK GmbH Germany 5

Safety Instructions1 Safety Instructions

1.1 Intended Use

The FLOWSIC150 measuring system was designed for contactless measurement of flow velocity and air temperature in tunnels. It must only be used in the manner intended by the manufacturer. In particular, it is important that:

The system is operated in accordance with the technical data and specifications regarding assembly, connection, ambient, and operating conditions (see the documentation supplied, the order documents, device documents, and rating plates)

All of the measures required to maintain the device, e.g. maintenance and inspection, transport and storage, are provided.

1.2 Authorised Personnel

Persons responsible for safety issues must ensure that:

All work on the measuring system is carried out by qualified personnel and checked by the experts responsible. These persons must be qualified by virtue of their expertise (training, education, experience) or understanding of the relevant standards, specifications, accident prevention regulations, and properties of the system. It is crucial that these persons be able to identify and avoid potential hazards in good time. Technical experts are those persons defined in DIN VDE 0105, IEC 364, or other directly equivalent standards.

These persons must be familiar with the hazards posed during operation and must have received special training on how to operate the measuring system.

1.3 Safety Instructions and Protection Measures

1.3.1 General Information

Handling or using the device incorrectly can result in personal injury or material damage. Therefore take the following information into account absolutely to avoid damage:

The legal stipulations and associated technical regulations relevant for the present installation have to be adhered when preparing and carrying out work on the measuring system.

All work must be carried out in accordance with the local, system-specific conditions and with due consideration paid to the operating dangers and specifications.

The operating instructions for the measuring system and plant documentation must be available on site. The instructions for preventing danger and damage contained in these documents must be observed at all times.

Suitable safety equipment and personal protection measures must be available in accordance with the potential hazard and must be used by the personnel. 6 FLOWSIC150 CARFLOW Operating Instructions 8010815 V 1.2 SICK MAIHAK GmbH Germany

Safety Instructions1.3.2 Danger from electrical Equipment

The FLOWSIC150 measuring system is an item of electrical equipment designed for use in industrial power installations. When working on power connections or on live components, make sure that the power supply is switched off. If necessary, replace shock protection measures before reconnecting the power supply.

1.3.3 Preventive Measures for safe Operation

If the FLOWSIC150 is used in conjunction with process measurement and control equipment, the operator must ensure that any failure or malfunction does not lead to damaging or dangerous operating

In order to prevent device failure, the specified maintenance actions must be carried out by qualified and experienced service staff in regular intervals.

1.3.4 Detecting and Preventing Malfunctions

Any deviations from normal operation must be regarded as a serious indication of a functional impairment. These include:

Significant drift of measured values

Increased power consumption

Increased temperature of system components

Acting fuses, circuit breakers and safety switches

Development of smell or smoke

To prevent malfunctions, which can cause personal injury or damage to the system either directly or indirectly, the operator must ensure that

The maintenance personnel responsible can reach the site immediately, and at any time,

The maintenance personnel is sufficiently qualified to respond to malfunctions on the FLOWSIC150 and any resulting malfunctions (for example, if the system is used for open or closed-loop control purposes),

The defective equipment can be switched off immediately if necessary,

Switching off equipment does not indirectly cause further malfunctions.FLOWSIC150 CARFLOW Operating Instructions 8010815 V 1.2 SICK MAIHAK GmbH Germany 7

Safety Instructions8 FLOWSIC150 CARFLOW Operating Instructions 8010815 V 1.2 SICK MAIHAK GmbH Germany

System Features

System Design

Measuring Principle Flow Measurement

Elements for Display, Operation and Communication

Self-diagnosis

Technical Data

Dimensions, Part Numbers

FLOWSIC150 CARFLOW

Exhaust Gas Flow Meter

Product Description

Product Description2 Product Description

2.1 System Features

The FLOWSIC150 CARFLOW measuring system is designed for contactless measurements of gas velocity, pressure and temperature in exhaust gas pipes of motor and roll test stands in automotive industry. These measured variables are used to determine and output the vol-umetric flow rate normalized on pressure and temperature.

Fig. 2.1: FLOWSIC150 CARFLOW

Features and advantages

Direct measurement of the gas velocity independent on pressure, temperature and gas composition

Determination and output of standardized volume flow values by simultaneous measu-ring of exhaust gas temperature and pressure at the installation location

High rate of response direct and "real time assignment of emissions 1, 3 or 4 measuring paths and digital measured-value processing high accuracy also

at low gas velocities

Measurement of undiluted raw exhaust gas allows simultaneous gas analysis of lowest concentrations of pollutants

Practically no loss of pressure, no influence on engine characteristics

Simple installation to the exhaust gas pipe by means of selectable connection elements (e.g. quick-release connector 2 ")

Compact design, mobile system

Integrated heating unit prevents gas condensation if ambient conditions change

Diagnostic functions for system check

No moving parts, minimum wear-and-tear

Display and operation elements

Main switch

Control cabinet

Connections

Inlet pipe with flow straightener and protective insulation

Connection for gas inlet

Lockable rollerFLOWSIC150 CARFLOW Operating Instructions 8010815 V 1.2 SICK MAIHAK GmbH Germany 11

Product Description2.2 System Design

The FLOWSIC 150 CARFLOW is installed in the exhaust gas pipe of the engine test stand using selectable connection elements. The gas inlet module contains a flow straightener to reduce the influence of flow disturbances on the measurement accuracy while ensuring the pressure drop to be minimal. The gas is then heated to avoid condensate formation. A PT100 temperature sensor delivering the control signal for the heater regulator is installed next to the test cell.

A second heater regulator allows to connect an additional hose heating (not scope of supply). This requires an external Pt100 temperature sensor for the control.

The test cell contains the ultrasonic transducers for the gas velocity mesurement (details see Section 2.3) as a basis for the volumetric flow calculation.

Fig. 2.2: FLOWSIC150 CARFLOW system design, 3 paths version 2

The following temperature and pressure measurement delivers the values to calculate nor-malized volumetric flow rates. The measuring signals are read into the evaluation electronics synchronously with each flow measurement.

Diameter 1 mm Calibrated measuring range 0 ... 400 C

The gas temperature is measured by a jacket-type thermocouple element (Ni-CrNi). The temperature signal is collected by an thermocouple amplifier with cold junction compensa-tion and then digitalised. The pressure tapping connection is connected via a hose to the pressure sensor in the evaluation electronics. The measuring range is 660 mbar to 1100 mbar (absolute).

To avoid condensate formations at the control electronics after measurements at very low ambient temperatures (e.g. climate test) and following warming, a heater is installed in the

PTC = Positive Tempera-ture Coefficient

control cabinet. A PTC-resistor is used as the heating element.

If the temperature inside the cabinet falls below a minimum, the heater is turned on by a thermostat (default minimum temperature 15 C). The self-control function of the PTC-resis-tor ensures that a defined surface temperature is not exceeded (default setting: 105 C).

Control and evalu-ation electronics

Heater regulator(Watlow)

Heater regulator(Watlow)

Analog output4...20 mA

Connection for gas outlet

(Exhaust gas pipe) (Exhaust gas pipe)

Connection for gas inlet

Power supply

Normalized volume flow

external Heater

Test cell Ultrasonic transducer

Heater

Pt100

p T v

Path 2 Path 1, 3

Display and operation elementsHeater for control cabinet

Control cabinet

Exhaust gas

Flow straightener12 FLOWSIC150 CARFLOW Operating Instructions 8010815 V 1.2 SICK MAIHAK GmbH Germany

Product Description2.3 Measuring Principle Flow Measurement

The FLOWSIC150 operates by measuring the propagation delay of an ultrasonic pulse. It is equipped with at least a couple of identical ultrasonic transducers. The transducer pairs are integrated in the test cell and arranged opposite one another at a defined angle to the flow axis, thereby forming a direct measuring path (see Fig. 2.3).

Fig. 2.3: Measuring principle, 3 paths version 2

The FLOWSIC150 can be delivered with 1, 3 or 4 measuring path(s). A 3 paths version is designed with crossing paths, 4 path versions have all measuring paths in the same level. The number of measurements per second depends on the path number (1 path: 80; 3 paths: 3x30; 4 paths: 4x30 measurements).

