OI FLOWSIC150 en 8010815

OPERATING INSTRUCTIONS
FLOWSIC150 CARFLOW
Exhaust Gas Flow Meter
Description
Installation
Operation
Content
About this Document ..........................................................................................................5
1 Safety Instructions...............................................................................................................6
1.1
Intended Use ............................................................................................................................6
1.2
Authorised Personnel .............................................................................................................6
1.3
Safety Instructions and Protection Measures ................................................................6

1.3.1
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....................................................................... 13

2.3.1
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 ....................................................................................................................................... 29
4.1.1
General Notes .................................................................................................................................... 29
4.1.2
Prerequisites ....................................................................................................................................... 29
4.1.3
Preparations ........................................................................................................................................ 30
4.1.4
Basic Settings ..................................................................................................................................... 30
FLOWSIC150 Operating Instructions 8010815 V 1.2 SICK MAIHAK GmbH Germany
Content
4.2
4.3
Parameterization .................................................................................................................. 31
4.2.1
Setting Basic Parameters and Analog Output ......................................................................... 31
4.2.2
Calibration ............................................................................................................................................ 33
4.2.3
Start Standard Measuring Mode ................................................................................................. 33
MEPA-Carflow Program ...................................................................................................... 34

4.3.1
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 ..................................................................................................................... 54

5.2.1
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...............................................................................................................................67
FLOWSIC150 Operating Instructions 8010815 V 1.2 SICK MAIHAK GmbH Germany
About this Document
About 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.
Important
Indicates a risk of damage to the device or system components and potential functional
impairments.
ATTENTION
Warning
DANGER
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
Safety Instructions
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.
Safety Instructions
1.3.2
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.
Safety Instructions
FLOWSIC150 CARFLOW
Product Description
System Features
System Design
Measuring Principle Flow Measurement
Elements for Display, Operation and Communication
Self-diagnosis
Technical Data
Dimensions, Part Numbers
Product Description
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 volumetric flow rate normalized on pressure and temperature.
Display and operation elements

Main switch
Control cabinet
Connections
Inlet pipe with flow straightener
and protective insulation
Connection for gas inlet
Lockable roller
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 measuring 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
11
Product Description
2.2 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.
Display and operation elements

Heater
regulator
(Watlow)
Heater for
control
cabinet
Analog
output
4...20 mA
Control and evaluation electronics

Control
cabinet
Connection for
gas outlet
Heater
regulator
(Watlow)
external Heater
Power supply
Normalized volume flow
Flow straightener
Connection
for gas inlet
Pt100
Exhaust gas
(Exhaust gas pipe)
Path 2
Test cell
Path 1, 3
Heater
(Exhaust gas pipe)
Ultrasonic transducer
Fig. 2.2: FLOWSIC150 CARFLOW system design, 3 paths version 2
The following temperature and pressure measurement delivers the values to calculate normalized 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
PTC = Positive Temperature Coefficient
12
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 compensation 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
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-resistor ensures that a defined surface temperature is not exceeded (default setting: 105 C).
Product Description
2.3 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).
Ultrasonic transducer A
Test cell
Ultrasonic transducer B
Measuring pipe
Path 1
Path 2
Path 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 directions. 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 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 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 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.
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 homogeneous flow profile and under use of the SICK MAIHAK standard couplings. The calibration under differing conditions and under use of other connections is possible on request.
In this case a second flow straightener can be required.
13
Product Description
2.3.1
Determining the Gas Velocity

To the transit time of the sound in flow direction applies:
L:
Measuring path length
c:
Velocity of sound
vPath: Path velocity

