Danfoss SONO 3500 CT Operating guide

SONO 3500 CT

Ultrasonic Flowmeter

Operating Instructions

Edition 11/2020

Classified as Business

Classified as Business

Ultrasonic Flowmeter

SONO 3500 CT

Operating Instructions

11/2020

AQ237286479555en-010402

Introduction	1
Safety notes	2
Description	3
Installing/Mounting	4
Electrical connection	5
Commissioning	6
Functions	7
Service and maintenance	8
Troubleshooting/FAQs	9
Technical data	10
Parameter lists		A
Settings		B

Classified as Business

Legal information

Warning notice system

This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are graded according to the degree of danger.

DANGER

indicates that death or severe personal injury will result if proper precautions are not taken.

WARNING

indicates that death or severe personal injury may result if proper precautions are not taken.

CAUTION

indicates that minor personal injury can result if proper precautions are not taken.

NOTICE

indicates that property damage can result if proper precautions are not taken.

If more than one degree of danger is present, the warning notice representing the highest degree of danger will be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to property damage.

Qualified Personnel

The product/system described in this documentation may be operated only by personnel qualified for the specific task in accordance with the relevant documentation, in particular its warning notices and safety instructions. Qualified personnel are those who, based on their training and experience, are capable of identifying risks and avoiding potential hazards when working with these products/systems.

Proper use of Danfoss products

Note the following:

WARNING

Danfoss products may only be used for the applications described in the catalog and in the relevant technical documentation. If products and components from other manufacturers are used, these must be recommended or approved by Danfoss. Proper transport, storage, installation, assembly, commissioning, operation and maintenance are required to ensure that the products operate safely and without any problems. The permissible ambient conditions must be complied with. The information in the relevant documentation must be observed.

Trademarks

All names identified by ® are registered trademarks of Danfoss A/S. The remaining trademarks in this publication may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.

Disclaimer of Liability

We have reviewed the contents of this publication to ensure consistency with the hardware and software described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the information in this publication is reviewed regularly and any necessary corrections are included in subsequent editions.

Local Importer name and address

For goods delivered to UK, importer name and address is:

Danfoss Ltd.

Oxford Road

UB9 4LH Denham

UK

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Table of contents

1	Introduction.............................................................................................................................................		9
	1.1	Items supplied...........................................................................................................................	9
	1.2	Checking the consignment .....................................................................................................	10
	1.3	Device identification ................................................................................................................	10
	1.4	Further Information .................................................................................................................	12
	1.5	Transportation and storage.....................................................................................................	13
2	Safety notes..........................................................................................................................................		14
	2.1	General safety instructions .....................................................................................................	14
	2.2	Manufacturer's design and safety statement .........................................................................	14
	2.3	Conformity with European directives .....................................................................................	15
	2.4	Lithium batteries......................................................................................................................	15
	2.5	Installation in hazardous area.................................................................................................	16
3	Description............................................................................................................................................		17
	3.1	Overview .................................................................................................................................	17
	3.2	System components ...............................................................................................................	17
	3.3	Design.....................................................................................................................................	17
	3.4	Features..................................................................................................................................	18
	3.5	Principle of operation ..............................................................................................................	19
4	Installing/Mounting ................................................................................................................................		21
	4.1	Flowmeter installation .............................................................................................................	21
	4.2	Sensor installation ..................................................................................................................	21
	4.2.1	Inlet/Outlet conditions .............................................................................................................	21
	4.2.2	Reduction................................................................................................................................	25
	4.2.3	Insulation.................................................................................................................................	26
	4.3	Transmitter installation (compact/remote versions)................................................................	26
	4.3.1	Installation wall mounting kit (remote transmitter) ..................................................................	27
5	Electrical connection .............................................................................................................................		28
	5.1	Backup battery ........................................................................................................................	28

5.2Connecting battery (battery-powered versions and mains-powered versions with back-up

	battery)....................................................................................................................................	28
5.3	Connecting sensor link cable..................................................................................................	29
5.4	Connecting power supply cable (main-powered systems only) .............................................	30
5.4.1	Connecting pulse output signal cable(s).................................................................................	31
5.4.2	Finishing connection ...............................................................................................................	32
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7