The ultrasonic pulses cross the measuring pipe from transducer to transducer. With no gas flowing, the pulses are propagated with the same velocity (velocity of sound) in both direc-tions. When a gas is flowing through the test cell, 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 trans-ducer 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 sound and 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 ef-fect 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.

Note The measuring precision specified in section 2.6 applies to a device with integrated flow straightener that is calibrated by the manufacturer with undisturbed inlet section with a ho-mogeneous flow profile and under use of the SICK MAIHAK standard couplings. The calib-ration under differing conditions and under use of other connections is possible on request. In this case a second flow straightener can be required.

Ultrasonic transducer A

Path 1 Path 2 Path 3

Ultrasonic transducer B

Measuring pipe

Test cellFLOWSIC150 CARFLOW Operating Instructions 8010815 V 1.2 SICK MAIHAK GmbH Germany 13

Product Description

12.3.1 Determining the Gas Velocity

To the transit time of the sound in flow direction applies:

(1)

Sound transit time against the direction of flow tBA:

(2)

The path velocity (vPath) is calculated from the difference between the two transit times:

(3)

If several measuring paths are arranged across the flow profile, differences in the flow profile can be better taken into account, i.e. the gas velocity can be determined more precisely. The mean flow velocity in the cross-section vA is then calculated by averaging of the weight-ed individual paths.

(4)

If the measurement fails in one measuring path, the flow velocity in the cross-section can still be calculated without any changes in the measuring arrangement, although with a slight-ly lower accuracy. This is possible because a replacement value is calculated for the faulty measuring path.

2.3.2 Calculating the Volumetric Flow

The volumetric flow in operating state is calculated from the determined flow velocity and the cross-sectional area in the measuring pipe:

(5)

The volumetric flow in normalized state QN.S. is calculated from the volumetric flow in ope-rating state and the currently measured values for pressure and temperature in the meas-uring pipe:

2.3.3 Determining the Velocity of Sound

The actual velocity of sound c in the gas is calculated from the sum of the two measured transit times tAB and tBA of a path.

(6)

A theoretical velocity of sound can be derived from the gas composition, pressure and temperature information. This theoretical velocity of sound and the measured velocity of sound should be identical. The velocity of sound thus provides an excellent possibility of

tAB =L

c + vPath cos L: Measuring path length

c: Velocity of sound

vPath: Path velocity

: Angle between thelongitudinal axis of thetest cell and the path

N: Number of measuring paths

vA: Mean flow velocity in thecross-section

wi: Weighting factor of a measuring path

tBA =L

c - vPath cos

L 1 1

1

N i = 1

N

vA = wi vPfad i

vPath = ( )2 cos tAB tBA

A: Cross-sectional area inthe measuring pipe

QO.S.: Volumetric flow in operating state

p0, T0: Pressure and tempe-rature in normalizedstate

p, T: Pressure and tempe-rature in operatingstate

QO.S. = vA A = vA D 4

QN.S. = QO.S. p T0p0 T

c = ( + )L 1 12 tAB tBA4 FLOWSIC150 CARFLOW Operating Instructions 8010815 V 1.2 SICK MAIHAK GmbH Germany

system diagnosis.

Product Description2.3.4 Compensating Path Failure

Path failure is compensated using the ratio of the measuring path flow velocities to each other. These mainly depend on the complexity of the flow profiles and the flow rate.

Operating principle

During normal operation, the individual path ratios PPath are calculated continuously.

(7)

These ratios are used for an adaptive mean value calculation for each individual path. This suppresses statistical fluctuations caused by turbulence without slowing down the process of adapting to new flow profile situations.

In addition to the adaptive calculation of the path ratios, the system differentiates between low (1 - 8 m/s) and high flow rates. This improves the result of the compensation because the path ratios are more stable with higher flow rates. The path ratios are not adjusted below 1 m/s.

Adaptive compensation of one or more path failures

The self-diagnosis function implemented in the meter (see Section 2.5) can reliably filter out implausible results. If the ratio between accepted and rejected measurements for a

Failures of more paths are compensated accordingly

measuring path exceeds the permitted threshold, this path is excluded from the calculation of the mean area velocity vA (equation 8). When this occurs, the following formula is used to calculate the average area velocity from the applicable measured values for the remaining paths and the stored adapted path ratios.

(8)

The system signals the compensation of a path error with the "Check requested" signal. An additional measurement uncertainty of less than 0.5 % should be expected for 4 path systems when operating in this mode.

Static compensation of one or more path failures

If no statistically stable path ratio values are present when a path fails, default path ratios are used for compensation.

PPath =vPath

vA

vA =

i = 1

N

bi wi vPfad i

PPfad i

i = 1

N

bi wi

bi: Status bit for path ibi = O: Path inactivebi = 1: Path activeFLOWSIC150 CARFLOW Operating Instructions 8010815 V 1.2 SICK MAIHAK GmbH Germany 15

Product Description2.4 Elements for Display, Operation and Communication

The elements for displaying measuring values and system status and as well as for the op-eration and communication are placed on the top side of the control cabinet.

Fig. 2.4: Top side of the control cabinet

Indication

Control keys

LED LCD Control keys

RS 232 interface Regulator for heating the measuring pipe

Main switch

Signalisation for status Malfunction

Signalisation for status Operation

Reglulator for exter-nal hose heating

Type Display of

LC Display 1st line

2nd line Status messages

LED Operation Normal, fault-free system operation. The analog output is updated periodically.

Malfunction This LED is activated when faults occur that prevent the system from measuring accurately. If the cause for the fault ceases to exist, the system returns to "Measurement" mode automatically.

Maintenance Device is in maintenance mode; At multi path systems, this LED signalises that maintenance is needed because one of the measu-ring path has failed. The failure is compensated by the FLOWSIC150 with a slightly lower accuracy.

Lamps green Normal, fault-free system operation.

red Faulty device operation or system is heated up

Absolut pressure at the measuring

Gas temperature at the measuring location (Ni-CrNi temperature sensor)

Normalized volumetric flow

Display of AK Qn if AK mode is set

Functions Remark

AK = Study group Selecting a measuring variable Switching in AK mode (special

RS232 interface protocol for au-tomotive industry)

Activating maintenance mode

You can display all of the options available by pressing the SET key (the display scrolls automatically if you press the key for longer than >1 s). To choose the option cur-rently displayed, press the key.16 FLOWSIC150 CARFLOW Operating Instructions 8010815 V 1.2 SICK MAIHAK GmbH Germany

Product DescriptionRS232 interface

This interface can be used for connecting a PC/Notebook with installed MEPA CARFLOW program (Menu-operated Parameterisation CARFLOW) via standard serial interface cable for system configuration, logging of measured data and system diagnosis.

Heater regulator

Regulator for measuring pipe heaterFor details on modifying the settings refer to the separate document (WATLOW Users Manu-al)

This regulator controls in connection with the Pt100 sensor the heating of the exhaust gas before it enters in the test cell to avoid condensation. The default set-point temper-ature is 130 C. If the temperature drops below the threshold Alarm low (default setting 80 C), the regulator signals the status "Heater temperature < 80 C" via the switching output.

Note The "Alarm high" threshold also affects the switching output. Therefore this threshold should be set to a value outside of the plausible gas temperature range (default setting 500 C if not specified otherwise by the customer).

Regulator for external hose heatingThis regulator controls an external hose heating to be connected to the socket External Heater (see Fig. 2.5). The measures for the connection of the hose heating and the re-gulators settings are described in Chapt. 3.

Connections

Fig. 2.5: FLOWSIC150 connections

Analog output 0/2/4...20 mA for output of the normalized volumetric flow (BNC socket)

Analog output External Power 0 ... 20 mA Heater

+

Socket for connection of an external hose heating

Plug for connection mains voltage 115/230 V AC

4 3

3 11 22

546

7FLOWSIC150 CARFLOW Operating Instructions 8010815 V 1.2 SICK MAIHAK GmbH Germany 17

Product Description2.5 Self-diagnosis

In the measurement mode, the ratios of sound and path velocities, amplification settings, and signal-to-noise ratios are continuously monitored. If these parameters deviate from a preset range, a warning signal is generated. This enables immediate measures to be taken to prevent possible system malfunctions.

