Sonotec BS40 User manual

Operating Manual
BS40
Broadband structure-borne sound sensor for the SONAPHONE handheld unit
Translation of the German Original
Revision: 1.1 | 2023-04-27

Operating Manual | Content
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Content
1Introduction .......................................................................................................................3
1.1 Notes on this documentation.........................................................................................3
1.2 Representations in this documentation........................................................................3
1.3 Identification of warning instructions ...........................................................................4
2Safety instructions............................................................................................................5
2.1 Introduction......................................................................................................................5
2.2 Basic hazards...................................................................................................................5
2.3 Personnel and qualifications..........................................................................................6
2.4 Safety-conscious working practices ............................................................................6
2.5 Use of the product ..........................................................................................................7
2.6 Modifications and alterations.........................................................................................8
3Description of the sensor..................................................................................................9
3.1 Intended use ....................................................................................................................9
3.2 Prohibited use..................................................................................................................9
3.3 Sensor construction......................................................................................................10
3.4 Sensor identification ......................................................................................................11
3.5 Accessories.................................................................................................................... 12
4Operation of the sensor ..................................................................................................14
4.1 Requirements on the point of measurement..............................................................14
4.2 Preparing the point of measurement .......................................................................... 15
4.3 Coupling the sensor...................................................................................................... 15
4.3.1 Magnetic coupling for temporary measurements ......................................... 16
Uncoupling............................................................................................................................... 18
4.3.2 Screwed coupling for semi-stationary measurements................................. 19
5Cleaning and maintenance ............................................................................................ 20
5.1 Cleaning..........................................................................................................................20
5.2 Maintenance ..................................................................................................................20
6Technical data ................................................................................................................. 21
7Disposal .......................................................................................................................... 23
8Warranty ......................................................................................................................... 24
9Manufacturer information...............................................................................................25

Operating Manual | 1 Introduction
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1Introduction
This section is intended to explain function, structure and representations of this
documentation to simplify handling of this documentation.
1.1 Notes on this documentation
Purpose
This documentation constitutes an integral part of the product and contains important
advice on safe operation as well as all information on intended and efficient use. Thus, any
person using the product must have read and understood this documentation.
Accessibility
The staff working with this product must have constant access to this documentation to
prevent handling errors and guarantee trouble-free operation.
Up-to-dateness
Every effort has been made to ensure that the information contained in this documentation
is complete and correct at the time of release. This documentation describes all units and
functions known at the current point of time.
1.2 Representations in this documentation
Illustrations
Illustrations used in this documentation do not always contain all details or special cases.
They only represent the relevant information.
Tips
Tips are marked as follows:
Tips describe specific information or particular features that might not be evident, even
for experienced users. The neglect of a tip poses no direct safety risk. However, it can
lead to workflow disruptions.
General icons
The following general icons are used for visual emphasis:
Icon Function

Indicates a link to external content.

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1.3 Identification of warning instructions
Classes of danger, signal words and colors
This documentation contains warnings regarding hazards of different classifications. These
classes are characterized by signal words and colors. They include the following:
WARNING
Warns of possible immediate danger, which, if ignored, may lead to lasting damage to
health and/or property – including financial losses due to operational impairment.
CAUTION
Warns of dangers, which, if ignored, may lead to injury or damage to property – including
damage to property due to operational interruptions.
ATTENTION
Warns of dangers, which, if ignored, may lead to damage to property – including damage
to property due to operational interruptions.

Operating Manual | 2 Safety instructions
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2Safety instructions
This section contains safety information relating to the protection of persons as well as safe
and fault-free operation. All user groups of the product must be aware of and follow these
safety provisions.
2.1 Introduction
Reliable and safe operation of the product depends on the careful handling and execution of
operational and setting tasks.
Ignoring these safety instructions and warning information may lead to serious injury with
lasting health consequences for personnel as well as damage or destruction of product
components.
During handling of the product, please observe all safety instructions and warning
information in all parts of this user documentation as well as the related codes of practice.
Ensure that all those working with the product are also aware of these instructions.
Generally applicable safety regulations (such as accident prevention and environmental
protection regulations, etc.) must also be observed.
2.2 Basic hazards
Definition
Basic hazards are residual risks that remain even with safety-conscious intended use.
State of the art
The product meets the current state of the art and applicable safety rules. All components
of the product are tested thoroughly before they leave the factory and are delivered in a
condition for safe operation.
WARNING
Danger of injury!
Improper use of the product may lead to injuries.
• Do not open the product.
• Protect the product against extreme heat (excessive sunlight, immediate vicinity of
open fire or heating devices) during operation and storage.
• Avoid strong impacts that could damage the device and/or its components.