:
tAB =
(1)
c + vPath cos
Sound transit time against the direction of flow tBA:
Angle between the

longitudinal axis of the
test cell and the path
tBA =
(2)
c - vPath cos
The path velocity (vPath) is calculated from the difference between the two transit times:
vPath =
L
2 cos
( t1
AB
1
tBA
(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 weighted individual paths.
N: Number of measuring paths
vA: Mean flow velocity in the
cross-section
1
vA =
wi: Weighting factor of a

measuring path
i vPfad i
(4)
i=1
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 slightly 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:
A:
Cross-sectional area in
the measuring pipe
QO.S.: Volumetric flow in
operating state
p0, T0: Pressure and temperature in normalized

state
p, T: Pressure and temperature in operating
state
2.3.3
QO.S. = vA A = vA
D
4
(5)
The volumetric flow in normalized state QN.S. is calculated from the volumetric flow in operating state and the currently measured values for pressure and temperature in the measuring pipe:
QN.S. =
p0
T0
T
QO.S.
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.
c=
L
1
1
+
2
tAB
tBA
(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
system diagnosis.
14
Product Description
2.3.4
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.
vPath
(7)
PPath =
vA
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
Failures of more paths

are compensated
accordingly
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
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.
N
bi: Status bit for path i

bi = O: Path inactive
bi = 1: Path active
vA =
bi w i
i=1
vPfad i
PPfad i
(8)
wi
i=1
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.
15
Product Description
2.4 Elements for Display, Operation and Communication

The elements for displaying measuring values and system status and as well as for the operation and communication are placed on the top side of the control cabinet.
LED
LCD
Control keys
Main switch
Signalisation for
status Malfunction
Signalisation for
status Operation
Reglulator for external hose heating
RS 232 interface
Regulator for heating the measuring pipe
Fig. 2.4: Top side of the control cabinet
Indication
Type
LC Display
Display of
1st line
Gas temperature at the measuring

location (Ni-CrNi temperature sensor)
Absolut pressure
at the measuring
Normalized volumetric flow
Display of AK Qn if AK mode is set
LED
2nd line
Status messages
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 measuring 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
Control keys
Functions
AK = Study group
Selecting a measuring variable

Switching in AK mode (special
RS232 interface protocol for
tomotive industry)
Activating maintenance mode
16
Remark
You can display all of the options available by pressing
the SET key (the display scrolls automatically if you press
au- the key for longer than >1 s). To choose the option currently displayed, press the key.
Product Description
RS232 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
For details on modifying
the settings refer to the
separate document
(WATLOW Users Manual)
Note
Regulator for measuring pipe heater

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 temperature 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.
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 heating
This 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 regulators settings are described in Chapt. 3.
Connections
Analog output
0 ... 20 mA
External
Heater
1
+
3
4
6
7
Analog output 0/2/4...20 mA

for output of the normalized
volumetric flow (BNC socket)
Power
Socket for connection

of an external hose
heating
Plug for connection

mains voltage
115/230 V AC
Fig. 2.5: FLOWSIC150 connections
17
Product Description
2.5 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.
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.
Note
When setting the parameters, take into account plausible conditions for normal
operation (in particular temperature stratification).
Reception
gain
< 6 dB
Warning AGC
Deviation
The absolute difference between both path gain factors is evaluated and must
remain below the threshold value.
Important
High flow rates can also increase the difference in gain.
< 93 dB
Warning AGC
Limit
The absolute value of the reception gain is monitored.

Important
The 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.
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.
18
Product Description
2.6 Technical Data

Measured value acquisition
Measured variables
Gas velocity, volumetric flow (actual), volumetric flow (normalized), gas temperature, absolute
pressure
Pipe size 2"
1 measuring path
0 ... 150 l/s
3 measuring paths
Pipe size 4"
4 measuring paths
0 ... 300 l/s
1 measuring path
< 2,5 % of the measured value,
from 0,1 Qmax to Qmax
Measuring range actual

volumetric flow
Typical measuring uncertainty *
Temperature measurement
Pressure measurement (absolute)
Displays
2-row LCD
LED
Installation
Gas temperature
Transducer temperature
Inlet and outlet pipe thread **
Pressure drop by the integrated flow

straightener
3 measuring paths
4 measuring paths
Jacket-type thermocouple element, Ni-CrNi, "K" type, measuring range 0 ... 400 C
Measuring range 660 ... 1100 mbar
For measured variables, warnings and error messages
For operation, malfunction, maintenance
max. 300 C
max. 280 C
1 measuring path
3 measuring paths
4 measuring paths
1 measuring path
3 measuring paths
4 measuring paths
Output of measured values

