Danfoss SONO 3500 CT Operating guide
SONO 3500 CT
Ultrasonic Flowmeter
Operating Instructions
Edition
11/2020
Classified as Business
Classified as Business
11/2020
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
Ultrasonic Flowmeter SONO 3500 CT
Operating Instructions
AQ237286479555en-010402
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Legal information
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.
WARNING
Danfoss products may only be used for the applications described in the catalog and in the relevant technical
ambient conditions must be complied with. The information in the relevant documentation must be observed.
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.
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
Trademarks
Note the following:
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
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
SONO 3500 CT
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SONO 3500
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Table of contents
1
Introduction ............................................................................................................................................. 9
1.1
1.2
1.3
1.4
1.5
2
Safety notes .......................................................................................................................................... 14
2.1
2.2
2.3
2.4
2.5
3
Description ............................................................................................................................................ 17
3.1
3.2
3.3
3.4
3.5
Items supplied ........................................................................................................................... 9
Checking the consignment ..................................................................................................... 10
Device identification ................................................................................................................ 10
Further Information ................................................................................................................. 12
Transportation and storage ..................................................................................................... 13
General safety instructions ..................................................................................................... 14
Manufacturer's design and safety statement ......................................................................... 14
Conformity with European directives ..................................................................................... 15
Lithium batteries...................................................................................................................... 15
Installation in hazardous area ................................................................................................. 16
Overview ................................................................................................................................. 17
System components ............................................................................................................... 17
Design ..................................................................................................................................... 17
Features .................................................................................................................................. 18
Principle of operation .............................................................................................................. 19
4
5
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Installing/Mounting ................................................................................................................................ 21
4.1
4.2
4.2.1
4.2.2
4.2.3
4.3
4.3.1
Flowmeter installation ............................................................................................................. 21
Sensor installation .................................................................................................................. 21
Inlet/Outlet conditions ............................................................................................................. 21
Reduction ................................................................................................................................ 25
Insulation ................................................................................................................................. 26
Transmitter installation (compact/remote versions) ................................................................ 26
Installation wall mounting kit (remote transmitter) .................................................................. 27
Electrical connection ............................................................................................................................. 28
5.1
5.2
Backup battery ........................................................................................................................ 28
Connecting battery (battery-powered versions and mains-powered versions with back-up
battery) .................................................................................................................................... 28
5.3
5.4
5.4.1
5.4.2
Connecting sensor link cable .................................................................................................. 29
Connecting power supply cable (main-powered systems only) ............................................. 30
Connecting pulse output signal cable(s) ................................................................................. 31
Finishing connection ............................................................................................................... 32
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5.4.2.1 Connecting 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
5.6.1
5.6.2
5.6.3
5.7
5.8
5.8.1
5.8.2
6
Commissioning ...................................................................................................................................... 39
6.1
6.2
6.3
6.4
6.5
6.5.1
6.5.2
6.5.3
6.5.4
6.5.5
6.5.6
6.5.7
6.5.8
7
Functions ............................................................................................................................................... 50
Optional current output module .............................................................................................. 35
Finishing connection ............................................................................................................... 36
Connecting .............................................................................................................................. 37
Finishing connection ............................................................................................................... 37
Wiring energy calculator type INFOCAL 9 ............................................................................. 38
Sealing of SONO 3500 CT .................................................................................................... 38
User sealing ............................................................................................................................ 38
Verification sealing .................................................................................................................. 38
Introduction ............................................................................................................................. 39
Operating the local display ..................................................................................................... 39
Navigating the menu structure ................................................................................................ 40
Start-up routine ....................................................................................................................... 41
Commissioning via PDM......................................................................................................... 42
Installing and connecting the IrDA interface adapter .............................................................. 43
Installing EDD files .................................................................................................................. 43
Adding the device to the network ........................................................................................... 44
Configuring the device ............................................................................................................ 44
Optimizing the system ............................................................................................................ 46
Output A, terminals 56/57: ...................................................................................................... 47
Output B, terminals 66/67: ...................................................................................................... 48
Checking the operation readiness .......................................................................................... 48
7.1
7.2
7.3
7.4
8
Service and maintenance ....................................................................................................................... 53
8.1
8.2
8.3
8.4
8.5
8.6
8.7
8.8
Unit selection .......................................................................................................................... 50
Number of decimal digits ........................................................................................................ 50
Password-protected data ........................................................................................................ 51
Hardware key .......................................................................................................................... 51
Maintenance ........................................................................................................................... 53
Battery replacement ................................................................................................................ 53
Service menu .......................................................................................................................... 56
Technical support ................................................................................................................... 57
Application-specific data - Qualification certificate ................................................................. 57
Qualification certificate............................................................................................................ 59
Return procedures .................................................................................................................. 61
Battery disposal ...................................................................................................................... 62
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Legal information
9
Troubleshooting/FAQs ........................................................................................................................... 63
9.1
9.2
10 Technical data ....................................................................................................................................... 68
10.1 SONO 3500 CT ...................................................................................................................... 68
10.2
10.3
10.4
10.5
A
Parameter lists ...................................................................................................................................... 73
A.1
A.2
A.3
A.4
A.5
A.6
B
Settings ................................................................................................................................................ 85
B.1
Error codes ............................................................................................................................. 63
Diagnosing with PDM ............................................................................................................. 64
Battery .................................................................................................................................... 69
Sensor for SONO 3500 CT ..................................................................................................... 70
Dimensional drawings for SONO 3500 CT ............................................................................. 71
Pipe dimensions for SONO 3500 CT ...................................................................................... 71
Identification ............................................................................................................................... 73
Output ......................................................................................................................................... 74
Diagnostic ................................................................................................................................... 76
Meter setup ................................................................................................................................ 81
Human Interface ......................................................................................................................... 83
Unit conversion table .................................................................................................................. 83
Factory settings .......................................................................................................................... 85
B.2
Factory settings for Modbus communication ............................................................................. 86
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Introduction
1.1 Items supplied
Compact system
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.