During commissioning or operation, you can adjust the signalling threshold values to suit individual application requirements. This enables you to create the most effective status warning system.

Note The "Warning" status signal does not affect the device function.

Additional signal and system diagnosis functions monitor the accuracy of the measured values, by checking the plausibility of the ultrasonic signals received and the ultrasound signal propagation times calculated from them.

Parameter Default threshold value

Warning message

Notes

Velocity of sound

< 5 m/s Warning SOS Deviation

This message is produced when the current measured path velocity of sound deviates from the mean value of the mean velocities of sound calculated for all the paths by more than the specified threshold value. The current flow velocity is used as a weighting factor, so that temperature stratification is disregarded at very low flow velocities.Used to indicate whether or not the path is measuring the correct propagation time. NoteWhen setting the parameters, take into account plausible conditions for normal operation (in particular temperature stratification).

Receptiongain

< 6 dB Warning AGC Deviation

The absolute difference between both path gain factors is evaluated and must remain below the threshold value.ImportantHigh flow rates can also increase the difference in gain.

< 93 dB Warning AGC Limit

The absolute value of the reception gain is monitored.ImportantThe current receiving sensitivity largely depends on the current process pressure (inversely proportional in initial approximation, that is, when the pressure doubles, the required receiving sensitivity is halved).

If one of the alarms is triggered by a path, this can indicate a malfunction in the ultrasonic transducers, electronics, probe cables or parameter settings (signal models, standard threshold values).

Signal-to-noise ratio

< 13 dB Warning SNR This alarm is activated when the signal-to-noise ratio is too small. Reasons for this include interference noise caused by fittings in the pipeline, valves that are not fully open, sources of noise near the measuring location, or defective ultrasonic transducers.18 FLOWSIC150 CARFLOW Operating Instructions 8010815 V 1.2 SICK MAIHAK GmbH Germany

Product Description2.6 Technical Data

* tested at ambient air conditions (see note in Section 2.3)** Other dimensions on request

Measured value acquisitionMeasured variables Gas velocity, volumetric flow (actual), volumetric flow (normalized), gas temperature, absolute

pressureMeasuring range actualvolumetric flow

Pipe size 2" 1 measuring path3 measuring paths

0 ... 150 l/s

Pipe size 4" 4 measuring paths 0 ... 300 l/s

Typical measuring uncertainty * 1 measuring path < 2,5 % of the measured value, from 0,1 Qmax to Qmax 3 measuring paths < 0,7 % of the measured value, from 0,05 Qmax to Qmax4 measuring paths < 0,5 % of the measured value, from 0,05 Qmax to Qmax

Temperature measurement Jacket-type thermocouple element, Ni-CrNi, "K" type, measuring range 0 ... 400 CPressure measurement (absolute) Measuring range 660 ... 1100 mbarDisplays2-row LCD For measured variables, warnings and error messagesLED For operation, malfunction, maintenanceInstallationGas temperature max. 300 C < 10 min per 1 h, total stress maximum 100 cyclesTransducer temperature max. 280 C Inlet and outlet pipe thread ** 1 measuring path

3 measuring pathsG 2"

4 measuring paths G 4Pressure drop by the integrated flow straightener

1 measuring path3 measuring paths

approx. 0.45 mbar at 20 l/sapprox. 1.40 mbar at 35 l/sapprox. 5.50 mbar at 70 l/s

4 measuring paths approx. 0.5 mbar at 50 l/sapprox. 2.2 mbar at 100 l/sapprox. 5.4 mbar at 150 l/s

Output of measured valuesAnalog output 0/2/4... 20 mA; max. load 760 Ohm; update rate 10/s; scaling freely programmable RS232 (Modbus/AK) 10/s (in burst mode)InterfacesRS232 For configuration via PC using the MEPA CARFLOW programPower supplyOperating voltage 90 ... 140 V AC; 50/60Hz or 190 ... 260V AC; 50/60HzPower consumption 695 W

1095 W24

without external hose heating

Heating capacity measuring system 600 W 1000 W

24

Maximum switchable heating capacity for external hose heating

1.6 kW (230 V AC)0.8 kW (115 V AC)

for 2 und 4

Ambient conditionsTemperature range 20 ... +50 C Class of protection IP 65Dimensions, massW x H x D (in mm) 900 x 630 x 380 (with flow straightener)Mass approx. 80 kgFLOWSIC150 CARFLOW Operating Instructions 8010815 V 1.2 SICK MAIHAK GmbH Germany 19

Product Description2.7 Dimensions, Part Numbers

All dimensions are indicated in mm.

Fig. 2.6: FLOWSIC150 dimensions

L

Type FLOWSIC150 Part no. L A B D H

FL150 1P1 2,5Z XT 0H1 measuring path, connection thread 2 " 7041982

900 250 200 2 " 300FL150 3P2 2,5Z XT 0H3 measuring paths, connection thread 2 " 7041984

FL150 4P1 4,0Z XT 0H4 measuring paths, connection thread 4"

1026307 765 125 65 4" 260

600

A

B

380

63

0

H

D20 FLOWSIC150 CARFLOW Operating Instructions 8010815 V 1.2 SICK MAIHAK GmbH Germany

FLOWSIC150 CARFLOW

Exhaust Gas Flow Meter

Installation

Installation3 Installation

GEFAHR

Warning

All installation work must be carried out in line with the relevant safety regulations and in-structions listed in Chapter 1.

The measuring system should be installed in the exhaust gas pipe only when the plant is shut down!

Take suitable measures to protect against local or installation-specific hazards!

Activities

Install the Flowsic150 in the exhaust gas pipe by connecting the respective connection elements to the gas inlet and outlet of the measuring pipe (standard: 2 " for 1 and 3 path version, 4 for 4 path version).

Check the assignment of the plug bridges to the terminals 15 to 26 in the control cabinet under consideration of the existing supply voltage according to Fig. 3.2 and correct if nec-essary.

To protect the integrated heating units, the terminals are equipped with exchangeable fuses (see Fig. 3.2). This prevents a damage of heating units at incorrect power connec-tion. In case of faults destroyed fuses have to be replaced against new ones.

fuse type: fine-wire fuse 5x20 mm, SuperFlink, 250 V ACcurrent value: see tab. 3.1

Terminal / Heater module FL150 1-path, 3-path (2,5) FL150 4-path (4)

15, 18 / pipe heating FF 1,25 A FF 3 A (3,15 A)

21, 24 / meter body heating FF 2 A FF 2 A

Tab. 3.1: current valuesFLOWSIC150 CARFLOW Operating Instructions 8010815 V 1.2 SICK MAIHAK GmbH Germany 23

InstallationFig. 3.2: Assignment of the plug bridges for supply voltage in the FLOWSIC150 control cabinet

Connect the power cable (scope of supply) with a power supply 115 / 230 V AC and the socket Power at the FLOWSIC150 (see Fig. 3.3).

Connect the analog output (socket Analog output) via coaxial cable with BNC plug (see Fig. 3.3).

Connections

Fig. 3.3: FLOWSIC150 connections

Connecting an external hose heater

Connect a cable with a suitable plug to the External Heater socket (for terminal assign-ment see Fig. 3.3 and connection table).

Assignment of the plug bridgesSupply voltage 115 V AC Supply voltage 230 V AC

(6 pcs. 1 to 4) (2 pcs. 1 to 6, 2 pcs. 1 to 3)

exchangeable fuses

Terminal 1 2 3 4 5 6 7

External Heater socket assignment L N - - Pt100 PE

Power plug assignment L - N PE

+ 4 33 11 2

2

546

7

Analog output External Power 0 ... 20 mA Heater24 FLOWSIC150 CARFLOW Operating Instructions 8010815 V 1.2 SICK MAIHAK GmbH Germany

InstallationACHTUNG

Attention

The cable may only be made by an authorized expert!

Connect the terminals 13 and 14 in the control cabinet using the enclosed jumper (see Fig. 3.4).

Fig. 3.4: Jumper for connection of an external hose heater

Configure the heater regulator according to the attached instruction (WATLOW User's Manual).

Note If the jumper is set, but the external hose heater not connected, the display of this heater regulator shows the message Er 4 when the FLOWSIC150 is switched on. This only means that no thermocouple element is connected to the regulator. The normal system function is ensured.