Analog output
RS232 (Modbus/AK)
Interfaces
RS232
Power supply
Operating voltage
Power consumption
< 10 min per 1 h, total stress maximum 100 cycles
G 2"
G 4
approx. 0.45 mbar at 20 l/s
0/2/4... 20 mA; max. load 760 Ohm; update rate 10/s; scaling freely programmable
10/s (in burst mode)
For configuration via PC using the MEPA CARFLOW program
Heating capacity measuring system

Maximum switchable heating capacity
for external hose heating
Ambient conditions
Temperature range
Class of protection
Dimensions, mass
W x H x D (in mm)
Mass
90 ... 140 V AC; 50/60Hz or 190 ... 260V AC; 50/60Hz

695 W
2
1095 W
4
600 W
2
1000 W
4
1.6 kW (230 V AC)
for 2 und 4
0.8 kW (115 V AC)
without external hose

heating
20 ... +50 C
IP 65
900 x 630 x 380
approx. 80 kg
(with flow straightener)
* tested at ambient air conditions (see note in Section 2.3)

** Other dimensions on request
19
Product Description
2.7 Dimensions, Part Numbers

All dimensions are indicated in mm.
L
600
380
A
630
Type FLOWSIC150
FL150 1P1 2,5Z XT 0H

1 measuring path, connection thread 2 "
FL150 3P2 2,5Z XT 0H
3 measuring paths, connection thread 2 "
FL150 4P1 4,0Z XT 0H
4 measuring paths, connection thread 4"
Part no.
900
250
200
2 "
300
765
125
65
4"
260
7041982
7041984
1026307
Fig. 2.6: FLOWSIC150 dimensions
20
FLOWSIC150 CARFLOW
Installation
Installation
Installation
Warning
All installation work must be carried out in line with the relevant safety regulations and instructions listed in Chapter 1.
GEFAHR
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 necessary.
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 connection. In case of faults destroyed fuses have to be replaced against new ones.
fuse type:
current value:
fine-wire fuse 5x20 mm, SuperFlink, 250 V AC

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 values
23
Installation
exchangeable
fuses
Assignment of the plug bridges

Supply voltage 115 V AC
Supply voltage 230 V AC
(6 pcs. 1 to 4)
(2 pcs. 1 to 6, 2 pcs. 1 to 3)
Fig. 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
Analog output
0 ... 20 mA
External
Heater
Power
2
3
4
6
7
Fig. 3.3: FLOWSIC150 connections

Terminal
External Heater socket assignment
Power plug assignment
PE
Pt100
7
PE
Connecting an external hose heater

Connect a cable with a suitable plug to the External Heater socket (for terminal assignment see Fig. 3.3 and connection table).
24
Installation
Attention
The cable may only be made by an authorized expert!
ACHTUNG
Connect the terminals 13 and 14 in the control cabinet using the enclosed jumper (see
Fig. 3.4).
Jumper
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.
25
Installation
26
FLOWSIC150 CARFLOW
Commissioning and Parameterization
Basics
Parameterization
MEPA-CARFLOW Program

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 parameters. The existing program menus allow an easy configuration of the required settings. Other 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.
Access level Service,

for password contact SICK
MAIHAK
Device internal parameters which have to be changed if necessary for the adaption of the
FLOWSIC150 to plant-specific conditions (e.g., if the device is not deployed in line with the
specifications 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
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)
The FLOWSIC150 must be connected to the power supply.
29
4.1.3
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
Program details are described in Section 4.3
Basic Settings
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
30
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 session file (recommended)
"File / New session"
To store all device settings and operating

actions, see Section 4.3.4
4.2 Parameterization
Program details are described 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.
"Operating Mode" menu
Adjustable parameters
in the password level
"Operator"
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 button "Write register". We recommend to check the take-over of the values into the device by
pressing the button "Read register".
4.2.1
Directory "Meter Setup"
Setting Basic Parameters and Analog Output

Basic parameters
Parameter
Meaning
LCD Display
Norm. Pressure
Norm. Temperature
Set value
Assignment
Setting/change of the language at the LCD

on the top side of the control cabinet
German
English
Reference value for device-internal normalisation of the volumetric flow.
1013,3
0 hPa
20
SI standard
20
US standard
31
Analog output
The analog output (BNC socket, see Fig. 3.3) provides the measuring value for the volumetric 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 assignment 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
Parameter
Meaning
AO Live Zero
Value for Live Zero (LZ)
Set value
Assignment
0 mA
2 mA
4 mA
AO RangeLow
Lower measuring range limit

