HACH LANGE SONATAX sc User manual

DOC023.52.00117
SONATAX sc
User manual
04/2012, Edition 3A
© HACH-LANGE GmbH, 2006, 2010, 2012. All rights reserved. Printed in Germany

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Table of contents
Section 1 Technical data ........................................................................................................................................ 5
Section 2 General information ............................................................................................................................... 7
2.1 Safety information .............................................................................................................................................. 7
2.1.1 Use of hazard information ........................................................................................................................ 7
2.1.2 Precautionary labels ................................................................................................................................. 7
2.2 General sensor information................................................................................................................................ 8
2.2.1 Property rights note .................................................................................................................................. 8
2.2.2 Usage areas ............................................................................................................................................. 8
2.3 Device overview................................................................................................................................................. 8
2.4 Functional principle ............................................................................................................................................ 9
Section 3 Installation ............................................................................................................................................ 11
3.1 Unpack sensor ................................................................................................................................................. 11
3.1.1 Handling of the immersed probe ............................................................................................................ 11
3.2 Connect sensor to an sc controller .................................................................................................................. 11
3.2.1 Connect sensor with quick connection ................................................................................................... 11
3.3 Function test .................................................................................................................................................... 12
3.4 Install sensor.................................................................................................................................................... 13
3.4.1 Select the measurement location and pre-set the device....................................................................... 13
3.4.1.1 Determine the distance to the tank edge ....................................................................................... 15
3.4.1.2 Determine measurement location .................................................................................................. 15
3.4.2 Installation of the sensor......................................................................................................................... 18
3.5 Advanced settings............................................................................................................................................ 18
Section 4 Operation .............................................................................................................................................. 23
4.1 Use of the sc controller .................................................................................................................................... 23
4.2 Sensor data logging ......................................................................................................................................... 23
4.3 Sensor setup.................................................................................................................................................... 23
4.3.1 Change of the sensor name ................................................................................................................... 23
4.4 SENSOR STATUS menu................................................................................................................................. 23
4.5 SENSOR SETUP menu................................................................................................................................... 23
Section 5 Maintenance ......................................................................................................................................... 27
5.1 Maintenance tasks ........................................................................................................................................... 27
5.2 Wiper change................................................................................................................................................... 27
5.3 Cleaning tasks ................................................................................................................................................. 28
Section 6 Troubleshooting................................................................................................................................... 29
6.1 Operating state LED ........................................................................................................................................ 29
6.2 Error messages................................................................................................................................................ 29
6.3 Warnings.......................................................................................................................................................... 30
6.4 SLUDGE DOCTOR, (diagnostic software for SONATAX sc)........................................................................... 30
Section 7 Replacement parts and accessories ................................................................................................ 31
7.1 Replacement parts........................................................................................................................................... 31
7.2 Accessories...................................................................................................................................................... 31

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Table of contents
Section 8 Warranty and liability........................................................................................................................... 33
Section 9 Contact ................................................................................................................................................. 35
Modbus register .................................................................................................................................................. 37

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Section 1 Technical data
Changes reserved!
General
Measurement method Ultrasonic measurement (750–1250 kHz)
Measuring range 0.2 m–12 m (0.7 ft–40 ft) sludge level
Resolution 0.03 m (0.1 ft) sludge level
Accuracy 0.1 m (0.33 ft)
Response time 10–600 s (adjustable)
calibration One time on commissioning
Environmental conditions
Ambient temperature \> 0–50 °C (\> 0–122 °F)
Temperature compensation Automatic
Flow speed Max. 3 m/s
Pressure range 0.3 bar or 3 m (43.55 psi or 10 ft)
Sensor specifications
Dimensions 130 mm ×185 mm (5 in. ×7.3 in.) (H ×Ø)
Earth Approximately 3.5 kg (123.5 oz) (without struts)
Maintenance requirements < 1 hour/month, typically
Cable length 10 m (33 ft), maximum 100 m (330 ft) with extension cable
Power consumption 12 V, 2.4 W, (200 mA)
Protection type IP68 ( 1 bar (14.5 psi))
Compliance CE, TÜV GS, UL/CSA
Materials
Probe body Stainless steel 1.4581
Base plate and wiper POM
Wiper magnet casting compound Epoxy resin
Wiper rubber Silicone rubber
Housing seals NBR (acrylonitrile butadiene rubber)
Light guide seal Polyurethane
Light guide LEXAN polycarbonate
Sensor connection cable 
(fixed connection)
1 cable pair AWG 22 / 12 VDC twisted, 1 cable pair AWG 24 / data twisted,
common cable shield, Semoflex (PUR)
Sensor connection plug (fixed
connection) Type M12, protection type IP67
Cable gland Stainless steel 1.4571
Cable gland insert TPE-V
Cable gland O-ring NBR, silicone