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2.3 Personnel and qualifications
Basic requirements
The product must only be used by operators that have completely read and understood the
safety instructions and all documents of the user documentation.
Personnel undergoing training or instructions or persons taking part in general vocational
training programs may only operate the device under the continuous supervision of
operating or technical personnel.
Responsibility of the operating company
Regarding the personnel authorized and/or trained by the operating company, the operating
company carries the following responsibilities:
• The necessary training and instruction of personnel must be guaranteed.
• All personnel's competences and responsibilities must be clearly stated and
documented.
• All user information on the product (operating manual, user documentation etc.) must
be kept in the immediate vicinity of the product and must be accessible at all times.
2.4 Safety-conscious working practices
Accident prevention and environmental protection
In addition to the instructions in this operating manual, please mind the generally applicable
legal and other regulations on accident prevention and environmental protection.
This may include, for example:
• Handling of hazardous materials
• Wearing the required and mandatory personal protective clothing and safety
equipment
• Observing of and complying with all national and regional industrial safety regulations
• Observing of and complying with all internal working, operating and safety regulations

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2.5 Use of the product
Measures for personal safety
Improper use of the product may lead to injuries of operating personnel.
• During detection of ultrasonic signals on electrical equipment, make sure to keep the
mandatory safety distance from detected electrical defects.
• Always make sure that both hands are free for self-protection, if necessary.
• Always make sure to keep your hands, the product and/or connected equipment within
your field of vision.
• Use the torchlight functionality (LED light) of the product and/or additional lighting to
illuminate test sites with poor visibility.
• Always use the product without distraction. Do not read messages on the display
and/or operate the product while walking.
Measures for protection of the product and/or equipment
Improper use of the product may lead to product damage. Damaged components may affect
or distort the measurement result quality.
• During use, charging and storage, protect the device against extreme, unusual heat
(excessive sunlight, storage in heated cars or immediate vicinity of open fire or heating
devices). It is critical to stay within the temperature ranges given in the technical
specification.
• Do not use the product and its accessories if they display functional errors and/or
visible damage.
• Only connect the product to approved equipment received from SONOTEC GmbH or
its sales partners.
• The product adheres to the protection class given in the technical specification and is
not protected against water. Do not submerge the product in liquids. Protect the
product against moisture penetration.
• Handle the product with care and protect it against major shocks.
• When using the product, always make sure that cables cannot get stuck and/or caught
in moving parts.
• Do not use the product within strong electromagnetic fields.

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2.6 Modifications and alterations
No modifications on the product and/or accessories
The product and/or its accessories must not be opened or disassembled. The product does
not contain any components to be cleaned, maintained or repaired by operators.
Unauthorized modifications of the product and/or its accessories are prohibited and lead to
exclusion of liability by the manufacturer for resulting damage and consequences.
Spare parts and accessories
Spare parts and accessories must comply with the technical requirements specified by
SONOTEC GmbH and its suppliers. Whenever original parts are used, compliance is given.
No alterations to the software
Do not alter the supplied software or commission software alterations to third parties. The
software may not be disassembled, decrypted or decompiled in full or in part.

Operating Manual | 3 Description of the sensor
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3Description of the sensor
This section describes use, function, structure and accessories of the sensor.
3.1 Intended use
The Broadband structure-borne sound sensor BS40 is used in combination with the
SONAPHONE digital ultrasonic testing device. Applications of the sensor include condition
monitoring of machines, systems and processes with detectable structure-borne sound in
the ultrasonic range.
Variance of the sound signals indicate a change in condition and/or process of the test
object. The detection of this variation is the basis of condition monitoring in preventive
maintenance.
The Broadband structure-borne sound sensor BS40 is preferably used for magnetic
machine surfaces or points of measurement.
The coupling mode at the point of measurement depends on the test type. For recurring
measurements with measurement data recording, the sensor may be attached by a
magnetic foot or a general-purpose magnet. For continuous monitoring or fixed attachment,
the sensor may be screwed in with a threaded pin.
3.2 Prohibited use
Any use not approved by SONOTEC GmbH is prohibited and may lead to injury or damage to
property.
SONOTEC GmbH accepts no liability for damage caused by prohibited use of the product.
Prohibited are in particular:
• Use of equipment and/or accessories with visible damage
• Use in wet rooms
• Use in potentially explosive environments
• Use in environmental conditions that do not adhere to the stipulated requirements
• Unauthorized modifications of the equipment, the software and/or accessories
• Use of unauthorized spare parts and/or unauthorized accessories

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3.3 Sensor construction
Sensor elements
Figure 1: Sensor elements of the BS40
No. Component
1 Ultrasonic transducer with UNF ¼" 28 threaded pin
2 Status LED
• green light: sensor is activated
• red light: sensor is in boot mode
• orange light: sensor is in service mode
Boot mode is required for sensor firmware updates.
(see Updating sensor firmware with the SONAPHONE Hardware Manager app)
3 Sensor cable socket
• Type: LEMO 0B (4-pin)
• with marked plug-in position

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3.4 Sensor identification
Identification plate
Figure 2: Identification plate with its components
No. Identification
1 CE marking
2 Manufacturer’s address
3 Serial number
4 Disposal symbol (see "7 Disposal", page 23)