(corresponds to Live Zero)
x l/s
AO RangeHigh
Upper measuring range limit

(corresponds to 20 mA)
x l/s
AO Maintenance
Output value for operating mode

"Configuration"
0 mA
LZ
Current measuring
value (MV)
Span (test value)
The current at the analog output is calculated as follows:

Iout = LZ + (MV - AO RangeLow)
20 mA - LZ
AO RangeHigh - 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
32
FLOWSIC150 (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 geometric 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 precision, an additional comparison measurement is carried out with standards. The characteristic 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 comparison measurement with a reference measuring system. The calibration coefficiants determined 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 + cc0
QN_corr
QN_ncorr
cc2
cc1
cc0
=
=
=
=
=
normalized volumetric flow corrected

normalized volumetric flow not corrected
square calibration coefficient
linear calibration coefficient
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 register".
Directory
Assignment
NFlowrate CC0
cc0
NFlowrate CC1
cc1
NFlowrate CC2
cc2
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).
33
4.3 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 displays are hidden. All functions are only accessible in the password level "Service" (description see service manual).
The displays and functions available in the password level "Operator" are more fully explained 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
Options
Help
34
Velocity of gas
Displays the velocity of gas in all paths
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
Version
MEPA-CARFLOW program version
Help F1
Online help
Tool bar
The tool bar contains major functions which shall be activated quickly and simply.
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 sound
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
35
4.3.2
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.
Menu bar
Tool bar
Tabs
current
meas.
values
Normalized flow rate

Actual flow rate
Gas temperature
Pressure in the measuring pipe
Average velocity of sound
Average gas velocity
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
temporal course of the measured values
with display of average, minimum and maximum
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.
36
Device 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.
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
Analog Output
NFlowrate CC0
absolute calibration coefficient
NFlowrate CC1
linear calibration coefficient
NFlowrate CC2
square calibration coefficient
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)
"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
37
The 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:
Logging rate e.g. once
in 2 s
Automatic mode
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).
Removing with
"Remove" button
(or double-click on
the entry)
Selection with
"Add" button
(or double-click on
the entry)
Fig. 4.5: Configuring the variables to be displayed (selected entries form an example)
Fig. 4.6: Display of the selected data
38
Burst mode
The 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.
Sampling rate
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!".
Selectable storing intervals
Fig. 4.8: Possibilities for logging in the burst mode
39
The 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 analogy with generally usual pictographs for these functions.
Open logging
Play logging
Start logging
Stop logging
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 session are listed (see Fig. 4.10).
40
Fig. 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).
41
4.3.4
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
management
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
management
Sessions can be saved and are thereby closed. If further operations become necessary 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 session
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 session
This command saves the currently open session.
Save session as
A default session file is generated always after starting the MEPA-CARFLOW program. All further activities are stored in this file. The default session can be stored as
a new regular session by the operator.
Note
If 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 collected 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 history
This menu item is used to monitor the current session and activities contained therein. Certain operations performed in a session can also be stored in ASCII files (e.g.
measuring records).
"File" menu
42
Contents 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 entry
Type of
information
Corresponding activity
Description
Current device
configuration
Parameter
set
Automatically when a Contains the current configuration of

new session is
created
Continuous update
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 Event
measurement and
configuration mode
Switching between
measurement and
configuration mode
Logging the operational mode

change
Opening and
closing a session
Opening/ closing
Each opening and closing of the

session file will be logged together
with a time stamp.
Event
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.
43
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
See Section Session

history and following
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.
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
3. 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.
45
Exporting 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
Diagnosis 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 MEPACARFLOW 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 setup 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).
47
Data 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 Cancel
If you click on the Apply to registers button to apply the parameters of the valid system to
the other system.
48
File type overview