6
Technical data

7
Section 2 General information
The information in this manual has been carefully checked and is
believed to be accurate. However, the manufacturer assumes no
responsibility for any inaccuracies that may be contained in this
manual. In no event will the manufacturer be liable for direct,
indirect, special, incidental or consequential damages resulting
from any defect or omission in this manual, even if advised of the
possibility of such damages. In the interest of continued product
development, the manufacturer reserves the right to make
improvements in this manual and the products it describes at any
time, without notice or obligation.
Revised editions are found on the manufacturer’s web site.
2.1 Safety information
Please read this entire manual before unpacking, setting up or
operating this equipment. Pay attention to all danger, warning and
caution statements. Failure to do so could result in serious injury to
the operator or damage to the equipment.
Make sure that the protection provided by this equipment is not
impaired, do not use or install this equipment in any manner other
than that specified in this manual.
2.1.1 Use of hazard information
Note: Information that supplements points in the main text.
2.1.2 Precautionary labels
Read all labels and tags attached to the instrument. Personal injury
or damage to the instrument could occur if not observed.
DANGER
Indicates a potentially or imminently hazardous situation which, if not
avoided, will result in death or serious injury.
WARNING
Indicates a potentially or imminently hazardous situation which, if not
avoided, could result in death or serious injury.
CAUTION
Indicates a potentially hazardous situation that may result in minor or
moderate injury.
Notice
Indicates a situation that, if not avoided, could result in damage to the
instrument. Information that requires special emphasis.
This symbol, if noted on the instrument, references the instruction manual for operation
and/or safety information.

8
General information
2.2 General sensor information
The SONATAX sc is intended for the measurement of sludge levels
in water. Use in other media without test of the materials (refer to
Section 1 Technical data on page 5) or consultation with the
manufacturer is regarded as explicitly not in accordance with
requirements.
Any use other than use in accordance with requirements defined in
the user manual leads to the loss of the warranty claims and can
lead to personal injury and property damage, for which the
manufacturer assumes no liability.
2.2.1 Property rights note
Parts of the device software are based on the work of the
Independent JPEG Group.
2.2.2 Usage areas
The SONATAX sc can be used anywhere that the solid/liquid
separation layer must be monitored. 
For example in the area of final sedimentation or in sludge
treatment (thickeners).
2.3 Device overview
Figure 1 shows the device components of the SONATAX sc.
Electrical devices marked with this symbol may after August 12, 2005 no longer be disposed of in unsorted
domestic or industrial waste Europe-wide. In conformity with European local and national regulations (EU
Directive 2002/96/EC), European electrical equipment users must now return old or end-of life equipment to
the manufacturer for disposal This is free for the consumer.
Note: Obtain instructions on the correct disposal of all (marked and not marked) electrical products that were
supplied or manufactured by the manufacturer at the relevant sales office.
Figure 1 Device overview
1Operating state LED (refer to Section 6.1)3Mount for the tank edge attachment
2Wiper 4Sensor head

