Honeywell VERSAFLOW SONIC 1000/TWS 9000 User manual

Ultrasonic clamp-on flowmeter for liquids
ER 4.1.1_
VERSAFLOW SONIC 1000/TWS 9000
VERSAFLOW SONIC 1000/TWS 9000VERSAFLOW SONIC 1000/TWS 9000
VERSAFLOW SONIC 1000/TWS 9000 Handbook
HandbookHandbook
Handbook

Notices and Trademarks
Copyright 2020 by Honeywell
WARRANTY/REMEDY
Honeywell warrants goods of its manufacture as being free of defective materials and faulty
workmanship. Contact your local sales office for warranty information. If warranted goods are
returned to Honeywell during the period of coverage, Honeywell will repair or replace without
charge those items it finds defective. The foregoing is Buyer's sole remedy and is in lieu of all
other warranties, expressed or implied, including those of merchantability and fitness for a
particular purpose. Specifications may change without notice. The information we supply is
believed to be accurate and reliable as of this printing. However, we assume no responsibility for
its use.
While we provide application assistance personally, through our literature and the Honeywell
web site, it is up to the customer to determine the suitability of the product in the application.
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: IMPRINT
::::::::::::::::::::::::::::::::::::::::::

ABOUT THIS DOCUMENT
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Abstract
AbstractAbstract
Abstract
This document provides descriptions and procedures for the Installation, Configuration,
Operation, and Troubleshooting of your device.
Contacts
ContactsContacts
Contacts
World Wide Web:
The following lists Honeywell’s World Wide Web sites that will be of interest to our
customers.
Telephone:
Contact us by telephone at the numbers listed below.
Honeywell Organization
Honeywell OrganizationHoneywell Organization
Honeywell Organization
Honeywell Corporate
Honeywell Process Solutions
Technical Assistance
WWWWWWWWW AdW Address (URL)W Address (URL)W Address (URL)dress (URL)
www.process.honeywell.com
www.process.honeywell.com/flowmeters/
www.process.honeywell.com
Organization
OrganizationOrganization
Organization Phone Number
Phone NumberPhone Number
Phone Number
Global Technical Support: 1-800-423-9883
Outside United States:
Outside United States:Outside United States:
Outside United States:
Technical Support: 001-215/641-3610
Customer Service 1-800-343-0228

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ABOUT THIS DOCUMENT
VERSAFLOW SONIC 1000/TWS 9000

CONTENTS
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1 Safety instructions 9
1.1 Software history ............................................................................................................... 9
1.2 Intended use ................................................................................................................... 10
1.3 Certification .................................................................................................................... 10
1.4 Safety instructions from the manufacturer ................................................................... 11
1.4.1 Copyright and data protection .............................................................................................. 11
1.4.2 Disclaimer ............................................................................................................................. 11
1.4.3 Product liability and warranty .............................................................................................. 12
1.4.4 Information concerning the documentation......................................................................... 12
1.4.5 Warnings and symbols used................................................................................................. 13
1.5 Safety instructions for the operator............................................................................... 13
2 Device description 15
2.1 Scope of delivery............................................................................................................. 15
2.2 Device description .......................................................................................................... 17
2.2.1 Field housing (remote version)............................................................................................. 18
2.2.2 Wall housing.......................................................................................................................... 18
2.3 Nameplates .................................................................................................................... 19
2.3.1 Overview of the nameplates (examples)............................................................................... 19
2.3.2 Examples of nameplates on the signal converter................................................................ 19
2.3.3 Example nameplate of the flow sensor rail ......................................................................... 20
2.3.4 Example of IO nameplate...................................................................................................... 21
3 Installation 23
3.1 General notes on installation ......................................................................................... 23
3.2 Storage ........................................................................................................................... 23
3.3 Transport ........................................................................................................................ 23
3.4 Pre-installation requirements ....................................................................................... 24
3.5 General requirements .................................................................................................... 24
3.6 Installation and safety instructions................................................................................ 24
3.7 Installation conditions ....................................................................................................26
3.7.1 Inlet, outlet and recommended mounting area ................................................................... 26
3.7.2 Horizontal (long) pipes.......................................................................................................... 27
3.7.3 Bends in 2 or 3 dimensions................................................................................................... 27
3.7.4 T-section ............................................................................................................................... 28
3.7.5 Bends .................................................................................................................................... 28
3.7.6 Open feed or discharge......................................................................................................... 29
3.7.7 Position of pump ................................................................................................................... 30
3.7.8 Position of control valve........................................................................................................ 30
3.7.9 Pipe diameters and sensor rail(s) construction................................................................... 31
3.7.10 Pipe and media parameters ...............................................................................................31
3.8 Installation of the sensor rail ......................................................................................... 32
3.8.1 General mechanical installation........................................................................................... 32
3.8.2 Installation of solid contact material.................................................................................... 34
3.8.3 Standard installation options................................................................................................ 35
3.8.4 Installation instructions for small and medium sensor rail(s) ............................................ 36
3.8.5 Mechanical installation of large version .............................................................................. 37
3.8.6 Installation of the UP sensor rail.......................................................................................... 37