JumperFLOWSIC150 CARFLOW Operating Instructions 8010815 V 1.2 SICK MAIHAK GmbH Germany 25

Installation26 FLOWSIC150 CARFLOW Operating Instructions 8010815 V 1.2 SICK MAIHAK GmbH Germany

Basics

Parameterization

MEPA-CARFLOW Program

FLOWSIC150 CARFLOW

Exhaust Gas Flow Meter

Commissioning and Parameterization

Commissioning and Parameterization4 Commissioning and Parameterization

4.1 Basics

4.1.1 General Notes

Commissioning essentially entails entering the base parameters and configuring the analog output (Section. 4.2.1). In certain cases (e.g. disturbed flow profile in the inlet section) an additional calibration can be required after installation of the system (Section 4.2.2).

The MEPA CARFLOW program is supplied with the device for configuring the system param-eters. The existing program menus allow an easy configuration of the required settings. Oth-er functions (such as data backup and graphical display functions) are also available (see Section 4.3).

Password protection

Access level "Operator", see Section 4.1.4

All program components and device parameters required for standard commissioning and system use are accessible without password.

Device internal parameters which have to be changed if necessary for the adaption of theAccess level Service, for password contact SICK MAIHAK

FLOWSIC150 to plant-specific conditions (e.g., if the device is not deployed in line with thespecifications set out in the technical data) are accessible only after entering a password. Changes only may be carried out by sufficiently qualified persons.

4.1.2 Prerequisites

Laptop/PC with:

Processor: Pentium 2 or higher VGA graphics card Serial interface COM 1 or COM 2 Main memory (RAM): minimum 32 MB Operating system: Microsoft Windows 95 or higher

Interface cable (serial cable for connecting a laptop/PC to the FLOWSIC150 (connection at the RS232 interface).

Pin assignment

The FLOWSIC150 must be connected to the power supply.

FLOWSIC 150 socket PC connector 9 pole

Pin 2 (txd) Pin 2 (rxd)

Pin 3 (rxd) Pin 3 (txd)

Pin 5 (gnd) Pin 5 (gnd)FLOWSIC150 CARFLOW Operating Instructions 8010815 V 1.2 SICK MAIHAK GmbH Germany 29

Commissioning and Parameterization4.1.3 Preparations

Install the MEPA CARFLOW operating and parameterization program:

Insert the CD

Choose the CD drive

Start "MEPA-CARFLOW_SETUP.exe and follow the instructions

Connect the interface cable with socket from the front panel on the control cabinet to the RS232 port on the laptop/PC.

Change to the installation directory and start "MepaCarFlow.exe.The menu "Connect to" occurs.

4.1.4 Basic Settings

Program details are de-scribed in Section 4.3

Before you configure the parameters, carry out the steps listed in the table below (if applicable).

Step Menu Notes/ action

Choose the port on the PC

"Connect to Choose the port (e.g. COM 1) in the "Connect to menu

Connect to the FLOWSIC150

Click on "Connection to confirm - the active parameter set of the device is downloaded to the MEPA CARFLOW program

Set the language "Options / Language For using the MEPA CARFLOW

Generate a new ses-sion file (recommen-ded)

"File / New session" To store all device set-tings and operating actions, see Section 4.3.4 30 FLOWSIC150 CARFLOW Operating Instructions 8010815 V 1.2 SICK MAIHAK GmbH Germany

Commissioning and Parameterization4.2 Parameterization

Program details are de-scribed in Section 4.3

To set the parameters described below, activate "Configuration" in the menu "Operation mode". After selecting the ""Device parameter" tab page the following picture appears.

Fig. 4.1: "Device parameter" tab page (password level "Operator")

After selecting the respective parameter (click on subdirectory in the "Parameters" window) enter the required value in "Parameter editor" windows, "Register value" box. After entering of the parameters these must be transferred to the FLOWSIC150. To do this, press the but-ton "Write register". We recommend to check the take-over of the values into the device by pressing the button "Read register".

4.2.1 Setting Basic Parameters and Analog Output

Directory "Meter Setup" Basic parameters

"Operating Mode" menu

Adjustable parameters in the password level"Operator"

Parameter Meaning Set value Assignment

LCD Display Setting/change of the language at the LCD on the top side of the control cabinet

0 German

1 English

Norm. Pressure Reference value for device-internal norma-lisation of the volumetric flow.

1013,3 0 hPa

Norm. Temperature 20 SI standard

20 US standardFLOWSIC150 CARFLOW Operating Instructions 8010815 V 1.2 SICK MAIHAK GmbH Germany 31

Commissioning and ParameterizationAnalog output

The analog output (BNC socket, see Fig. 3.3) provides the measuring value for the volumet-ric flow (normalized with pressure and temperature) as an analog signal 0 ... 20 mA. The zero point, the measuring range as well as the output value in the "Configuration" mode and in case of errors have to be adjusted in the "Device parameter" tab page for the exact assign-ment of the measuring value to the output value (see Fig. 4.2 and the following table).

Fig. 4.2: "Device parameter" tab page, analog output settings

The current at the analog output is calculated as follows:

Iout = LZ + (MV - AO RangeLow)

The parameter "AO Test" serves to check the correct function of the analog output. To do it, enter a value between 0 and 20 mA in the "Register value" box and transfer it into the

Parameter Meaning Set value Assignment

AO Live Zero Value for Live Zero (LZ) 0 0 mA

2 2 mA

4 4 mA

AO RangeLow Lower measuring range limit (corresponds to Live Zero)

x x l/s

AO RangeHigh Upper measuring range limit (corresponds to 20 mA)

x x l/s

AO Maintenance Output value for operating mode "Configuration"

0 0 mA

1 LZ

2 Current measuring value (MV)

3 Span (test value)

20 mA - LZ

AO RangeHigh - AO RangeLow32 FLOWSIC150 CARFLOW Operating Instructions 8010815 V 1.2 SICK MAIHAK GmbH Germany

Commissioning and ParameterizationFLOWSIC150 (click on button "Write register"). Then check the value at the analog output with a multimeter. Set and output value must be the same if the device works correctly.

Malfunctions are signaled at the analog output with 20mA (see section 6.3).

4.2.2 Calibration

The FLOWSIC150 is delivered in a pre-calibrated condition. This calibration includes a geo-metric survey of the meter body, zero point test, signal transit time measurements and the determination of other system-specific parameters. To achieve the highest possible preci-sion, an additional comparison measurement is carried out with standards. The character-istic generated with this procedure is stored in the device. No further calibration is usually required after the installation.

Under certain circumstances (e.g. at unfavorable installation conditions) it can be required, however, to re-calibrate the measuring system in the specific installation situation by a com-parison measurement with a reference measuring system. The calibration coefficiants de-termined in this way have to be entered in the 2nd order calibration function implemented in the FLOWSIC150.

QN_corr = cc2 QN_ncorr2 + cc1 QN_ncorr + cc0QN_corr = normalized volumetric flow corrected QN_ncorr = normalized volumetric flow not correctedcc2 = square calibration coefficient cc1 = linear calibration coefficient cc0 = absolute calibration coefficient

To set the calibration coefficients select the respective directory, enter the values for cc0, cc1 and cc2 in the "Register value" boxes and apply your setting by clicking on "Write regis-ter".

The manufacturer settings are cc 0 = 0, cc 1 = 1, cc 2 = 0.

4.2.3 Starting Standard Measuring Mode

Standard measuring mode is started when you switch to "Measure mode" ("Operating mode / Measure mode" menu).

Directory Assignment

NFlowrate CC0 cc0

NFlowrate CC1 cc1

NFlowrate CC2 cc2FLOWSIC150 CARFLOW Operating Instructions 8010815 V 1.2 SICK MAIHAK GmbH Germany 33

Commissioning and Parameterization4.3 MEPA-CARFLOW Program

The MEPA-CARFLOW operating program was developed as an application software based on Microsoft Windows . The control elements used, i.e. buttons, menu bars, dialog boxes, are designed to correspond with generally used Windows elements.

The program interface is generally divided into five parts: menu bar, tool bar (icons), tabs, dialog area and status bar (see Fig. 4.3).