The following table shows the file types produced by the MEPA-CARFLOW program.
File
Remark
Program language 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.
Important
Changes 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- Basic settings of the MEPA-CARFLOW program made by the user during the
lisation file
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 configuration 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 parameters are saved in the form of structured ASCII text.
ASCII export
file
Measured values exported from the session history are saved as text in structured ASCII files. The measured values are arranged in columns. The data contained 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 program 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.
49
50
FLOWSIC150 CARFLOW
Maintenance
General
Routine Checks
Maintenance
Maintenance
5.1 General
The FLOWSIC150 is a low-maintenance measuring system. The use of Titanium and highquality stainless steel for components that come into contact with the gaseous media ensure that these are resistant to corrosion, provided that the device is implemented in accordance 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).
53
Maintenance
5.2 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 acoustically 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.
Warning
Observe and adhere to the required protective measures!
DANGER
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).
Acoustically determined temperature
Temperature measured by the thermocouple element
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
54
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.
Maintenance
5.2.2
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.
Parameter
Standard
value
Error
Comment
Difference between
theoretical and
measured sound velocity
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 differences of the sound velocities in the individual paths of > 10 m/s, particularly in a hot
measuring cell.
Deviations from the standard values specified in the table can indicate a malfunction. In addition 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.
Warning
Observe and adhere to the required protective measures!
DANGER
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
Do not use hard brushes to not damage the transducer surfaces!
Do not damage the coat thermocouple when cleaning!
ATTENTION
55
Maintenance
56
FLOWSIC150 CARFLOW
Troubleshooting
Fault Diagnosis
Warning Messages
Malfunction Messages
Troubleshooting
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 diagnose 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
Faulty power supply

No display
No active status signal
Different velocities of
sound in the individual
paths (only for multipath
devices)
Contact the manufacturer
Transducer or
electronics fault
Replace the transducer(s) (see service

manual)
Note
Different 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).
Induvidual transducer(s)
ratio and reception sen- damaged
sitivity
Increased number of
Additional sources of noirejected measurese due to fittings, noise
ments in individual pasources near the device
ths
Temperature stratifications
Increased number of
rejected measurements
in all paths (only for
multipath devices)
Check cables and terminal connections

Important
Take the relevant safety precautions!
Defective device
Lower signal-to-noise
Increased reception
sensitivity
Remedy
Replace the transducer(s) (see service

manual)
Check the measurement plausibility and

number of rejected measurements and,
if necessary, remove noise sources.
Check, whether the faults disappear at
larger velocities.
Different gas composition or No work required on the device

process pressure
Transducer(s) are dirty
Clean the transducer(s)
Additional noise sources
Remove noise sources
Gas velocity outside of the

measurement range
59
Troubleshooting
6.2 Warning Messages
see Fig. 2.4

Note
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
at the LCD.
Warning messages do not influence the device function.
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!
DANGER
Additional signalisation on the

top side of the control cabinet:
The red lamp shines
LED Maintenance flashes
Indication on the LCD
Possible reason
Remedy
Warning!
Heating up
Operating temperature still not Start the measuring mode only if

reached.
the operating temperature is reached.

or alarm temperature (regulator Check the values and correct them,
for measuring pipe heater, see
if necessary (see WATLOW Users
Fig. 2.4)
Manual).
Changed settings for set and/
Warning!
Reduced Accuracy!
(only for multi-path
devices)
Transmitted or received signal
Check the connection of the trans-
too low
Transducer cable not really
contacted or defective
Gas velocity outside of the
measuring range
Failure of a measuring path
ducer cables (see Fig. 6.1 and service 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
transmitter
Fig. 6.1: Connections of the transducer cables in the control cabinet
60
Troubleshooting
6.3 Malfunction Messages
see Fig. 2.4
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
top side of the control cabinet and advertorials at the LCD.
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!
DANGER
Indication on the LCD
Possible reason
Error!
No Signal
Failure of all measuring pa- Check the application

ths
Check the parameter setting
Ultrasonic damping too
Check the connection of the transducer
strong
Wrong signal parameter
EPROM
RS485 cable
Error!
No USM-Communic.
Fault/defect in the cabling
Error!
Dev. Para
Wrong check sum at EP-
Error!
I/O-Module
Fault/defect in the cabling to

the I/O module (no pressure
and temperature measurement)
Evaluation electronics
Remedy
cables (see Fig. 6.1 and service manual).
Check the RS485 cable (see Fig. 6.2)