CONTENTS
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3.8.7 Installing the DOWN sensor rail in V-mode ......................................................................... 39
3.8.8 Installation of the DOWN sensor rail.................................................................................... 40
3.8.9 Find the transducer location with a fixed reference point................................................... 40
3.8.10 Determine the transducer position with a paper roll......................................................... 41
3.8.11 Installing the DOWN sensor rail in Z-mode ....................................................................... 43
3.8.12 Configuration instructions for large sensor rail(s) ............................................................ 44
3.8.13 Installation instructions for X mode configuration............................................................. 45
3.9 Installation of the converter........................................................................................... 46
3.9.1 Pipe mounting ....................................................................................................................... 46
3.9.2 Wall mounting....................................................................................................................... 47
3.9.3 Turning the display of the field housing version .................................................................. 49
3.10 Install for energy measurement .................................................................................. 50
3.10.1 Preparation of energy measurement ................................................................................. 50
3.11 Program the converter for energy measurement ....................................................... 51
3.11.1 Program the I/O input ......................................................................................................... 51
3.11.2 Program the process input................................................................................................. 52
3.11.3 Program the totalisers........................................................................................................ 53
3.11.4 Start measurement............................................................................................................. 54
4 Electrical connections 55
4.1 Safety instructions.......................................................................................................... 55
4.2 Laying electrical cables correctly .................................................................................. 55
4.3 Electrical connections signal converter ........................................................................ 56
4.4 Power supply .................................................................................................................. 57
4.4.1 Signal converter power supply connections ........................................................................ 58
4.5 Example of connecting the cable extension (splitter) box............................................. 59
4.6 Signal cable to converter ............................................................................................... 60
4.7 Modular inputs/outputs connections ............................................................................. 63
4.8 Inputs and outputs, overview ......................................................................................... 65
4.8.1 Combinations of the inputs/outputs (I/Os) ........................................................................... 65
4.8.2 Description of the CG-number.............................................................................................. 66
4.8.3 Fixed, non-alterable input/output versions.......................................................................... 67
4.8.4 Alterable input/output versions............................................................................................ 68
4.9 Description of the inputs and outputs............................................................................ 69
4.9.1 Control input ......................................................................................................................... 69
4.9.2 Current output ...................................................................................................................... 70
4.9.3 Pulse output and frequency output ...................................................................................... 71
4.9.4 Status output and limit switch .............................................................................................. 72
4.9.5 Current input......................................................................................................................... 73
4.10 Connection diagrams of inputs and outputs ................................................................ 74
4.10.1 Important notes................................................................................................................... 74
4.10.2 Description of the electrical symbols................................................................................. 75
4.10.3 Basic inputs/outputs ........................................................................................................... 76
4.10.4 Modular inputs/outputs and bus systems .......................................................................... 79
4.10.5 Ex i inputs/outputs .............................................................................................................. 87
4.10.6 Current input active or passive........................................................................................... 91
4.10.7 HART
®
connection .............................................................................................................. 94
5 Start-up 95
5.1 Switching on the power .................................................................................................. 95