Depending on the selected password level, different displays and settings are available. In the password level "Operator" provided for the normal system use some functions and dis-plays are hidden. All functions are only accessible in the password level "Service" (descrip-tion see service manual).

The displays and functions available in the password level "Operator" are more fully ex-plained in the following sections more.

4.3.1 Program Interface

Menu bar

Menu Item Description

File New session Opens a new session file ("DEFAULT.SF)Open session Opens an existing session file

Save session Saves the current session file

Save session as Saves the current session under a new name

Diagnosis session Starts a diagnosis session

Session history Opens the "Session history dialog box and displays scanned session contents

Upload configuration Starts transmission of a configuration to the FLOWSIC150

Printer selection Opens the printer selection menu

Exit Terminates the program after a confirmation dialog

Connection Connection Opens the "Connect to dialog box (see Section 4.1.4)

Operating mode Configuration Measure mode

Changes the FLOWSIC150 operational mode

Monitors System status Indicates the current system status

% Errors Displays the error rates in all paths

SNR Displays the signal-to-noise ratio in all paths

AGC levels Displays the gain in all paths

Velocity of sound Displays the velocity of sound in all paths

Relation of velocity of sound

Relative variation of the sound velocity among the individual paths

Velocity of gas Displays the velocity of gas in all paths

Options Trend set-up Opens a dialog box to change the trend representation on the "Log/ trend tab (colours, time slot - X axis)

Language Opens a dialog box to select the interface language

Colour adjustment Opens a dialog box to select a global colour pattern

Diagnosis setup Opens a dialog box to select the time slot for data recording in a diagnosis session, distinguished into signal and value recording

FLA Terminal Opens a box for entering terminal commands

Help Version MEPA-CARFLOW program version

Help F1 Online help34 FLOWSIC150 CARFLOW Operating Instructions 8010815 V 1.2 SICK MAIHAK GmbH Germany

Commissioning and ParameterizationTool bar

The tool bar contains major functions which shall be activated quickly and simply.

Tabs

Tab Content

Measuring values Display of currently measured values and status information (see Fig.4.3)

Device parameters Display of device identification parameters, display and input of all parameters for meter setup, calibration, analog outputs (see Fig.4.1)

Log/ trend Dialog for collecting measured values, menu to select measured values for logging

Open a new session

Open an existing session

Save current session

Create a diagnosis session

Upload an external configuration file

History information of current session and editing

Connect to device or change to offline mode

Switch device to configuration mode

Switch device to measurement mode

Open logged data

Find record

Stop logging

Start logging

Play log

Pause

Go to first record

Go to previous record (hold mouse button down to scroll)

Go to next record (hold mouse button down to scroll)

Go to last record

Enable signal soundFLOWSIC150 CARFLOW Operating Instructions 8010815 V 1.2 SICK MAIHAK GmbH Germany 35

Commissioning and Parameterization4.3.2 Menu Description

"Measured values" tab

This tab shows the measured values as well as information to the system status (see Fig. 4.3). The display depends on the password level.

Fig. 4.3: "Measured values" tab (Password level "Operator")

The "Measure values (FLA)" field shows the current values of normalized and actual flow rate, temperature, pressure, velocity of sound and gas velocity.

If you place the cursor in the graphic fields for flow rate, temperature or pressure(right part of the dialog area) you can read the mean value as well as maximum and minimum value of these measured values.

Menu barTool barTabs

current meas. values

Status code(detailed information by clicking on the respective field)

Display of malfunctions and warnings (description see Section 6.2 and 6.3)

Status bar

Normalized flow rateActual flow rateGas temperature Pressure in the measuring pipeAverage velocity of soundAverage gas velocity

temporal course of the measured values with display of average, minimum and maximum36 FLOWSIC150 CARFLOW Operating Instructions 8010815 V 1.2 SICK MAIHAK GmbH Germany

Commissioning and ParameterizationDevice parameters tab

see Section 4.2.1 This tab provides the possibility to change device parameters. The FLOWSIC150 must be set to the configuration mode to be able to modify parameters. Parameter modifications are saved in the current session and in the FLOWSIC150 logbook (session concept see Section 4.3.4).

The following table shows the parameters adjustable in the "Operator" password level.

"Log/ trend" tab

This tab allows to log device-internal measuring data. These measuring data are read out from the FLOWSIC150 by the operating program and saved in a session file. These data can be exported from the session file into a structured ASCII file by selecting the item "Session history from the "File menu (see Section 4.3.4 Session history).

Fig. 4.4: "Log/ trend" tab

Group of parameters, parameter Description

Meter Setup LCD Display Setting of the language at the LCD

Norm. Pressure Reference values for pressure und temperature

Norm. Temperature

Calibration NFlowrate CC0 absolute calibration coefficient

NFlowrate CC1 linear calibration coefficient

NFlowrate CC2 square calibration coefficient

Analog Output AO Maintenance Output value for operating mode "Configuration"

AO RangeLow Lower measuring range limit (corresponds to Live Zero)

AO RangeHigh Upper measuring range limit (corresponds to 20 mA)

AO Test Test value to check the analog output

AO Life Zero Value for Live Zero (0, 2, 4 mA)FLOWSIC150 CARFLOW Operating Instructions 8010815 V 1.2 SICK MAIHAK GmbH Germany 37

Commissioning and ParameterizationThe inquired data can be displayed in a table or trend diagram. Use the "Trend" / "Log table" button to switch between the two display modes.

The data can be logged in different ways:

Automatic modeLogging rate e.g. once in 2 s

The data are logged with low speed (provided by the measuring system).

You can select the data to be logged by clicking on the "Add" or "Remove" button (see Fig. 4.5). Confirm your settings with "OK. The data is now shown in the table or diagram (see Fig. 4.6).

Fig. 4.5: Configuring the variables to be displayed (selected entries form an example)

Fig. 4.6: Display of the selected data

Selection with "Add" button(or double-click on the entry)

Removing with "Remove" button(or double-click on the entry)38 FLOWSIC150 CARFLOW Operating Instructions 8010815 V 1.2 SICK MAIHAK GmbH Germany

Commissioning and Parameterization Burst modeThe data are logged with fundamentally higher speed. The maximum possible logging rate is set automatically if you click on the button "Burst mode start!" (approx. 10 times per s; displayed in the status bar, see Fig. 4.8).

No choice for logging All data listed in the box "Available registers" (see Fig. 4.5) and not excluded by the log are recorded.

Fig. 4.7: Burst mode

The logging rate can be selected manually in the box "Storing intervals" by clicking on the "Start" button in the Tool bar instead of the button "Burst mode start!".

Sampling rate

Selectable storing intervalsFLOWSIC150 CARFLOW Operating Instructions 8010815 V 1.2 SICK MAIHAK GmbH Germany 39

Fig. 4.8: Possibilities for logging in the burst mode

Commissioning and ParameterizationThe selected data will be saved in the session file only after clicking on the "Start" button in the tool bar (see the following Section).

Note: Do not change to another tab while data are being logged, otherwise the data of the new tab will be recorded (the tab cannot be changed in the burst mode).

4.3.3 Data recorder

A data recorder was integrated into the MEPA-CARFLOW operating program. The functions of this recorder are controlled by the buttons as shown in Fig. 4.9. They are formed by ana-logy with generally usual pictographs for these functions.

Fig. 4.9: Icons of the data recorder

The recorder functions can be used for all tabs. The data sets recorded with that are stored into the session file and can be analyzed afterwards into two variants.

1. Export into a structured ASCII file using the storing function of the menu "File / Session history" .

2. Account of the tab contents in the operating interface.

Data logging

To log the data content of a tab, call up the tab and click on the "Start logging icon (red circle). The saving of the individual data records is indicated in the status bar of the program.

Click on the "Stop logging icon to stop data logging.

Replaying tab contents

All logged data records of the current session will be saved in a session file. If you click on the "Open log data" icon in the tool bar, a dialog box will appear in which all logs of the ses-sion are listed (see Fig. 4.10).

Start logging

Stop logging

Open logging

Play logging40 FLOWSIC150 CARFLOW Operating Instructions 8010815 V 1.2 SICK MAIHAK GmbH Germany

Commissioning and ParameterizationFig. 4.10: Log selection dialog box

Select an entry with the mouse and open it to replay that log. The control program will change to the corresponding tab and shows an activity bar to control the replay functions.