8

6

5.4.2.1Connecting battery (battery-powered versions and mains-powered versions with back-up

	battery) .................................................................................................................................	33
5.5	Compact and remote transmitters: Connecting output and power supply .............................	33
5.6	Optional current output module ..............................................................................................	35
5.6.1	Finishing connection ...............................................................................................................	36
5.6.2	Connecting ..............................................................................................................................	37
5.6.3	Finishing connection ...............................................................................................................	37
5.7	Wiring energy calculator type INFOCAL 9 .............................................................................	38
5.8	Sealing of SONO 3500 CT ....................................................................................................	38
5.8.1	User sealing ............................................................................................................................	38
5.8.2	Verification sealing ..................................................................................................................	38
Commissioning ......................................................................................................................................		39
6.1	Introduction .............................................................................................................................	39
6.2	Operating the local display .....................................................................................................	39
6.3	Navigating the menu structure ................................................................................................	40
6.4	Start - up routine .......................................................................................................................	41
6.5	Commissioning via PDM .........................................................................................................	42
6.5.1	Installing and connecting the IrDA interface adapter ..............................................................	43
6.5.2	Installing EDD files ..................................................................................................................	43
6.5.3	Adding the device to the network ...........................................................................................	44
6.5.4	Configuring the device ............................................................................................................	44
6.5.5	Optimizing the system ............................................................................................................	46
6.5.6	Output A, terminals 56/57: ......................................................................................................	47
6.5.7	Output B, terminals 66/67: ......................................................................................................	48
6.5.8	Checking the operation readiness ..........................................................................................	48
Functions	...............................................................................................................................................	50
7.1 ..........................................................................................................................	Unit selection	50
7.2 ........................................................................................................	Number of decimal digits	50
7.3 ........................................................................................................	Password - protected data	51
7.4 ..........................................................................................................................	Hardware key	51
Service and .......................................................................................................................maintenance		53
8.1 ...........................................................................................................................	Maintenance	53
8.2 ................................................................................................................	Battery replacement	53
8.3 ..........................................................................................................................	Service menu	56
8.4 ...................................................................................................................	Technical support	57
8.5 .................................................................	Application - specific data - Qualification certificate	57
8.6 ............................................................................................................	Qualification certificate	59
8.7 ..................................................................................................................	Return procedures	61
8.8 ......................................................................................................................	Battery disposal	62

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9	Troubleshooting/FAQs ...........................................................................................................................		63
	9.1	Error codes .............................................................................................................................	63
	9.2	Diagnosing with PDM .............................................................................................................	64
10	Technical data .......................................................................................................................................		68
	10.1	SONO 3500 CT ......................................................................................................................	68
	10.2	Battery ....................................................................................................................................	69
	10.3	Sensor for SONO 3500 CT.....................................................................................................	70
	10.4	Dimensional drawings for SONO 3500 CT.............................................................................	71
	10.5	Pipe dimensions for SONO 3500 CT......................................................................................	71
A	Parameter lists......................................................................................................................................		73
	A.1	Identification ...............................................................................................................................	73
	A.2	Output.........................................................................................................................................	74
	A.3	Diagnostic...................................................................................................................................	76
	A.4	Meter setup ................................................................................................................................	81
	A.5	Human Interface.........................................................................................................................	83
	A.6	Unit conversion table..................................................................................................................	83
B	Settings ................................................................................................................................................		85
	B.1	Factory settings ..........................................................................................................................	85
	B.2	Factory settings for Modbus communication .............................................................................	86

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Introduction

1

These instructions contain all information required to commission and use the device. It is your responsibility to read the instructions carefully prior to installation and commissioning. In order to use the device correctly, first review its principle of operation.

The instructions are aimed at persons mechanically installing the device, connecting it electronically, configuring the parameters and commissioning it, as well as service and maintenance engineers.

1.1Items supplied

The device can be delivered as either a compact or a remote system.

Compact system

•Sensor

•Transmitter

•Connection PCB

•DVD with documentation and cerificates

•Safety note

•Calibration report

•Sensor link cable

•Connection accessories

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Remote system

•Sensor

•Transmitter

•Connection PCB

•DVD with documentation and cerificates

•Safety note

•Calibration report

•Mounting kit with bracket and terminal box

•Sensor link cable

•Connection accessories

Note

Scope of delivery may vary, depending on version and add-ons. Make sure the scope of delivery and the information on the nameplate correspond to your order and the delivery note.

1.2Checking the consignment

1.Check the packaging and the device for visible damage caused by inappropriate handling during shipping.

2.Report any claims for damages immediately to the shipping company.

3.Retain damaged parts for clarification.

4.Check the scope of delivery by comparing your order to the shipping documents for correctness and completeness.

1.3Device identification

The SONO 3500 CT flowmeter is delivered with different labels (nameplates) on the transmitter and sensor. The transmitter and sensor are matched paired.