The device can be delivered as either a compact or a remote system.
• Sensor
• Transmitter
• Connection PCB
• DVD with documentation and cerificates
• Safety note
• Calibration report
• Sensor link cable
• Connection accessories
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CT
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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.
1.2 Checking 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.
1.3 Device 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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①
System number (order code identifying selected options and system serial number)
②
Transmitter production code and serial number
③
Sensor production code and serial number
④
Maximum flow value (qs), Nominal flow value (qp), Minimum flow value (qi)
⑤
Pulse value (output A)
⑥
Pulse width (output A)
⑦
⑧
⑨
⑩
⑪
⑫
⑬
Transmitter system nameplate
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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①
②
③
④
⑤
⑥
⑦
⑧
Water temperature range
⑨
Production year
⑩
System number (order code identifying selected options and system serial number)
⑪
⑫
Accuracy class
⑬
Environmental class
⑭
Verification markings
⑮
PED marking
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 range
Type approval number
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.
1.4
Product information on the Internet
Further Information
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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NOTICE
● Provide additional packaging as necessary.
1.5
1.3.1 Keep the original packaging for subsequent transportation.
1.3.2 Devices/replacement parts should be returned in their original packaging.
1.3.3 If the original packaging is no longer available, ensure that all shipments are properly
Transportation and storage
To guarantee sufficient protection during transport and storage, observe the following:
packaged to provide sufficient protection during transport. Danfoss cannot assume liability
for any costs associated with transportation damages.
Insufficient protection during storage
The packaging only provides limited protection against moisture and
infiltration.
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CT
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Safety notes
2
CAUTION
Correct, reliable operation of the product requires proper transport, storage, positioning and
assembly as well as careful operation and maintenance.
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.
2.1 General safety instructions
Only qualified personnel should install or operate this instrument.
2.2 Manufacturer'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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WARNING
Potential hazard
–
Do not expose contents to water.
2.3 Conformity 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
2.4 Lithium batteries
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.
Lithium batteries are primary power sources with high energy content designed to represent
the highest possible degree of safety.
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 or incinerate
the battery.
–
Do not crush, puncture or open cells or disassemble battery packs.
–
Do not weld or solder to the battery’s body.
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WARNING
NOT allowed for use in hazardous areas!
2.5 Installation in hazardous area
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
Sensor type
Transmitter
Flowmeter system
DN 100 to DN 1200
SONO 3500 CT transmitter
3.1 Overview
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:
SONO 3500 CT (2-path)
3.2 System 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"))
3.3 Design
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.
incl SONO 3500 CT
SONO 3500 CT
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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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3.4 Features
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 m
●
Two digital outputs for volume pulse or alarm
3
/h and m
3
●
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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3.5 Principle 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).
SONO 3500 CT flowmeters
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.
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 × (t
B,A
A,B
) / (t
A,B
× t
B,A
) = K × Δt/t²
– t
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 (D
and Du) shown in the figure below.
i
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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
CAUTION
Direct sunlight
4.1 Flowmeter 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.
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.
4.2 Sensor installation
4.2.1
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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
Orienting the sensor
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
Horizontal orientation, terminal box upwards or downwards
Precautions
In horizontal installation avoid any upward/downward position of the transducers.
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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Note
To obtain maximum battery lifetime with the Lithium Thionyl Chloride battery pack. it is
Flowmeter pipe section may be installed in either a horizontal or vertical position.
recommended to install the flowmeter transmitter in an upright position.
4.2.2
Reduction
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4.2.3
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 (D
= 0.5) gives a pressure drop of 9 mbar.
1/D2
L2: Min. 10 x pipe diameter
Insulation
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.
4.3 Transmitter 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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4.3.1 Installation wall mounting kit (remote transmitter)
Mount wall/pipe mounting bracket in an appropriate place.
Wall mounting
Pipe mounting
Note
Take coaxial cable length into consideration and allow adequate space for cable inlets
underneath and on both sides.
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