between evaluation electro- Check the bonding of the interface monics and USM measuring
dule (see Fig. 6.2)
transmitter
Switch the device off and switch on after
Interface module not really
short waiting period again
contacted
Use the service manual
Device in service mode
Check the EPROM bonding (see Fig.
ROM reading
6.2)
Incorrect parameter setting Check the parameter setting
Check the cabling (see Fig. 6.2)
Terminal for temperature measurement
Interface module
I/O module
Pressure sensor
Fig. 6.2: Evaluation electronics and I/O module
61
Troubleshooting
62
FLOWSIC150 CARFLOW
Parts Overview
Standard Components
Spare Parts
Parts Overview
Parts Overview
7.1 Standard Components
Name
Part number
FLOWSIC150 CARFLOW FL150 1P1 2,5Z XT 0H

1 measuring path, connection thread 2 "
7041982

3 measuring paths, connection thread 2 "
7041984

4 measuring paths, connection thread 4"
1026307
65
Parts Overview
7.2 Spare Parts

Elektronics
Name
Part number
FL150-1 measuring transmitter with case
7041640
7041080
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
Ultrasonic transducers
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
Connection for exhaust pipe

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
Miscellaneous
Name
66
Part number
Steering roll d75 antistatic
7041621
Steering roll antistatic double lockable
7041622
FLOWSIC150 CARFLOW
Appendix
Power supply 230 V / 50 Hz
Fuse protection max. 16 A
optional 115 V / 60 Hz (change bridges!)
Heater
external heater
Temp. contr.
external heater
Bridge
for Ub_N2
Temp. contr.
internal heater
red
Plug-in bridges for 1150 V ac (6 pcs. 1 -4)
Meter body heater
Bridges plugged for 230 V / 50 Hzr
Piper heater
green
Heating connection
Plug-in bridges for 230 V ac (2 pcs. 1 -8; 2 pcs. 1 -3)
Evaluation electronics
Analog output
Thermocouple
lower ring heater
board
System
cable
Probe
Probe
Converter box
Control panel
Thermostat
short circiut-prrof 1.4 A
Appendix
Appendix
Fig. 8.1: Wiring diagram power supply
69
Appendix
70
8010815/2010-03 (V 1.2)
FLOWSIC150 CARFLOW
SICK worldwide
You will find our local subsidiary

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

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

OI FLOWSIC150 en 8010815

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OPERATING INSTRUCTIONS

About this Document ..........................................................................................................5

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

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

Safety Instructions and Protection Measures ................................................................6

General Information ............................................................................................................................ 6

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

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

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

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

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

Measuring Principle Flow Measurement....................................................................... 13

Determining the Gas Velocity ........................................................................................................ 14

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

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

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

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

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

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

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

General Notes .................................................................................................................................... 29

Basic Settings ..................................................................................................................................... 30

FLOWSIC150 Operating Instructions 8010815 V 1.2 SICK MAIHAK GmbH Germany

Setting Basic Parameters and Analog Output ......................................................................... 31

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

MEPA-Carflow Program ...................................................................................................... 34

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

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

Routine Checks ..................................................................................................................... 54

Gas temperature Measurement................................................................................................... 54

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

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

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

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

FLOWSIC150 Operating Instructions 8010815 V 1.2 SICK MAIHAK GmbH Germany

About this Document

About this Document

Identifies potential danger for personnel, particularly due to electrical equipment or as a

1.2 Authorised Personnel

1.3 Safety Instructions and Protection Measures

Danger from electrical Equipment

Preventive Measures for safe Operation

Detecting and Preventing Malfunctions

Display and operation elements

Fig. 2.1: FLOWSIC150 CARFLOW

Features and advantages

2.2 System Design

Display and operation elements

Control and evaluation electronics

(Exhaust gas pipe)

(Exhaust gas pipe)

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

PTC = Positive Temperature Coefficient

The gas temperature is measured by a jacket-type thermocouple element (Ni-CrNi). The

2.3 Measuring Principle Flow Measurement

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

Determining the Gas Velocity

Measuring path length

vPath: Path velocity

Sound transit time against the direction of flow tBA:

Angle between the

wi: Weighting factor of a