Sonotec SONOCHECK ABD06 Series User manual

Sensor for Air Bubble Detection
at Liquid Filled Tubes
SONOCHECK
Type ABD06.xx
Operating Manual

Manufacturer: SONOTEC Ultraschallsensorik Halle GmbH
Model: Air Bubble Detector
Type: ABD06.xx
SONOTEC Ultraschallsensorik Halle GmbH
Nauendorfer Str. 2
06112 Halle (Saale), Germany
Phone: [phone]
Fax: [phone]
E-mail: [e-mail]
Internet: www.sonotec.eu
© 2014
SONOTEC Ultraschallsensorik Halle GmbH
All rights reserved
The content of this manual is the property of SONOTEC Ultraschallsensorik Halle
GmbH and is protected by copyright. Duplication and distribution in any form,
particularly reprinting, photographic, mechanical or electronic reproduction, or in
the form of storage in data processing systems or data networks, is prohibited
without the consent of the copyright holder.
Revision: 1.2, Date: 2014-01-30
Information is subject to change without notice!

SONOCHECK – Air Bubble Detector Type ABD06.xx
ABD 06.xx 3
Table of Content
1General Information.................................................................................................................4
1.1 Safety information.............................................................................................................4
1.2 Application........................................................................................................................4
1.3 Measuring Principle ..........................................................................................................4
2Technical Specifications...........................................................................................................5
2.1 Sensitivity of Bubbles/Direction of Mounting .....................................................................5
2.2 Liquid Standards...............................................................................................................5
2.3 Tube Standards................................................................................................................5
2.4 Connection of the Sensor .................................................................................................7
2.5 Settings/ABD Monitor........................................................................................................7
3Cleaning and disinfection.........................................................................................................8
4Technical Drawings................................................................................................................11
4.1 Dimensions Model S for an Outer diameter of the Tube of 3.0 ... approx. 8.5 mm ..........11
4.2 Dimensions Model L for an Outer Diameter of the Tube of 8.0 ... approx. 17.0 mm........12

SONOCHECK – Air Bubble Detector Type ABD06.xx
ABD 06.xx 4
1 General Information
1.1 Safety information
The SONOCHECK ABD06 is a state of the art product that complies with all applicable safety
regulations. The sensor is factory tested and is delivered in a safe condition for operation.
The following safety instructions apply:
Warning!
Incorrect installation and use of the ABD06 sensor and its components can present a
hazard for the user.
• The plant operator is responsible for the legal compliance of the SONOCHECK ABD06
installation and documentation.
• The SONOCHECK ABD06 may only be operated with power sources in the operating
voltage range specified in the technical data.
• Operation and storage of the SONOCHECK ABD06 outside the temperature ranges
specified in the technical data is not permitted.
• The SONOCHECK ABD06 may not be immersed.
• The SONOCHECK ABD06 may only be exposed to a minimal risk of mechanical damage.
In other cases, the sensor must be protected against mechanical influences.
• If there is visible damage, the SONOCHECK ABD06 must be taken out of operation
immediately.
1.2 Application
The air bubble detector is used for the recognition of air bubbles in liquid filled tubes made of
synthetic material. It is also suitable for wet/dry indication at tubes.
The sensor is used especially in the fields of medical and food technology, since it has no contact
with the liquid. The sensor is also suitable for industrial applications such as the bubble detection
at tubes filled with glue or paint.
The type and dimensions of the sensor depend on the diameter and the flexibility of the tube as
well as on the kind of liquid.
Without using any coupling medium the tube is easily put into the sensor and enables a smooth
and uncomplicated change.
The sensor is constructed as a component to be integrated into machines and apparatus. The
mechanical installation and electrical integration into the control system can be carried out easily.
Besides standardized applications the sensors can also be adapted to customized applications.
1.3 Measuring Principle
An ultrasonic principle with short high-frequency pulses is used for measuring. If there is liquid in
the tube, a part of the ultrasonic sound is transmitted from the emitter through the tube to the
receiver. If the tube is empty or a bubble is placed in the measuring point, the part of sound is
much smaller. The amplitude of the received ultrasonic pulses is analysed.
The sensor adapts to dynamically changing acoustic conditions. Hence, a high reading stability
against varying environmental conditions can be ensured.

