Danfoss SONO 3500 CT User manual

Ultrasonic Flowmeter
Operating Instructions
SONO 3500 CT
07/2019
Edition

Ultrasonic Flowmeter
SONO 3500 CT
Operating Instructions
07/2019
VI.SH.P2.02
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

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 t
o 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.
SONO 3500 CT
Operating Instructions, 07/2019, VI.SH.P2.02

SONO 3500 CT
Operating Instructions, 07/2019, VI.SH.P2.02 3
Table of contents
1 Introduction ............................................................................................................................................. 7
1.1 History .......................................................................................................................................7
1.2 Items supplied...........................................................................................................................7
1.3 Checking the consignment .......................................................................................................8
1.4 Device identification ..................................................................................................................8
1.5 Further Information .................................................................................................................10
2 Safety notes.......................................................................................................................................... 13
2.1 General safety instructions .....................................................................................................13
2.2 Lithium batteries......................................................................................................................13
2.3 Installation in hazardous area.................................................................................................14
2.4 Certificates ..............................................................................................................................14
3 Description............................................................................................................................................ 15
3.1 Overview .................................................................................................................................15
3.2 System components ...............................................................................................................15
3.3 Design .....................................................................................................................................15
3.4 Features ..................................................................................................................................16
3.5 Principle of operation ..............................................................................................................17
4 Installing/Mounting ................................................................................................................................ 19
4.1 Flowmeter installation .............................................................................................................19
4.2 Sensor installation...................................................................................................................19
4.2.1 Inlet/Outlet conditions .............................................................................................................19
4.2.2 Reduction................................................................................................................................23
4.2.3 Insulation.................................................................................................................................24
4.3 Transmitter installation (compact/remote versions)................................................................24
4.3.1 Installation wall mounting kit (remote transmitter) ..................................................................25
5 Electrical connection ............................................................................................................................. 27
5.1 Backup battery ........................................................................................................................27
5.2 Remote transmitter only: Electrical connection of sensor cable .............................................28
5.3 Compact and remote transmitters: Connecting output and power supply..............................31
5.4 Wiring energy calculator type INFOCAL 9..............................................................................33
5.5 Sealing of SONO 3500 CT .....................................................................................................34
5.5.1 User sealing of sensor ............................................................................................................34
5.5.2 Verification sealing..................................................................................................................34

Table of contents
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6 Commissioning ..................................................................................................................................... 37
6.1 Operating the local display..................................................................................................... 37
6.2 Navigating the menu structure ............................................................................................... 38
6.3 Start-up routine ...................................................................................................................... 39
6.4 Commissioning via PDM ........................................................................................................ 40
6.4.1 Installing and connecting the IrDA interface adapter ............................................................. 40
6.4.2 Installing EDD files ................................................................................................................. 41
6.4.3 Adding the device to the network........................................................................................... 42
6.4.4 Configuring the device ........................................................................................................... 42
6.4.5 Optimizing the system............................................................................................................ 43
6.4.6 Output A, terminals 56/57: ..................................................................................................... 45
6.4.7 Output B, terminals 66/67: ..................................................................................................... 45
6.4.8 Checking the operation readiness ......................................................................................... 46
7 Functions.............................................................................................................................................. 49
7.1 Unit selection.......................................................................................................................... 49
7.2 Number of decimal digits ....................................................................................................... 49
7.3 Password-protected data ....................................................................................................... 50
7.4 Hardware key ......................................................................................................................... 50
8 Service and maintenance...................................................................................................................... 53
8.1 Maintenance........................................................................................................................... 53
8.2 Battery replacement............................................................................................................... 53
8.3 Technical support................................................................................................................... 56
8.4 Application-specific data - Qualification certificate................................................................. 56
8.5 Qualification certificate ........................................................................................................... 58
8.6 Return procedures ................................................................................................................. 60
8.7 Battery disposal...................................................................................................................... 61
9 Troubleshooting/FAQs .......................................................................................................................... 63
9.1 Error codes............................................................................................................................. 63
9.2 Diagnosing with PDM............................................................................................................. 64
10 Technical data ...................................................................................................................................... 67
10.1 SONO 3500 CT...................................................................................................................... 67
10.2 Battery.................................................................................................................................... 68
10.3 Sensor for SONO 3500 CT .................................................................................................... 69
10.4 Dimensional drawings for SONO 3500 CT ............................................................................ 70
10.5 Pipe dimensions for SONO 3500 CT ..................................................................................... 70

Table of contents
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Operating Instructions, 07/2019, VI.SH.P2.02 5
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
Index..................................................................................................................................................... 87

Table of contents
6
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Operating Instructions, 07/2019, VI.SH.P2.02

SONO 3500 CT
Operating Instructions, 07/2019, VI.SH.P2.02 7
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.
1.2 Items supplied
The device can be delivered as either a compact or a remote system.
Compact system
•Sensor
•Transmitter
•Operating Instruction
•Calibration report

Introduction
1.3 Checking the consignment
8
SONO 3500 CT
Operating Instructions, 07/2019, VI.SH.P2.02
Remote system
•
Sensor
•
Transmitter
•
Operating Instruction
•
Calibration report
•
Wall/pipe mounting kit with bracket and
terminal box
•
4 Transducer coaxial cables
Note
The 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.
1.3
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.
1.4
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.