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3.5 Accessories
Intensity and behavior of ultrasonic signals depend on factors such as the process during
which they are generated. Measurement value recordings with high signal quality are
necessary for valid conclusions on system conditions. Signal quality also depends on a
number of factors.
To record high-quality signals for processing in the sensor, equipment for differing
applications is available.
The frequency characteristic varies depending on the used equipment and/or the
coupling mode. Always use the same equipment and/or coupling mode for recurring
comparison measurements.
Flat surface magnetic base
Application • Magnetic sensor coupling on even coupling surfaces for recurring
temporary tests
• Including UNF ¼" 28 internal thread for screwing on the sensor
Article number 300 01 0102
Multi-purpose magnetic base
Application • Magnetic sensor coupling on curved surfaces for temporary tests
• Including UNF ¼" 28 internal thread for screwing on the sensor
Article number 300 01 0103

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Mounting pad
Application • Fitting a designated coupling position for magnetic or screwed
sensor coupling for recurring temporary or semi-stationary tests
• Including UNF ¼" 28 internal thread for screwing in the sensor
Article number 300 01 0104

Operating Manual | 4 Operation of the sensor
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4Operation of the sensor
This section contains descriptions and instructions for operating the sensor and using it in
combination with the SONAPHONE handheld unit.
CAUTION
Risk of crushing by magnetic foot or general-purpose magnet!
The magnetic foot and the general-purpose magnet exhibit a very strong magnetic force.
This may cause crushing injuries on the hands during sensor coupling.
• Make sure that your fingers are not positioned between the magnetic foot/general-
purpose magnet and the surface of the point of measurement.
• Only transport the sensor including magnetic foot/general-purpose magnet with
mounted protective pad. The protective pad may only be removed from the
magnetic foot/general-purpose magnet during measurements.
• Always position the sensor with magnetic foot/general-purpose magnet inclined and
with care on the point of measurement.
4.1 Requirements on the point of measurement
A point of measurement suited for ultrasonic measurement has to satisfy the following
requirements:
• The surface must be level, without dust and grease and free of scratches.
• The point of measurement should not be covered by paint layers.
For satisfaction of these requirements and high reproducibility of the measurement results,
we recommend to mark and prepare the point of measurement.
Attaching mounting pads (article number: 300 01 0104) allows for consistently
comparable coupling conditions.

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4.2 Preparing the point of measurement
For correct and reproducible measurement results during recurring measurements, the point
of measurement may be prepared as follows depending on the application:
1. Ensure that the surface is clean and free of scratches.
2. If possible, remove the paint layer from the surface.
3. Depending on the application:
Drill a UNF 1/4" 28 threaded hole (depth: 6 mm).
or
Glue a mounting pad.
4.3 Coupling the sensor
Correct and reproducible measurement results depend on:
• selection of an appropriate point of measurement,
• selection of appropriate equipment,
• correct alignment and positioning of the sensor depending on the used equipment as
well as
• consistent contact pressure of the sensor during measurement value recording.
This section contains descriptions and instructions on coupling the sensor with the
corresponding equipment.
The frequency characteristic varies depending on the used equipment and/or the
coupling mode. Always use the same equipment and/or coupling mode for recurring
comparison measurements.

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4.3.1 Magnetic coupling for temporary measurements
Coupling methods
For temporary measurements, the sensor may be coupled magnetically with the point of
measurement. Depending on the local conditions and the particular application, one of the
following coupling methods may be used:
No. Coupling method
1 Magnetic foot for even coupling surfaces
2 Magnetic foot on glued mounting pad
3 General-purpose magnet for curved surfaces

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Coupling
1. Screw the required magnet on the sensor and hand-tighten.
2. Push the protective pad sideways to remove it from the magnet.
3. Carefully position the sensor on the point of measurement by placing the edge of the
magnet.
4. Carefully tilt the sensor on the point of measurement until the magnet rests on the
point of measurement with its complete surface.

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Uncoupling
1. Carefully tilt the sensor from the point of measurement.
2. Carefully pull the sensor from the point of measurement.
3. Carefully push the protective pad sideways on the magnet.

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4.3.2 Screwed coupling for semi-stationary measurements
Coupling methods
For semi-stationary measurements, the sensor may be screwed into a prepared point of
measurement. Depending on the local conditions and the particular application, one of the
following coupling methods may be used:
No. Coupling method
1 Direct screw coupling with the point of measurement
2 Screw coupling with the glued mounting pad
The sensor must always be tightened with a defined tightening torque (preferably 2
Nm).

Operating Manual | 5 Cleaning and maintenance
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5Cleaning and maintenance
5.1 Cleaning
Guidelines
Do not open the product! The product contains no parts to be cleaned by the operator.
Suitable cleaning products
Only clean the product on the outside with soft, lint-free cloth.
ATTENTION
Check the compatibility of used cleaning agents!
The compatibility of all cleaning agents with used materials and colors must be confirmed
and approved by SONOTEC GmbH or the respective supplier.
Unsuitable cleaning agents
Do not clean the product with:
• scratchy, aggressive, solvent-containing or benzine-containing cleaning agents,
• pressured air, high-pressure cleaner or other kinds of cleaning machine.
After cleaning
After cleaning the device, make sure that:
• cables, connectors and fittings are free of cleaning agents and
• cables, wires, connectors and electrical components are dry.
5.2 Maintenance
Guidelines
Do not open the device! The device contains no parts to be maintained or repaired by the
operator.