9
General information
2.4 Functional principle
In a tank where solid materials in water (or another fluid) can settle
to the bottom, there is a boundary between the settled solids and
the clear phase above. The distance from the water surface to the
bottom is the sludge level. The sludge height is the distance from
the tank floor.
More precisely, the sludge level (or the sludge height) indicates the
place in a tank where (viewed from the water surface) the solid
content first exceeds a defined limit. This limit value depends on the
application. It will, for example, be higher in a pre-thickener of a
wastewater treatment plant than in its final sedimentation, where
the overlying fluid should be clear water.
The SONATAX sc measures the sludge level via an echo signal
(refer to Figure 2) of an ultrasonic pulse. This echo signal is shown
in the probe menu SENSOR SETUP > TEST / MAINT > SIGNALS
in the echo list (refer to ECHO LIST on page 26). The depth and the
echo strength are specified at the ultrasonic transducer in digits
(1 digit approximately 1 µV).
Echos from layers that are further away are quieter (weaker) than
those which are closer. The SONATAX sc compensates for this
attenuation. The result is indicated on the SONATAX sc as a profile.
The data is found in the probe menu SENSOR SETUP > TEST /
MAINT > SIGNALS in the profile list (refer to PROFILE LIST on
Figure 2 Functional principle

10
General information
page 26) ((2) Figure 3). The graphic display (for example sc1000)
shows the profile in the measurement operation as a graphic ((1)
Figure 3).
The example shows a typical profile curve of a sludge level
measurement. The Y axis in this graphic reaches from the floor
(which can be set in the probe menu SENSOR SETUP >
CALIBRATE > TANK DEPTH on page 24) up to the water surface.
The profile strength is given on the X axis. The profile increases at
a sludge level. If the solid content below the sludge level remains
constant, the profile strength decreases again due to the absorption
of the ultrasound in the sludge. At the very bottom, the echo of the
floor is normally detected.
The vertical line represents the threshold. The sludge level is
detected by the SONATAX sc at the point at which the profile
exceeds this threshold for the first time viewed from above
(analogous to the abovementioned definition of the sludge level). In
the graphic, the detected sludge level is identified by a mark on the
Y axis.
The threshold is set automatically on the SONATAX sc (setting:
THRESHOLD AUTO = xy % in the probe menu SENSOR SETUP >
CALIBRATE > ADV.SETTINGS > THRESHOLD AUTO on
page 24). The automatic threshold function searches for the
maximum in the detected profile. Through an exact setting of the
tank depth, a faulty measurement due to the echo of the floor is
ruled out.
The background is that the echo signal of the floor in most tanks is
the strongest in the profile. With a correct setting of the tank depth,
the floor signal is not considered by the automatic threshold
function during the determination of the sludge level.
For more information on the correct determination of the tank
depth, refer to section Section 3.4.1 on page 13.
Figure 3 Profile as graphic and list

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Section 3 Installation
The SONATAX sc can be used with an sc100, sc200 or with an
sc1000 controller. Installation instructions are found in the
handbook of the controller.
3.1 Unpack sensor
The SONATAX sc is supplied with the following components:
•Sensor
•User manual
•Wiper blades set (5 pieces)
If one of the parts is missing or damaged, please contact the
manufacturer or dealer.
3.1.1 Handling of the immersed probe
The immersed probe contains a sensitive ultrasound transducer.
Make sure that this is subjected to no hard mechanical impacts. Do
not install the probe hanging on the cable. Make sure before the
insertion of the probe into the medium that all functions run
undisrupted through a check of the system. Check the probe
carefully for external damage.
3.2 Connect sensor to an sc controller
3.2.1 Connect sensor with quick connection
The sensor cable is very easy to connect to the controller using a
quick connection (Figure 4). Keep the protective cap of the
connection socket in case you remove the sensor later and must
seal the socket. For longer sensor cable lengths, optional extension
cables are available.
DANGER
The installation described in this section of the user manual should only
be performed by qualified and specialized personnel. The sensor is not
suitable for installation in hazardous areas.
Figure 4 Connect sensor with quick connection