Introduction
1.4 Device identification
SONO 3500 CT
Operating Instructions, 07/2019, VI.SH.P2.02 9
Transmitter system nameplate
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
Cable length (one transducer cable); Software version
⑧
Calibration factor; Production year
⑨
Ambient temperature range
⑩
Type approval number
⑪
Accuracy class
⑫
Environmental class
⑬
Verification markings
Figure 1-1 Transmitter system nameplate

Introduction
1.5 Further Information
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Operating Instructions, 07/2019, VI.SH.P2.02
Sensor system nameplate
①
Sensor production code and serial number
②
Dimension (nominal size ordered)
③
Pressure rating (nominal pressure rate ordered)
④
Maximum flow value (qs), Nominal flow value (qp), Minimum flow value (qi)
⑤
Cable length (one transducer cable)
⑥
Calibration factor
⑦
Ambient temperature range
⑧
Water temperature range
⑨
Production year
⑩
System number (order code identifying selected options and system serial number)
⑪
Type approval number
⑫
Accuracy class
⑬
Environmental class
⑭
Verification markings
⑮
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.
1.5
Further 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
(http://www.danfoss.com/en/products/energy-metering/dhs/energy-metering/)

Commissioning
6.4 Commissioning via PDM
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Operating Instructions, 07/2019, VI.SH.P2.02
6.4
Commissioning via PDM
SIMATIC PDM (Process Device Manager) is a software package for configuring,
parameterizing, commissioning, and maintaining field devices (for example transducers).
Among other features, SIMATIC PDM contains a simple process for monitoring process
values, interrupts and status/diagnosis signals of a field device.
Note
For instructions on installation and operation of SIMATIC PDM, refer to the SIMATI
C PDM
Getting Started (included in the documentation package that comes with PDM).
Note
Minimum PDM version required is SIMATIC PDM V6.0 + SP5
Note
Default password
Any data change in PDM requires a password. The default password is 1000. For furth
er
information, see
Password-protected data (Page 50).
Note
For type
-approved and verified SONO 3500 CT flowmeter the settings are HW key prot
ected
and can only be read, but not changed via PDM. This HW key is protected via the verification
sealing. The verification sealing can only be broken by the user with the acceptance of the
local authorities.
In the following it is described how the device is commissioned using SIMATC PDM.
The commissioning is divided into the following steps:
1. Installing and connecting the IrDA interface adapter (Page 40)
2. Installing EDD files (Page 41)
3. Adding the device to the network (Page 42)
4. Configuring the device (Page 42)
5. Optimizing the system (Page 43)
6. Checking the operation readiness (Page 46)
6.4.1
Installing and connecting the IrDA interface adapter
Note
IrDA driver installation
For installation of the IrDA driver, refer to the instructions delivered with the adapter.

Introduction
1.5 Further Information
12
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Operating Instructions, 07/2019, VI.SH.P2.02

SONO 3500 CT
Operating Instructions, 07/2019, VI.SH.P2.02 13
Safety notes
2
2.1
General 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.
2.2
Lithium 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 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.
–Do not expose contents to water.

Safety notes
2.3 Installation in hazardous area
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Operating Instructions, 07/2019, VI.SH.P2.02
2.3
Installation 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!
2.4
Certificates
Certificates are posted on the Internet.

SONO 3500 CT
Operating Instructions, 07/2019, VI.SH.P2.02 15
Description
3
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:
Sensor type
Transmitter
Flowmeter system
SONO 3500 CT (2-path)
DN 100 to DN 1200
incl SONO 3500 CT
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.
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).

Description
3.4 Features
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Operating Instructions, 07/2019, VI.SH.P2.02
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 m3/h and m3
●Two digital outputs for volume pulse or alarm
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.

Description
3.5 Principle of operation
SONO 3500 CT
Operating Instructions, 07/2019, VI.SH.P2.02 17
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).
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 (Diand Du) shown in the figure below.

Description
3.5 Principle of operation
18
SONO 3500 CT
Operating Instructions, 07/2019, VI.SH.P2.02
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.