Fig. 4.11: "Replay log activity bar

This activity bar allows you to navigate the data log. In addition, the tool bar provides icons to start the first, previous, next and last record (see Section 4.3.1).

The logged measured values will be visualised in the displays of the tabs when you play the log, so that you can simulate and analyse the device conditions afterwards, without a direct connection to the device. In addition, all monitors in the "Monitors menu can be activated while you play a log, so that you can analyse major diagnosis data at the same time (e.g. velocity of sound, AGC).

These data can be exported into an ASCII export file by selecting the item "Session history from the "File menu (see page 45).FLOWSIC150 CARFLOW Operating Instructions 8010815 V 1.2 SICK MAIHAK GmbH Germany 41

Commissioning and Parameterization4.3.4 Data Collection, Data Management, Data Save

The following sections inform about data collection, data management and data save using the MEPA-CARFLOW program.

Functions, terms

Function Description

Session The term "session includes controlling, monitoring, data collecting and configuration activities of a FLOWSIC150 with the help of the MEPA-CARFLOW program. All major operations in the program during a session are automatically logged by the software and are available for later offline reading and analysis.

Session file All operations performed on a certain device with the help of MEPA-CARFLOW after a session is opened are saved in this file. Session files have the extension *.FSF.

Device manage-ment

A session opened for a certain device only contains information about this device. New session files can be generated for further devices. The correspondence between the open session and connected device is monitored by the software, instances of inconsistency will be signalled.

Long-term data manage-ment

Sessions can be saved and are thereby closed. If further operations become neces-sary later, the existing session file can be opened again. All further operations will then be in the existing session file. It will always be saved in the session history when you open a session, so that you operations and time can be related over the entire installation period of a device.

New session This command opens a session and creates a new session file.

Open ses-sion

This command is used to open an existing session file. All operations which are now performed in the MEPA-CARFLOW program will be logged in this session file

Save ses-sion

This command saves the currently open session.

Save ses-sion as

A default session file is generated always after starting the MEPA-CARFLOW pro-gram. All further activities are stored in this file. The default session can be stored as a new regular session by the operator. NoteIf the default session is not stored with a file name, she is overwritten completely at the next program start. The old data are lost in this case.

Diagnosis session

The diagnosis session aims to save all important information which should be coll-ected during maintenance actions. If you call up this command, the program will automatically start, execute and exit a data logging session. The information is saved in a session file which can be opened and analysed later

Session his-tory

This menu item is used to monitor the current session and activities contained ther-ein. Certain operations performed in a session can also be stored in ASCII files (e.g. measuring records).

"File" menu42 FLOWSIC150 CARFLOW Operating Instructions 8010815 V 1.2 SICK MAIHAK GmbH Germany

Commissioning and ParameterizationContents of a session file

The following operations and information collected in a session are saved in a session file (see also Fig. 4.14).

Session scenario

The session concept of the MEPA CARFLOW control program was developed to manage all measured values, parameters, operations etc. of several FLOWSIC150 devices consistently and comprehensibly over the entire life of the devices. If you use this function with care, these data provide information over years on the condition of the device at each point of time you have carried out actions on the device.

A sample scenario is illustrated below.

Compare Section 4.1.4 1. Creating a new session

Run the MEPA-CARFLOW program and establish a data connection.Ask the question whether you wish to open the last session with "No" ("Nein"), as you want to create a new session.

Fig. 4.12: "Open last session" dialog

Select "New session from the "File menu or the tool bar.The program creates a new default session file and logs the activities listed in the table above during the session.

Session entry Type of information

Corresponding activity Description

Current device configuration

Parameter set

Automatically when a new session is created

Continuous update

Contains the current configuration of the FLOWSIC150

FLASH file Program code

Automatically when a new session is created

Program code segment of the flash memory

EEPROM file Parameter code

Automatically when a new session is created

Data code segment of the EEPROM memory

Parameter modifications

Parameters Parameter modifications Entry of the modification of a parameter, parameter name, old and new value

Log/ trend Record Log/ trend Start logging

Collection of the values measured by the FLOWSIC150

Selection of measured variables for data logging in the "Log/ trend menu

Switching between measurement and configuration mode

Event Switching between measurement and configuration mode

Logging the operational mode change

Opening and closing a session

Event Opening/ closing Each opening and closing of the session file will be logged together with a time stamp.FLOWSIC150 CARFLOW Operating Instructions 8010815 V 1.2 SICK MAIHAK GmbH Germany 43

Commissioning and Parameterization Closing a session. If you have finished the operating activities, select "Save session" in the "File" menu or "Save current session" in the tool bar. Ask the question whether you want to save the current default session under a new name with "Yes" ("Ja") and enter a session file name.

Fig. 4.13: "Rename default session" dialog

You have now created an ordinary session file for your session.

Note The name of a session file should be associated with the FLOWSIC150 it relates to (e.g. serial no., measuring point no. etc.). The session file can be used and managed during the entire life of the device, even if it is modified or reinstalled somewhere else. Session files automatically receive the extension *.FSF.

See Section Session history and following

You may save the EEPROM and FLASH code segment and the current logbook (if any) when saving the session.

2. Continuing an existing session

If further operations become necessary on the FLOWSIC150 at a later point of time, they should be performed while the session file generated during commissioning is open. Carry out the following steps:

Run the MEPA-CARFLOW program and connect to the FLOWSIC150.

Open the associated session file ("File / Open session" menu).The program title bar now shows the session file name.

Carry out further operations (e.g. trend logging).

Switch to the "Log/ trend tab.

Select the measuring variable registers for data logging (see Fig. 4.5).

Start data logging, record data and stop data logging (see Fig. 4.9).

Fig. 4.14: "Log / Trend" tab

The logged data are saved in the session file. If you do not want to carry out further operations, you can exit the program. 44 FLOWSIC150 CARFLOW Operating Instructions 8010815 V 1.2 SICK MAIHAK GmbH Germany

Commissioning and Parameterization3. Offline modification of parameters in the session file

Session files can be opened online with the FLOWSIC150 connected and offline without a connection to the measuring system. This allows to set parameters before you connect to the device. The FLOWSIC150 is updated with the changed information when you connect to the device the next time. Proceed as follows:

Run MEPA-CARFLOW.

Select "Offline" from the interface dropdown list in the Connect to dialog box.

Open the existing session file associated with the FLOWSIC150 by selecting Open session from the File menu.

Modify the parameters as desired.The parameters are automatically saved in the session file.

If the changed session file is opened during the next connection, non-conformance of parameters saved in the session file and the information stored in the FLOWSIC150 will be detected automatically. You can confirm the validity of the changed parameters saved in the session file and upload them to the measuring system (see also Fig. 4.18).

Session history

Type and scope of logged information are shown in the table on page 43

You can monitor and analyse the history of a session including all operations, data logging events etc. while the program is connected to the device (online) or later, i.e. without a connection to the device (offline). It is necessary to open the associated session file by selecting Open session from the File menu. If you want to use the offline option, you must select Offline from the interface dropdown list in the Connect to dialog box when you start MEPA-CARFLOW.

Fig. 4.15: Dialog "Sitzungsverlauf"

Several entries in the session history can be exported and printed.FLOWSIC150 CARFLOW Operating Instructions 8010815 V 1.2 SICK MAIHAK GmbH Germany 45

Commissioning and ParameterizationExporting data records

Data records will be exported to a structured ASCII file if you click on the Export entry button. An export dialog box will appear in which you can configure export formats (see Fig. 4.16).

Fig. 4.16: Measured values export dialog

Exporting current parameters

The current set of parameters will be exported to a configuration file if you select the Current device configuration entry (see dialog area in Fig. 4.15) and click on the Export entry button. You can name the file as desired. Configuration files have the extension *.COF.