CONTENTS
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5.2 General instructions for programming.......................................................................... 95
5.3 Function description installation menu ......................................................................... 96
5.4 Start measurement (standard setup) ............................................................................ 98
5.5 Start measurement of large version.............................................................................. 99
6 Operation 101
6.1 Display and operating elements .................................................................................. 101
6.1.1 Display in measuring mode with 2 or 3 measured values ................................................. 103
6.1.2 Display for selection of submenu and functions, 3 lines ................................................... 103
6.1.3 Display when setting parameters, 4 lines .......................................................................... 104
6.1.4 Display when previewing parameters, 4 lines.................................................................... 104
6.1.5 Using an IR interface (option) ............................................................................................. 105
6.2 Menu overview..............................................................................................................106
6.3 Function tables ............................................................................................................. 120
6.3.1 Menu A, Quick Setup ........................................................................................................... 120
6.3.2 Menu B; test ........................................................................................................................ 122
6.3.3 Menu C; setup ..................................................................................................................... 124
6.3.4 Set free units....................................................................................................................... 140
6.4 Description of functions ............................................................................................... 141
6.4.1 Reset totaliser in the menu "Quick Setup"......................................................................... 141
6.4.2 Deleting error messages in the menu "Quick Setup"........................................................ 141
6.4.3 Diagnosis messages ........................................................................................................... 142
6.4.4 Optical keys ......................................................................................................................... 142
6.4.5 Graphic page ....................................................................................................................... 142
6.4.6 Save settings ....................................................................................................................... 142
6.4.7 Load settings....................................................................................................................... 142
6.4.8 Passwords........................................................................................................................... 143
6.4.9 Date and time...................................................................................................................... 143
6.4.10 Low flow cutoff .................................................................................................................. 143
6.4.11 Time constant.................................................................................................................... 144
6.4.12 Dual phase pulse output ................................................................................................... 144
6.4.13 Timeouts in programming mode ...................................................................................... 144
6.4.14 Function 5: Reynolds linearisation ................................................................................... 145
6.4.15 Output hardware ............................................................................................................... 145
6.5 Status messages and diagnostic information.............................................................. 146
7 Service 153
7.1 Periodic maintenance................................................................................................... 153
7.1.1 Regreasing of transducers ................................................................................................. 153
7.2 Cleaning........................................................................................................................ 153
7.3 Exchange of electronics unit ........................................................................................ 153
7.3.1 Before and after opening .................................................................................................... 154
7.3.2 Field version........................................................................................................................ 155
7.3.3 Wall version......................................................................................................................... 157
7.4 Replacing the mains fuse............................................................................................. 159
7.4.1 Field version........................................................................................................................ 159
7.4.2 Wall version......................................................................................................................... 159
7.5 Spare parts availability................................................................................................. 160
7.6 Availability of services .................................................................................................. 160
7.7 Returning the device to the manufacturer................................................................... 160

CONTENTS
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7.7.1 General information............................................................................................................ 160
7.7.2 Form (for copying) to accompany a returned device.......................................................... 161
7.8 Disposal ........................................................................................................................ 161
7.9 Disassembly and recycling........................................................................................... 162
7.9.1 Remove the connection and/or other cable(s) ................................................................... 163
7.10 Disassembling the sensor rail ................................................................................... 165
7.11 Overview of the sensor materials and components .................................................. 167
7.12 Overview of the converter materials and components.............................................. 168
8 Technical data 171
8.1 Measuring principle...................................................................................................... 171
8.2 Technical data............................................................................................................... 172
8.3 Dimensions and weight ................................................................................................ 183
8.3.1 Housing ............................................................................................................................... 183
8.3.2 Clamp-on sensor rail.......................................................................................................... 184
8.3.3 Mounting plate of field housing .......................................................................................... 186
8.3.4 Mounting plate of wall-mounted housing .......................................................................... 186
9 Description of HART interface 187
9.1 General description ...................................................................................................... 187
9.2 Identification codes and revision numbers.................................................................. 187
9.3 Connection variants...................................................................................................... 188
9.3.1 Point-to-Point connection - analogue / digital mode......................................................... 189
9.3.2 Multi-drop connection (2-wire connection)........................................................................ 190
9.3.3 Multi-drop connection (3-wire connection)........................................................................ 191
9.4 Inputs/outputs and HART dynamic variables and device variables ............................ 192
9.5 Remote operation ......................................................................................................... 194
9.5.1 Online/offline operation ...................................................................................................... 194
9.5.2 Parameters for the basic configuration ............................................................................. 195
9.5.3 Units .................................................................................................................................... 195
9.6 Field Communicator 375/475 (FC 375/475) ................................................................. 196
9.6.1 Installation .......................................................................................................................... 196
9.6.2 Operation............................................................................................................................. 196
9.7 Asset Management Solutions (AMS)............................................................................ 197
9.7.1 Installation .......................................................................................................................... 197
9.7.2 Operation............................................................................................................................. 197
9.8 Process Device Manager (PDM)................................................................................... 198
9.8.1 Installation .......................................................................................................................... 198
9.8.2 Operation............................................................................................................................. 198
9.9 HART Menu Tree........................................................................................................... 199
9.9.1 HART Menu Tree - Field Communicator HART Application............................................... 199
9.9.2 HART Menu Tree AMS - Device's context menu ................................................................ 200
9.9.3 HART Menu Tree PDM - Menu Bar and Working Window ................................................. 201
9.9.4 Process Variables Root Menu............................................................................................. 202
9.9.5 Diagnostic Root Menu ......................................................................................................... 202
9.9.6 Device Root Menu ............................................................................................................... 203
9.9.7 Offline Root Menu ............................................................................................................... 208
10 Description of HART interface 209