12
Installation
3.3 Function test
Directly after the connection of the sensor to the controller, perform
a function check.
1. Connect the controller to the mains power.
2. If the controller does not recognize the new sensor, go to the
SCAN SENSORS menu (refer to the user manual of the
controller).
3. Confirm any prompt and wait until the new sensor is found.
If the new sensor is found, the controller switches to the
measurement operation.
A wipe process is triggered and the device switches to the
measurement operation. If no other messages appear, the sensor
is functional.
Note: Measurements in air lead to no measurement values. The error
message SENSOR MEASURE is shown. This does not show a
malfunction.
Figure 5 Pin assignment of the quick connection
Number Assignment Wire color
1 +12 V= Brown
2EarthBlack
3 Data (+) Blue
4 Data (–) White
5Shield
Shield (gray wire for existing quick
connection)
6 Insulator notch
1
2
3
4
56

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Installation
3.4 Install sensor
The SONATAX sc is intended for installation with a tank edge
attachment. For more information, refer to the installation
instructions of the tank edge attachment.
Note: Do not begin with the installation of the tank edge attachment before
the installation location is determined (refer to Section 3.4.1).
Figure 6 SONATAX sc scale drawing
3.4.1 Select the measurement location and pre-set the device
In the determination of the sludge level over the duration of an
ultrasonic echo, the entire space between the probe on the water
surface and the tank bottom is required for the measurement. As
solid bodies in this area disrupt the measurements, special
attention is required in the selection of the measurement location.
In the following, it is explained how the suitability of a possible
measurement location can be tested. The tank depth should be
known here.
A suitable measurement location must be found depending on tank
type. The graphics that follow show typical examples for a round
tank and a rectangular tank. The point (1) in Figure 7 and Figure 8
is a suitable measurement location.

14
Installation
At a suitable measurement location, there should be:
•Sufficient sludge present for the measurement, and
•A calm, clear phase above the sludge level
In the examples shown, area (A) shows only very little or no sludge,
while in the area (C) above the sludge layer, sludge clouds may
disrupt the measurement. The measurement points (A) and (C) are
Figure 7 Round tank graphic
Figure 8 Rectangular tank graphic

15
Installation
not suitable for the installation. Suitable measurement points can be
found in between.
Note: Installation note: For round tanks with a rotating scraper bridge,
install the probe in the direction of rotation on the back of the bridge
(Figure 7).
3.4.1.1 Determine the distance to the tank edge
If the SONATAX sc is installed on the tank edge (i.e. not on a
scraper bridge), make sure there is sufficient distance from the
SONATAX sc to the tank edge.
This distance is dependent on the depth of the tank. 
Use this formula to find a guideline value for this distance:
0.20 m + (0.05 x tank depth in meters) = distance to tank edge
This value can vary depending on composition of the tank. How a
possible installation location can be checked for its suitability is
described in Section 3.4.1.2 Determine measurement location.
3.4.1.2 Determine measurement location
1. Connect the probe to the sc controller and carefully immerse
the probe in the water (approximately 20 cm (7.9 in.)) on the
probe cable at the selected measurement location.
2. Select the probe menu SENSOR SETUP > CALIBRATE and do
a measurement in the REFLEXLIST menu item.
After a few seconds, the reflex list is shown (refer to REFLEXLIST
on page 24). This list usually contains the tank floor as the
strongest signal.
If strong reflections between the water surface and the tank floor
are present (for example due to pipes, plates etc.), another
measurement location must be selected. Sometimes it is sufficient
to move the probe by a few centimeters.
In the example (Table 1), there are two disruptive reflexes at a
depth of 0.87 m and 2.15 m, and the tank floor is at a depth of
3.30 m.
At an ideal measurement location, no disruptive reflections should
occur above the floor in the reflex list after multiple measurements
(Table 2).
Table 1 Reflex list
Meters Intensity
0.87 25 %
2.15 2 %
3.30 100 %
Table 2 Reflex list
Meters Intensity
3.30 100 %