Printing current parameters

The current set of parameters will be printed to a specified printer if you select the Current device configuration entry and click on the Print entry button.46 FLOWSIC150 CARFLOW Operating Instructions 8010815 V 1.2 SICK MAIHAK GmbH Germany

Commissioning and ParameterizationDiagnosis session

After completion of maintenance work on the FLOWSIC150 it is recommended to diagnose and to save the current condition of the measuring system. For this purpose, you can run a diagnosis session in addition to the standard session. If you start the session, the MEPA-CARFLOW program will automatically detect any measuring variables and parameters which characterise the condition of the measuring system and save them in a diagnosis session file. Proceed as follows:

Run the MEPA-CARFLOW program and connect to the FLOWSIC150.

Specify the scope of data collected in the diagnosis session by selecting Diagnosis set-up from the Options menu.

fr

Fig. 4.17: Diagnosis session settings dialog box

Select Diagnosis session from the File menu to start the diagnosis session.

The MEPA-CARFLOW program automatically collects the following information:

EEPROM and FLASH code segment

Current parameter configuration

After changing to the Log/ trend tab, it automatically records all major measured variables.

After changing to the Measured values tab, it automatically records further measured variables.

Saving and termination of the diagnosis session file

The information collected in a diagnosis session can be analysed afterwards in two different ways:

1. Export to a structured ASCII file

Export a completed diagnosis session through the item Session history in the File menu, just like a standard session (see page 45).

2. Replaying recorded tab contents in the MEPA-CARFLOW program

The tab recordings of the diagnosis session can be replayed with the help of the data recorder integrated into the MEPA-CARFLOW program (see Section 4.3.3).FLOWSIC150 CARFLOW Operating Instructions 8010815 V 1.2 SICK MAIHAK GmbH Germany 47

Commissioning and ParameterizationData consistency

The MEPA-CARFLOWprogram checks whether or not the configuration saved in the session file is identical to that stored in the connected FLOWSIC150 when you open a session file. If differences are detected, the dialog box shown in Fig. 4.18 will appear. It contains a list of all deviating parameters.

Fig. 4.18: Consistency check: session configuration device configuration

You can now decide:

The parameters stored in the FLOWSIC150 are valid Device is valid button The parameters stored in the session file are valid Session is valid button The session file is not associated with the FLOWSIC150 CancelIf you click on the Apply to registers button to apply the parameters of the valid system to the other system.48 FLOWSIC150 CARFLOW Operating Instructions 8010815 V 1.2 SICK MAIHAK GmbH Germany

Commissioning and ParameterizationFile type overview

The following table shows the file types produced by the MEPA-CARFLOW program.

File Remark

Program lan-guage file

The available program interface languages are managed in the language file MEPA.LNG. This file contains any text modules in the available languages in the ASCII format. ImportantChanges of the language file directly affect the running of the MEPA-CARFLOW program and may result in faulty execution of the control program. Changes should only be performed after consultation of the manufacturer.

Program initia-lisation file

Basic settings of the MEPA-CARFLOW program made by the user during the execution of the program are saved in the binary file MEPA.INI and are used during initialisation in the context of the next program start (e.g. program layout, interface, directories etc.).

Device confi-guration file

The device configuration file contains the current device configuration which can be exported from a session history. Identifier, register no. and value of all para-meters are saved in the form of structured ASCII text.

ASCII export file

Measured values exported from the session history are saved as text in struc-tured ASCII files. The measured values are arranged in columns. The data con-tained may be formatted as locally required during the export operation from the session history (see Fig.4.16). ASCII files have the extension *.TXT. You can name the file as desired during export.

EEPROM memory image

If you export the EEPROM segment from a session, the MEPA-CARFLOW pro-gram will create a binary file with the extension *.EEP which contains a memory image of the EEPROM parameters.

FLASH memory image

If you export the FLASH segment from a session, the MEPA-CARFLOW program will create a binary file with the extension *.TSK which contains a memory image of the FLASH firmware memory. FLOWSIC150 CARFLOW Operating Instructions 8010815 V 1.2 SICK MAIHAK GmbH Germany 49

Commissioning and Parameterization50 FLOWSIC150 CARFLOW Operating Instructions 8010815 V 1.2 SICK MAIHAK GmbH Germany

General

Routine Checks

FLOWSIC150 CARFLOW

Exhaust Gas Flow Meter

Maintenance

Maintenance5 Maintenance

5.1 General

The FLOWSIC150 is a low-maintenance measuring system. The use of Titanium and high-quality stainless steel for components that come into contact with the gaseous media en-sure that these are resistant to corrosion, provided that the device is implemented in ac-cordance with the relevant specifications. In addition, the FLOWSIC150 does not contain any mechanically moved parts.

Maintenance work is confined mainly to routine checks to determine the plausibility of measured values produced by the FLOWSIC150 as well as cleaning work.

Maintenance intervals

The plant operator is responsible for defining the maintenance intervals. These intervals will depend on the specific operation parameters, such as plant operation and ambient conditions. We recommend to start with shorter maintenance intervals (e.g. 4 weeks) and to extend this step by step on a measure adjusted to the respective conditions. The activities required and their completion must be documented by the operator in a maintenance log.

Maintenance agreement

If requested, all maintenance activities can also be performed by the SICK MAIHAK Service department, or an authorized service partner. As part of maintenance and repair agreements, SICK MAIHAK assumes responsibility for all maintenance activities; repairs are carried out by specialists on site (as far as possible).FLOWSIC150 CARFLOW Operating Instructions 8010815 V 1.2 SICK MAIHAK GmbH Germany 53

Maintenance5.2 Routine Checks

The proper function of the FLOWSIC150 can be stated directly at the display elements on the top side of control cabinet of the (see Fig. 2.4).

5.2.1 Gas Temperature Measurement

Because the velocity of sound depends on the temperature, the gas temperature may also be determined by measuring the ultrasonic transit time in the gas. A comparison of the acou-stically determined temperature and the value measured by the jacket-type thermocouple element forms a simple method of checking the plausibility of the gas temperature measurement. The reference measurements must be conducted in air.

Activities:

Disconnect the FLOWSIC150 from the exhaust gas line.

DANGER

Warning

Observe and adhere to the required protective measures!

Switch off the internal heater.

Wait until the measuring pipe is cooled down on ambient temperature.

Press the Set button at the front panel until the information shown below is displayed (display is maintained for approx. 30 s).

Fig. 5.1: Display for the function check of the gas temperature measurement

The gas temperature measurement is performed correctly if the difference between both temperature values does not exceed 10 C.

Note If the device is still heated up, there may be significant differences between acoustically measured temperature and temperature measured by the thermocouple element due to thermal stratification. If you want to check the function of the gas temperature measurement while the device is heated up, it is recommended to effect an even temperature distribution across the pipe cross-section, e.g. using a hairdryer, to prevent thermal stratification.

Acoustically determined temperatureTemperature measured by the thermocouple element54 FLOWSIC150 CARFLOW Operating Instructions 8010815 V 1.2 SICK MAIHAK GmbH Germany

Maintenance5.2.2 Velocity of sound

The plausibility of the measured gas velocity and the volume flow which is calculated from it can be checked by comparison of the theoretical sound velocity and that which is measured by the FLOWSIC150, as well as at multipath systems by comparison of the sound velocities of the individual paths.

Deviations from the standard values specified in the table can indicate a malfunction. In ad-dition to diagnosing the error (as described in Section 6), you can also create a diagnosis and status log and send this to SICK MAIHAK for analysis.

5.2.3 Checking Measuring Pipe on Depositions

At exhaust gas measurings behind diesel engines, strong soot depositions can cover the inside of the measuring cell and the ultrasonic transducers. Repeated path failures are a symptom for this. To avoid measurement problems therefore we recommend to check the FLOWSIC150 on soot depositions considering the respective use duration and intensity of the check cycles, and to clean measuring cell and ultrasound transducers if required.

Activities

Disconnect the FLOWSIC150 from the exhaust gas line.

DANGER

Warning

Observe and adhere to the required protective measures!

Switch off the internal heater.

Wait until the measuring pipe is cooled down on ambient temperature.

Clean measuring pipe and ultrasound transducers with a soft brush carefully.

ATTENTION

Attention

Do not use hard brushes to not damage the transducer surfaces!

Do not damage the coat thermocouple when cleaning!

Parameter Standard value

Error Comment

Difference between theoretical and measured sound velo-city

0,5 m/s 2 m/s When calculating the theoretical velocity of sound, you must take special care to ensure that the gas composition, pressure and, in particular, the temperature are the same as at the measuring location when the log was recorded.