The transmitter has two nameplates. One (silver) is placed on the front of the transmitter. The transmitter system nameplate (white) is placed on the right side of the transmitter. Both provide valuable information about the device and system. The sensor system nameplate (white) is placed on middle of the sensor.

Note Identification

Identify your device by comparing your ordering data with the information on the product and specification nameplates.

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Transmitter system nameplate

System number (order code identifying selected options and system serial number) Transmitter production code and serial number

Sensor production code and serial number

Maximum flow value (qs), Nominal flow value (qp), Minimum flow value (qi) Pulse value (output A)

Pulse width (output A)

Cable length (one transducer cable); Software version Calibration factor; Production year

Ambient temperature range Type approval number Accuracy class Environmental class Verification markings

Figure 1-1 Transmitter system nameplate

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Sensor system nameplate

Sensor production code and serial number

Dimension (nominal size ordered)

Pressure rating (nominal pressure rate ordered)

Maximum flow value (qs), Nominal flow value (qp), Minimum flow value (qi)Cable length (one transducer cable)

Calibration factor

Ambient temperature rangeWater temperature range

Production year

System number (order code identifying selected options and system serial number)Type approval number

Accuracy class

Environmental classVerification markings

PED marking

Figure 1-2 Sensor system nameplate

Note

The matched paired transmitter and sensor shall be mounted together

Please check that the system nameplates of transmitter and sensor have the same system serial number.

1.4Further Information

Product information on the Internet

The Operating Instructions are available on the Danfoss homepage, where further information on the range of Danfoss flowmeters may also be found: Product information (https://www.danfoss.com/en/products/energy-metering/dhs/energy-metering/)

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1.5Transportation and storage

To guarantee sufficient protection during transport and storage, observe the following:

1.3.1Keep the original packaging for subsequent transportation.

1.3.2Devices/replacement parts should be returned in their original packaging.

1.3.3If the original packaging is no longer available, ensure that all shipments are properly packaged to provide sufficient protection during transport. Danfoss cannot assume liability for any costs associated with transportation damages.

NOTICE

Insufficient protection during storage

The packaging only provides limited protection against moisture and infiltration.

● Provide additional packaging as necessary.

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Safety notes

2

2.1General safety instructions

CAUTION

Correct, reliable operation of the product requires proper transport, storage, positioning and assembly as well as careful operation and maintenance.

Only qualified personnel should install or operate this instrument.

Note

Alterations to the product, including opening or improper modifications of the product are not permitted.

If this requirement is not observed, the CE mark and the manufacturer's warranty will expire.

2.2Manufacturer's design and safety statement

●Responsibility for the choice of flowmeter pipe material as regards abrasion and corrosion resistance lies with the purchaser. The effect of any change in process medium during operation of the meter should be taken into account. Incorrect selection of flowmeter pipe material could lead to failure of the flowmeter.

●Stresses and loading caused by earthquakes, traffic, high winds and fire damage are not taken into account during flowmeter design.

●Do not install the flowmeter such that it acts as a focus for pipeline stresses. External loading is not taken into account during flowmeter design.

●Please be aware of the risk of installing the sensor in a highly vibrating environment. Parts may shake loose and the complete system must be monitored in that case.

●Flanges and joints as well as related pressure/temperature (p/t) classification has been described in EN 1092-1. See ferrite steel group 1E1: table 15.

●During operation do not exceed the pressure and/or temperature ratings indicated on the data label or in these operating instructions.

●It is recommended that all installations include an appropriate safety valve and adequate means for draining.

●Under the „Pressure Equipment Directive" (PED), this product is a pressure accessory and not approved for use as a safety accessory, as defined by the PED.

Environmental conditions according MID (Directive 2014/32/EU)

●Environment class: E2 (electromagnetic), M1 (mechanical)

●Climatic class: -10°C - +55°C, condensing, closed

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2.3Conformity with European directives

The CE marking on the device symbolizes the conformity with the following European directives:

Electromagnetic compatibility EMC 2014/30/EU

Directive of the European Parliament and of the Council on the harmonization of the laws of the Member States relating to electromagnetic compatibility

Low voltage directive LVD 2014/35/EU

Directive of the European Parliament and of the Council on the harmonization of the laws of the Member States relating to the making available on the market of electrical equipment designed for use within certain voltage limits

Pressure equipment directive PED EMC 2014/68/EU

Directive of the European Parliament and of the Council on the harmonization of the laws of the Member States relating to electromagnetic compatibility

Radio equipment directive RED 2014/53/EU

Directive of the European Parliament and of the Council on the harmonization of the laws of the Member States relating to the making available on the market of radio equipment and repealing Directive 1999/5/EC

Measuring instruments directive MID 2014/32/EU

Directive of the European Parliament and the Council on the harmonization of the laws of the Member States relating to the making available on the market of measuring instruments

Restriction of Hazardous Substances RoHS 2011/65/EU

Directive of the European Parliament and the Council on the restriction of the use of certain hazardous substances in electrical and electronic equipment

The applicable directives can be found in the EU declaration of conformity of the specific device.