SAFETY INSTRUCTIONS 1
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1.1 Software history
For all devices, the "Electronic Revision" (ER) is consulted to document the revision status of the
electronics according to NE 53. It is easy to see from the ER whether any fault repairs or major
changes to the electronic equipment have taken place and what effect they have had on
compatibility.
1Downwards compatible changes and fault repair with no effect on operation (e.g. spelling
mistakes on display)
2-_ Downwards compatible hardware and/or software change of interfaces:
HHART
®
version 7
MModbus
Xall interfaces
3-_ Downwards compatible hardware and/or software change of inputs and outputs
ICurrent output
F, P Frequency output, pulse output
SStatus output
CControl input
CI Current input
Xall inputs and outputs
4Downwards compatible changes with new functions
5Incompatible changes, i.e. electronic equipment must be changed
Table 1-1: Description of changes
INFORMATION!
In the table below, "x" is a place holder for possible multi-digit alphanumeric combinations,
depending on the available version.
Release date Electronic revision Changes and
compatibility
Documentation
2018-09 ER 4.0.0_ 5MA VFS1000-TWS 9000 R01
2020-01 ER 4.1.1_ 1MA VFS1000-TWS 9000 R02
Table 1-2: Changes and effect on compatibility

1 SAFETY INSTRUCTIONS
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1.2 Intended use
The VersaFlow Sonic 1000 with TWS 9000
VersaFlow Sonic 1000 with TWS 9000VersaFlow Sonic 1000 with TWS 9000
VersaFlow Sonic 1000 with TWS 9000 is designed exclusively as a clamp-on flowmeter that
can be fitted on the outside of piping for uni- or bidirectional measurements of liquid flows.
Contaminations, like entrained gas, particles, 2 phase and non-homegeneous mixtures, can
affect the acoustic signal and has to be avoided.
The overall functionality of the VersaFlow Sonic 1000 with TWS 9000
VersaFlow Sonic 1000 with TWS 9000VersaFlow Sonic 1000 with TWS 9000
VersaFlow Sonic 1000 with TWS 9000 clamp-on flowmeter, is the
continuous measurement of actual volume flow, mass flow, flow speed, velocity of sound, gain,
SNR, totalized flow mass and diagnosis values.
1.3 Certification
This device fulfils the statutory requirements of the relevant EU directives.
For full information of the EU directives and standards and the approved certifications, please
refer to the EU Declaration of Conformity or the website of the manufacturer.
Other approvals and standards
•NAMUR NE 107
For more information, please refer to the dedicated documentation.
CAUTION!
Responsibility for the use of the measuring devices with regard to suitability, intended use and
corrosion resistance of the used materials against the measured fluid lies solely with the
operator.
INFORMATION!
The manufacturer is not liable for any damage resulting from improper use or use for other than
the intended purpose.
CE marking
The manufacturer certifies successful testing of the product by applying the CE marking.
DANGER!
For devices used in hazardous areas, additional safety notes apply; please refer to the Ex
documentation.