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Installation
If no measurement location without disruptive reflexes can be
found, select the probe menu SENSOR SETUP > CALIBRATE and
trigger a measurement in the PROFILE LIST menu item.
•If there are increased values at the depth of the disruptive
reflexes in the PROFILE LIST which influence the
measurement value, another measurement location must be
selected. Sometimes it is sufficient to move the probe by a few
centimeters (refer to Figure 9, right).
•If the reflections do not disrupt the measurement value, this can
be a suitable measurement location (refer to Figure 9, left).
3. Then assemble the tank edge attachment there and install the
probe.
Note: The probe should be installed approximately 20 cm (7.9 in.) deep
at the installation location (somewhat more than the entire probe head) to
make sure that it remains immersed during the entire measurement
operation.
4. In the CALIBRATE probe menu, enter the actual plunger depth
(Item A, Figure 10) in the PLUNGERDEPTH menu item.
5. Trigger after approximately 2 minutes another measurement of
the reflex list (to adjust the temperature sensor to the water
temperature) (also refer to REFLEXLIST on page 24).
6. In the CALIBRATE probe menu, enter the recorded value of the
tank depth (Item C, Figure 10) in the TANK DEPTH menu item.
Important note: The shown value of the tank depth is calculated
from information shown:

Tank depth C = plunger depth A + measured distance to floor B 
This calculation is performed internally and leads to incorrect
results if the plunger depth is entered incorrectly.
Figure 9 Determine measurement location

17
Installation
Note: Should the reflex list not contain the tank depth (possible when there
is a lot of sludge above the floor), the tank depth must be determined in
another way (e.g. measuring).
Important note: The value entered in the TANK DEPTH menu item
must in no case be larger than the actual tank depth. This could
lead to incorrect measurement values.
In the determination of a suitable measurement location, the
optionally available SLUDGE DOCTOR diagnostic software can be
helpful (refer to 7.2 Accessories on page 31). The software enables
the representation and saving of all graphic profiles of the
SONATAX sc in a defined time interval (5 minutes–2 hours).
Figure 10 Plunger depth–tank depth

18
Installation
The software also shows and saves all important measurement and
configuration parameters, such as the reflex list, measurement
values, limit values and all advanced settings, such as response
time, frequency, amplitude, angle and temperature.
Take further information from the SLUDGE DOCTOR user manual
DOC013.98.90411.
3.4.2 Installation of the sensor
Note: Take further information on the installation from the installation
instructions.
Figure 11 Installation of the sensor
3.5 Advanced settings
In the SENSOR SETUP > CALIBRATE > ADV. SETTINGS menu,
special probe parameters can be found.
The default settings of these parameters are selected so that no
correction is required in most applications. In exceptional cases,
these parameters must be adapted depending on the application.
The examples that follow show typical sludge profiles.

19
Installation
Example 1: Pre-thickener with clear separation layer, but
sporadically empty.
The image shows a thickener with a clear profile. The signals above
the sludge level caused by turbid water do not disrupt the
measurement.
The same thickener is empty in this image. The threshold now
adjusts itself automatically to the signals of the turbid water. The
recorded measurement value at 0.63 m is incorrect.
Recommended measure:
Increase the adjustment of the ADV. SETTINGS > LL THRESH.
AUTO setting from 0.3 to 1.0.
Note: LL THRESH. AUTO gives the smallest possible value that the
threshold can accept.
The image shows the empty thickener after the adjustment. The
result 3.18 m is correct.
Example 2: Application with clear separation layer, but weak
signal.
Very low to absolutely no interference signals through turbid water
above the separation layer. Strength of the echo 0.61 is above the
LL THRESH. AUTO (pre-setting 0.3) and leads to correct
measurement value 2.28 m.

20
Installation
Very low to absolutely no interference signals through turbid water
above the separation layer. Strength of the maximum echo <0.3.
Instead of the correct measurement value, only the tank floor is
found.
Increase the adjustment of the ADV. SETTINGS > LL THRESH.
AUTO setting from 0.3 to 0.1. The threshold 0.16 finds the correct
measurement value 2.25 m.
Example 3: Thickener or other application with very high sludge
concentration up to just under the water surface; echo is absorbed
in the uppermost sludge layer:
In this application, the floor signal is no longer detected due to the
high absorption of the ultrasonic signal. The shown measurement
value 0.73 is correct. No adjustment of the ADV. SETTINGS
necessary.
If the sludge increases so far that the sludge level is above the
measurement range (the measurement range begins from 0.2 m
beneath the sensor), it can occur that no sludge level is detected
(SENSOR MEASURE error message). In this case, the application
must be checked.