2.4Lithium batteries

Lithium batteries are primary power sources with high energy content designed to represent the highest possible degree of safety.

WARNING

Potential hazard

Lithium batteries may present a potential hazard if they are abused electrically or mechanically.

•Observe the following precautions when handling and using lithium batteries:

–Do not short-circuit, recharge or connect with false polarity.

–Do not expose to temperature beyond the specified temperature range orincinerate the battery.

–Do not crush, puncture or open cells or disassemble battery packs.

–Do not weld or solder to the battery’s body.

–Do not expose contents to water.

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2.5Installation in hazardous area

WARNING

NOT allowed for use in hazardous areas!

Equipment used in hazardous areas must be Ex-approved and marked accordingly!

This device is NOT approved for use in hazardous areas!

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Description	3

3.1Overview

The SONO 3500 CT ultrasonic flowmeter systems consist of a sensor and a transmitter. The transmitter is type-approved with the custody transfer (CT) approval for use in energy metering systems. The transmitter is designed to measure flow water applications.

The ultrasonic flowmeter transmitter comes as a mains-powered version with battery backup. The following table shows the ultrasonic flowmeter systems with these transmitter types:

Sensor type	Transmitter	Flowmeter system
SONO 3500 CT (2-path)	incl	SONO 3500 CT
DN 100 to DN 1200

3.2System components

The flowmeter system includes:

●Mains-powered transmitter with battery backup

●The sensor is a 2-path sensor with flanges and inline transducers wet-calibrated from factory together with the transmitter (DN 100 (4") to DN 1200 (48"))

3.3Design

The transmitter is designed with fiberglass reinforced polyamide enclosure for remote or compact installation in normal areas. The remote versions are available with up to 30 meter distance from flowmeter to transmitter. When ordered as a compact version in the series SONO 3500 CT the transducer cables are pre-mounted at the sensor.

SONO 3500 CT transmitter

SONO 3500 CT display

The transmitter is available in an IP67/NEMA 4X/6 enclosure.

For spare part cases the transmitter is always ordered as part of a complete flowmeter system.

The transmitter can be ordered preprogrammed with the given sensor data (system serial number).

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3.4Features

The following features are available:

●Mains-powered transmitter

●Battery backup with 3.6 V Lithium single D-cell battery

●Suitable for sensor pipe diameters from DN 100 (4") up to DN 1200 (48")

●IP67 (NEMA 4X/6) rated polyamide transmitter enclosure

●Factory preset to the nominal dimensions of pipe type and pipe size

●Programming via SIMATIC PDM

●Local control panel with single push button, 8-digit display and IrDA optical interface for communication with SIMATIC PDM

●Display showing accumulated volume as well as instantaneous flow rate. The displayed units are m3/h and m3

●Two digital outputs for volume pulse or alarm

●4-20mA output (optional)

Applications

The main application for the type-approved SONO 3500 CT flowmeters is measurement of water flow in district heating plants, local networks, boiler stations, substations, chiller plants, irrigations plants, and other general water applications.

Integration

The flowmeter pulse output is often used as input for an energy meter or as input for digital systems for remote reading. The transmitter has two pulse outputs, with functions that can be individually selected, and integrated IRDA (optical eye) communication interface (Modbus RTU).

The settings of the transmitter, for example flow and pulse output rate, are defined when ordering the complete flowmeter. If the flowmeter forms part of an energy meter system for custody transfer, no further approvals are needed, except possible local approvals.

Transmitter communication solutions

The transmitter supports Modbus RTU communication via the optical IrDA interface at the display, enabling the change of different transmitter settings using the SIMATIC PDM software tool.

The transmitter is configured in a combination of hardware (HW) and firmware (FW). For the communication and parametrization via SIMATIC PDM a firmware-specific device description (EDD) is needed.

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3.5Principle of operation

Physical principle

Figure 3-1 Velocity distribution along sound path

A sound wave travelling in the same direction as the liquid flow arrives at point B from point A in a shorter time than the sound wave travelling against the flow direction (from point B to A).

The difference in sound transit time indicates the flow velocity in the pipe.

Since delay time is measured at short intervals both in and against flow direction, temperature has no influence on measurement accuracy.