SAFETY INSTRUCTIONS 1
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1.4 Safety instructions from the manufacturer
1.4.1 Copyright and data protection
The contents of this document have been created with great care. Nevertheless, we provide no
guarantee that the contents are correct, complete or up-to-date.
The contents and works in this document are subject to copyright. Contributions from third
parties are identified as such. Reproduction, processing, dissemination and any type of use
beyond what is permitted under copyright requires written authorisation from the respective
author and/or the manufacturer.
The manufacturer tries always to observe the copyrights of others, and to draw on works created
in-house or works in the public domain.
The collection of personal data (such as names, street addresses or e-mail addresses) in the
manufacturer's documents is always on a voluntary basis whenever possible. Whenever
feasible, it is always possible to make use of the offerings and services without providing any
personal data.
We draw your attention to the fact that data transmission over the Internet (e.g. when
communicating by e-mail) may involve gaps in security. It is not possible to protect such data
completely against access by third parties.
We hereby expressly prohibit the use of the contact data published as part of our duty to publish
an imprint for the purpose of sending us any advertising or informational materials that we have
not expressly requested.
1.4.2 Disclaimer
The manufacturer will not be liable for any damage of any kind by using its product, including,
but not limited to direct, indirect or incidental and consequential damages.
This disclaimer does not apply in case the manufacturer has acted on purpose or with gross
negligence. In the event any applicable law does not allow such limitations on implied warranties
or the exclusion of limitation of certain damages, you may, if such law applies to you, not be
subject to some or all of the above disclaimer, exclusions or limitations.
Any product purchased from the manufacturer is warranted in accordance with the relevant
product documentation and our Terms and Conditions of Sale.
The manufacturer reserves the right to alter the content of its documents, including this
disclaimer in any way, at any time, for any reason, without prior notification, and will not be liable
in any way for possible consequences of such changes.

1 SAFETY INSTRUCTIONS
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1.4.3 Product liability and warranty
The operator shall bear responsibility for the suitability of the device for the specific purpose.
The manufacturer accepts no liability for the consequences of misuse by the operator. Improper
installation or operation of the devices (systems) will cause the warranty to be void. The
respective "Standard Terms and Conditions" which form the basis for the sales contract shall
also apply.
1.4.4 Information concerning the documentation
To prevent any injury to the user or damage to the device it is essential that you read the
information in this document and observe applicable national standards, safety requirements
and accident prevention regulations.
If this document is not in your native language and if you have any problems understanding the
text, we advise you to contact your local office for assistance. The manufacturer can not accept
responsibility for any damage or injury caused by misunderstanding of the information in this
document.
This document is provided to help you establish operating conditions, which will permit safe and
efficient use of this device. Special considerations and precautions are also described in the
document, which appear in the form of icons as shown below.

SAFETY INSTRUCTIONS 1
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1.4.5 Warnings and symbols used
Safety warnings are indicated by the following symbols.
•HANDLING
HANDLINGHANDLING
HANDLING
This symbol designates all instructions for actions to be carried out by the operator in the
specified sequence.
iRESULT
RESULTRESULT
RESULT
This symbol refers to all important consequences of the previous actions.
1.5 Safety instructions for the operator
DANGER!
This warning refers to the immediate danger when working with electricity.
DANGER!
This warning refers to the immediate danger of burns caused by heat or hot surfaces.
DANGER!
This warning refers to the immediate danger when using this device in a hazardous atmosphere.
DANGER!
These warnings must be observed without fail. Even partial disregard of this warning can lead to
serious health problems and even death. There is also the risk of seriously damaging the device
or parts of the operator's plant.
WARNING!
Disregarding this safety warning, even if only in part, poses the risk of serious health problems.
There is also the risk of damaging the device or parts of the operator's plant.
CAUTION!
Disregarding these instructions can result in damage to the device or to parts of the operator's
plant.
INFORMATION!
These instructions contain important information for the handling of the device.
LEGAL NOTICE!
This note contains information on statutory directives and standards.
WARNING!
In general, devices from the manufacturer may only be installed, commissioned, operated and
maintained by properly trained and authorized personnel.
This document is provided to help you establish operating conditions, which will permit safe and
efficient use of this device.