Differences between the sound velocities of the individual paths at multipath systems

0,5 m/s 2 m/s The values only apply to flowing gas. If there is no or only low flow, temperature stratifications can occur which can cause dif-ferences of the sound velocities in the indivi-dual paths of > 10 m/s, particularly in a hot measuring cell. FLOWSIC150 CARFLOW Operating Instructions 8010815 V 1.2 SICK MAIHAK GmbH Germany 55

Maintenance56 FLOWSIC150 CARFLOW Operating Instructions 8010815 V 1.2 SICK MAIHAK GmbH Germany

Fault Diagnosis

Warning Messages

Malfunction Messages

FLOWSIC150 CARFLOW

Exhaust Gas Flow Meter

Troubleshooting

Troubleshooting6 Troubleshooting

6.1 Fault Diagnosis

If the routine checks described in Section 5.2 or device messages described in Section 2.5 indicate that the device is not functioning properly, the following table will help you to diag-nose and remove the fault. If you still cannot find the cause for the fault, you can use the MEPA CARFLOW program to carry out a more detailed fault diagnosis (see service manual).

Display, parameter Possible reason Remedy

No display No active status signal

Faulty power supply Check cables and terminal connectionsImportantTake the relevant safety precautions!

Defective device Contact the manufacturer

Different velocities of sound in the individual paths (only for multipath devices)

Transducer orelectronics fault

Replace the transducer(s) (see service manual)NoteDifferent velocities of sound can occur on the individual paths as a result of temperature stratification, especially with very low flow (higher temperatures higher velocities of sound).

Lower signal-to-noise ratio and reception sen-sitivity

Increased number of rejected measure-ments in individual pa-ths

Induvidual transducer(s) damaged

Replace the transducer(s) (see service manual)

Additional sources of noi-se due to fittings, noise sources near the device

Temperature stratifica-tions

Check the measurement plausibility and number of rejected measurements and, if necessary, remove noise sources.

Check, whether the faults disappear at larger velocities.

Increased reception sensitivity

Different gas composition or process pressure

No work required on the device

Transducer(s) are dirty Clean the transducer(s)

Increased number of rejected measurements in all paths (only for multipath devices)

Additional noise sources Remove noise sources

Gas velocity outside of the measurement rangeFLOWSIC150 CARFLOW Operating Instructions 8010815 V 1.2 SICK MAIHAK GmbH Germany 59

Troubleshooting6.2 Warning Messages

Warnings are displayed if measurements are not possible temporarily, or if the internal check detects a device status that can lead to a failure. They are signaled by advertorials

see Fig. 2.4 at the LCD.

Note Warning messages do not influence the device function.

DANGER

Warning

The gas-carrying parts are hot if the system is checked during or shortly after operation! Take suitable measures to protect against possible danger in this case!

Fig. 6.1: Connections of the transducer cables in the control cabinet

Indication on the LCD Possible reason Remedy

Additional signalisation on the top side of the control cabinet: The red lamp shines LED Maintenance flashes

Warning! Heating up

Operating temperature still not reached.

Changed settings for set and/or alarm temperature (regulator for measuring pipe heater, see Fig. 2.4)

Start the measuring mode only if the operating temperature is rea-ched.

Check the values and correct them, if necessary (see WATLOW Users Manual).

Warning! Reduced Accuracy! (only for multi-path devices)

Transmitted or received signal too low

Transducer cable not really contacted or defective

Gas velocity outside of the measuring range

Failure of a measuring path

Check the connection of the trans-ducer cables (see Fig. 6.1 and ser-vice manual).

Check the set measuring range.

Warning! No USM-Communic.

Device in Configuration mode and no signal burst (measuring values are not updated)

Finish Configuration mode and switch the device into Measuring mode after approx. 10 s.

Connections of the transducer cables

USM measuring transmitter60 FLOWSIC150 CARFLOW Operating Instructions 8010815 V 1.2 SICK MAIHAK GmbH Germany

Troubleshooting6.3 Malfunction Messages

Malfunctions are displayed if measurements are not possible, or device components (for example, the transducers) have failed. They are signaled by shining of the red lamp on the

see Fig. 2.4 top side of the control cabinet and advertorials at the LCD.

DANGER

Warning

The gas-carrying parts are hot if the system is checked during or shortly after operation! Take suitable measures to protect against possible danger in this case!

Fig. 6.2: Evaluation electronics and I/O module

Indication on the LCD Possible reason Remedy

Error! No Signal

Failure of all measuring pa-ths

Ultrasonic damping too strong

Wrong signal parameter

Check the application Check the parameter setting Check the connection of the transducer

cables (see Fig. 6.1 and service manu-al).

Error! No USM-Communic.

Fault/defect in the cabling between evaluation electro-nics and USM measuring transmitter

Interface module not really contacted

Device in service mode

Check the RS485 cable (see Fig. 6.2) Check the bonding of the interface mo-

dule (see Fig. 6.2) Switch the device off and switch on after

short waiting period again Use the service manual

Error! Dev. Para

Wrong check sum at EP-ROM reading

Incorrect parameter setting

Check the EPROM bonding (see Fig. 6.2)

Check the parameter setting

Error! I/O-Module

Fault/defect in the cabling to the I/O module (no pressure and temperature measure-ment)

Check the cabling (see Fig. 6.2)

RS485 cable Interface module Pressure sensor

EPROM Evaluation electronics Terminal for temperature measurement I/O moduleFLOWSIC150 CARFLOW Operating Instructions 8010815 V 1.2 SICK MAIHAK GmbH Germany 61

Troubleshooting62 FLOWSIC150 CARFLOW Operating Instructions 8010815 V 1.2 SICK MAIHAK GmbH Germany

FLOWSIC150 CARFLOW

Exhaust Gas Flow Meter

Parts Overview

Standard Components

Spare Parts

Parts Overview7 Parts Overview

7.1 Standard Components

Name Part number

FLOWSIC150 CARFLOW FL150 1P1 2,5Z XT 0H1 measuring path, connection thread 2 "

7041982

FLOWSIC150 CARFLOW FL150 3P2 2,5Z XT 0H3 measuring paths, connection thread 2 "

7041984

FLOWSIC150 CARFLOW FL150 4P1 4,0Z XT 0H4 measuring paths, connection thread 4"

1026307FLOWSIC150 CARFLOW Operating Instructions 8010815 V 1.2 SICK MAIHAK GmbH Germany 65

Parts Overview7.2 Spare Parts

Elektronics

Ultrasonic transducers

Connection for exhaust pipe

Miscellaneous

Name Part number

FL150-1 measuring transmitter with case 7041640

FL150-3 measuring transmitter with case 7041080

FL150-4 measuring transmitter with case 2033089

FLA150 master board 7042418

Prozessor board I960 7041300

FL150 Front panel with LCD 7041652

I/O module 7041651

EPROM M27C4002-12F1 for FLOWSIC150 7042420

Temperature controller type WATLOW 7041731

Thermocouple jacket-type 7041625

Switch cabinet heater 110 ... 250 V AC 6029772

Heater regulator for cabinet heater 7043277

Bridge Set 115 V / 230 V 7041094

Power cable with plug length 3 m 7041810

Name Part number

Set ultrasonic transducer D12F135P16 2033090

Spare part set transducer exchange in S3/1P 2039311

Spare part set transducer exchange in S3/3P 2039322

Name Part number

Coupling 2" female part 7041831

Coupling 2" male part 7042413

Coupling G4", Kamlok type D 5313693

Coupling G4", Kamlok type A 5313692

Inlet pipe D65 L291 (for 1/3 path version) 4041420

Insulating covering D165 L200 (for inlet pipe) 4041454

Flow straightener 2 (for 1/3 path version) 7041807

Flow straightener 2 Fix (for 1/3 path version) 4042353

Name Part number

Steering roll d75 antistatic 7041621

Steering roll antistatic double lockable 704162266 FLOWSIC150 CARFLOW Operating Instructions 8010815 V 1.2 SICK MAIHAK GmbH Germany

FLOWSIC150 CARFLOW

Exhaust Gas Flow Meter

Appendix

Appendix8 Appendix

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