SONO 3500 CT flowmeters

In SONO 3500 CT flowmeters the ultrasonic transducers are placed at an angle θ in relation to the pipe axis. The transducers function as transmitters and receivers of the ultrasonic signals. Measurement is performed by determining the time the ultrasonic signal takes to travel with and against the flow. The principle can be expressed as follows:

v = K × (tB,A – tA,B) / (tA,B × tB,A) = K × Δt/t² where

v = Average flow velocity t = Transit time

K = Proportional flow factor

This measuring principle offers the advantage that it is independent of variations in the actual sound velocity of the liquid, i.e. independent of the temperature.

The mechanical/geometrical pipe data is transducer angle (θ), distance between sensors (L) and pipe dimension (Di and Du) shown in the figure below.

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Figure 3-2 Measuring principle

The ultrasonic signal is sent directly between the transducers. The advantage gained sending signals from point to point is an extremely good signal strength.

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Installing/Mounting

4

4.1Flowmeter installation

The flowmeter installation is done in two steps:

1.Sensor installation

2.Transmitter installation

Environment

SONO 3500 CT flowmeters are suitable for indoor and outdoor installations.

●Make sure that temperature and ambient specifications indicated on the device type plate/label are not exceeded.

CAUTION

Direct sunlight

Device damage.

The device can overheat or materials become brittle due to UV exposure.

Protect the device from direct sunlight.

Make sure that the maximum permissible ambient temperature is not exceeded.

Refer to the information in Technical data (Page 68).

Ambient temperature for transmitter:

●-10 °C to +55 °C (14 to 131 °F)

●Non-MID versions -10 to +60°C (14 to 140°F)

●The enclosure rating of the transmitter is IP67 (NEMA 4X/6) or better.

4.2Sensor installation

4.2.1	Inlet/Outlet conditions
	Requirement for straight inlet before flowmeter
	In order to maximize performance it is necessary to have straight inlet and outlet flow
	conditions before and after the flowmeter.
	Furthermore, a minimum distance between flowmeter and pumps and valves must be
	respected.
	It is also important to centre the flowmeter in relation to flanges and gaskets.
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Make sure that flowmeter is positioned as low as possible to prevent air from being trapped in flowmeter at transducers.

Find a position on the pipeline where inlet pipe to flowmeter has a straight length as specified below.

Single bend

1 x 90° bend

L2: Min. 10 x pipe diameter L1: 3 x pipe diameter

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Dual bend

2 x 90° bends in the same plane L2: Min. 10 x pipe diameter

L1: 3 x pipe diameter

Triple bend

3 x 90° bends in two planes L2: Min. 20 x pipe diameter L1: 3 x pipe diameter

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Valves and pumps

Valves

L2: Min. 10 x pipe diameter, fully open valve

L1: 3 x pipe diameter

Pumps:

L2: Min. 20 x pipe diameter

L1: 3 x pipe diameter

Orienting the sensor

Horizontal orientation, terminal box upwards or downwards

In horizontal installation avoid any upward/downward position of the transducers.

Precautions

Avoid installation at the highest point in the system because air bubbles will be trapped in flowmeter.

Avoid installation at a point where there is a free outlet after flowmeter.

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Flowmeter pipe section may be installed in either a horizontal or vertical position.

Note

To obtain maximum battery lifetime with the Lithium Thionyl Chloride battery pack. it is recommended to install the flowmeter transmitter in an upright position.

4.2.2Reduction

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Installation in large pipes

The flowmeter can be installed between two reducers as shown. At 8° reducing angles the below pressure drop curve applies.

Delta-P example:

A water flow velocity of 3 m/s (V) in a sensor with a diameter reduction from DN 200 to DN 100 (D1/D2 = 0.5) gives a pressure drop of 9 mbar.

L2: Min. 10 x pipe diameter

4.2.3Insulation

Both versions can be insulated.

We always recommend insulation of sensor in the compact or remote version. For compact versions the insulation can prevent heat transfer to transmitter.

4.3Transmitter installation (compact/remote versions)

The transmitter is packed separately - ready for plug-in into base part.

There are two mounting versions of the transmitter (as shown in figures below):

●remote transmitter

●compact transmitter

Remote transmitter Compact transmitter

	Note
	The matched paired transmitter and sensor shall be mounted together. At installation, please
	check that the system nameplates of transmitter and sensor have the same system serial
	number.
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4.3.1Installation wall mounting kit (remote transmitter)

Mount wall/pipe mounting bracket in an appropriate place.

Pipe mounting

Wall mounting

Note

Take coaxial cable length into consideration and allow adequate space for cable inlets underneath and on both sides.

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