1 SAFETY INSTRUCTIONS
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DEVICE DESCRIPTION 2
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2.1 Scope of delivery
INFORMATION!
Do a check of the packing list to make sure that you have all the elements given in the order.
INFORMATION!
Inspect the packaging carefully for damages or signs of rough handling. Report damage to the
carrier and to the local office of the manufacturer.
INFORMATION!
The field device will arrive in two cartons. One carton contains the converter and one carton
contains the sensor.
INFORMATION!
Make sure to combine the sensor and the converter correctly, so they match by the devices
serial number.
Figure 2-1: Scope of delivery
1 Signal converter, wall version or field version
2 Quick Start and factory calibration report
3 Small, medium or large sensor rail(s) with signal cable
4 Metal strap
5 Mineral coupling grease (standard versions) or high temperature contact gel (XT versions)
6 Coupling pads
INFORMATION!
Assembly materials and tools are not part of the delivery. Use the assembly materials and tools
in compliance with the applicable occupational health and safety directives.

2 DEVICE DESCRIPTION
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The underneath accessories can be ordered optionally:
•GDC interface set
•Coupling grease; mineral (standard versions) or high-temperature contact (XT versions)
•Coupling pads
•Cable (splitter) box with signal cable
Figure 2-2: Additional items (depends on version)
1 Sensor with cable
2 4 fixing units
3 Coupling pads
4 2 metal straps
5 Optional: cable (splitter) box with signal cable (depends on ordered version)
INFORMATION!
No special tools, no training required!

DEVICE DESCRIPTION 2
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2.2 Device description
The ultrasonic clamp-on sensor rail is designed to be installed on the outside of the pipeline to
measure the volume flow of liquids. The device is a combination of sensor rail(s) and an
ultrasonic flow converter.
Figure 2-3: System configuration possibilities
1 Single path, small or medium sensor rail
2 X-mode with medium sensor rails
3 Dual path, small or medium sensor rail
4 Dual pipe, small or medium sensor rail
5 Single path, large sensor rails
6 Single path, dual pipe, large sensor rails
7 Dual pipe, dual path, large sensor rails
INFORMATION!
For more information regarding the different device versions and configurations, please refer to
Installation of the sensor rail on page 32
.

2 DEVICE DESCRIPTION
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2.2.1 Field housing (remote version)
2.2.2 Wall housing
Figure 2-4: Construction of the field housing for remote versions
1 Cover for electronics and display
2 Cover for power supply and inputs/outputs terminal compartment
3 Cover for flow sensor terminal compartment
4 Cable entry for signal cable
5 Cable entry for power supply
6 Cable entry for inputs and outputs
7 Mounting plate for pipe and wall mounting
INFORMATION!
Each time a housing cover is opened, the thread should be cleaned and greased.
Use only resin-free and acid-free grease.
Ensure that the housing gasket is properly fitted, clean and undamaged.
Figure 2-5: Construction of wall-mounted housing
1 Cover for terminal compartments
2 Terminal compartment for signal cables sensor rail(s)
3 Terminal compartment for inputs and outputs (I/O)
4 Terminal compartment for power supply with safety cover (shock-hazard protection)
5 Cable entry for signal cable
6 Cable entry for inputs and outputs
7 Cable entry for power supply

DEVICE DESCRIPTION 2
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2.3 Nameplates
2.3.1 Overview of the nameplates (examples)
2.3.2 Examples of nameplates on the signal converter
INFORMATION!
Look at the device nameplate to ensure that the device is delivered according to your order.
Check for the correct supply voltage printed on the nameplate.
Figure 2-6: Visual check
1 Flow sensor rail(s)
2 Signal converters (field or wall version)
Figure 2-7: Example of nameplate (field version)
1 Name and address of the manufacturer
2 Type designation of the flowmeter with CG number
3 Disposal logo and supplier website
4 Sensor serial number(s), corresponds with the number mentioned on type sticker
5 Electronic Revision number
6 Mains supply data
7 Data matrix
8 Protection category and Tag number
9 Ambient temperature

2 DEVICE DESCRIPTION
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2.3.3 Example nameplate of the flow sensor rail
Example of the nameplate wall version
Figure 2-8: Example of nameplate (wall version)
1 Name and address of the manufacturer
2 Type designation of the flowmeter and CE sign with manufacturing date
3 Disposal logo and supplier website
4 Serial number sensor 1/2/3 + short code flowsensor
5 Electronic Revision number
6 Mains supply data
7 Data matrix
1 Name and address of the manufacturer
2 Type designation and manufacturing date of the flowmeter
3 Media temperature and calibration data
4 Data matrix
5 Tag number
6 Protection category
7 Ambient temperature operating range
8 CE sign with number(s) of notified body/bodies