SONOCHECK – Air Bubble Detector Type ABD06.xx
ABD 06.xx 5
Example:
Outer diameter of tube = 6.5 mm
Inner diameter of tube = 4.9 mm
 Bubbles bigger than 5 µl are detected at a
flow rate of 1 ... 1000 ml/min.
2 Technical Specifications
2.1 Sensitivity of Bubbles/Direction of Mounting
The bubble sensitivity depends on the diameter of tube and on the mounting position. For optimal
bubble detection the tube must be placed vertically or horizontally with lateral insertion. This way
bubbles with a diameter greater than 30 % ... 50 % related to the inner diameter of tube will be
detected.
Figure 1. Recommended mounting position of the sensor
If the opening of the channel points upwards, the threshold at which bubbles can be detected
reliably is the highest.
2.2 Liquid Standards
In general, all low-viscosity liquids which contain no or only little filler are suitable. The intensity of
ultrasound, which is transmitted into the liquid is so small, that no biological damage occurs.
For industrial applications with high-viscosity liquids (e.g. fats/special paints), screening
tests must be made.
2.3 Tube Standards
According to the tube diameter there are various models with a different channel width. The type of
sensor depends on the outer diameter, the flexibility as well as the wall thickness of the tube.
In order to make sure to select the most appropriate type consult our service team. If
available, a short piece of the tube should be sent to our company.
Outer diameter
3 ... 17 mm
Wall thickness
optimal 10 ... 20 % of outer diameter
Material
Plastics, e.g. PVC, PE, silicon, PUR
Other materials only on request or after test
Features
Tube must be plane on the outside, no textile tube
Elasticity
Tube must be adaptable
Table 1. Requirements to the tube
side view

SONOCHECK – Air Bubble Detector Type ABD06.xx
ABD 06.xx 6
The tube is put into the measuring cell without coupling gel.
ATTENTION: There must be no liquid in the channel. An acoustic short circuit may
be caused due to the liquid. The function of the sensor is strongly disturbed.
Normally, after being put in, the tube is fixed firmly by a cover. Especially when using very small
tubes or tubes with a very low wall thickness (less than 10 % of the outer diameter) it is necessary,
that the cover presses the tube and keeps it firmly on the right position.
Optionally, there are sensors without cover available. In case the tube is made of a flexible material
and it is suitable for the application, a cover is not mandatory.
The elasticity of the tube may be changing by an increased operating temperature.
In case of a frequent changing of the tube (using disposables) we recommend a sensor type with a
snap-in cover.

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ABD 06.xx 7
2.4 Connection of the Sensor
For normal operating the sensor is connected via a M12 sensor connector (3 poles).
A suitable cable can be delivered optionally (lengths: 2 m/5 m/10 m). A shielding cable is not
necessary for short distances. We recommend a shielding for longer length (> 30 m) or in rough
industrial environments.
For the service a special cable (5 poles) is required. Using the additional lines it is possible to
configure the sensor and to adapt it to customized specifications. Do not connect unused lines!
Use the service lines only in combination with the ABD Monitor for the SONOCHECK
(delivered on request). Otherwise, the sensor could be damaged.
Figure 2. View on connector of the sensor Figure 3. View on connector of the cable (female)
Pin
Colour
Connection
1
brown
Power supply voltage +12 ... 30 VDC
2
white
For service only: serial control input (5V/TTL)
3
blue
Ground
4
black
Switching output, PNP, max. 150 mA
5
grey
For service only: serial control output (5V/TTL)
shield
If available: should be grounded on the side of controlling unit
Table 2. Pin configuration of M12 sensor connector
2.5 Settings/ABD Monitor
For settings or for diagnostics a computer is required.
By setting the parameters the sensor could be customized:
- Response time/hold time for output/state of output
- Adaption to the right kind of tube
For detailed information do not hesitate to contact our service team.
1
2
3
4
5
1
4
3
2
5

SONOCHECK – Air Bubble Detector Type ABD06.xx
ABD 06.xx 8
Figure 4. ABD-Monitor for diagnostics or for
setting parameters
Figure 5. USB Data Converter for connecting
the sensor to the USB Port of the computer
3 Cleaning and disinfection
The sensor should be cleaned using standard commercial cleaning agents. Standard commercial
spray disinfectants should be used for disinfection.
Caution!
Incorrect cleaning of the ABD06 sensor and its components can present a hazard for
the user.
Cleaning is prohibited
• in a steam steriliser or with hot steam in general
• with white spirit or acetone
• by immersion in solvents or other liquids

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Technical Data
SONOCHECK, Type ABD06.xx
Sensor for air bubble detection at liquid filled tubes
Measuring Principle
Ultrasonic principle
Tube is put dry in sensor, no coupling gel is required.
Type of Models
Model
Outer Diameter of Tube
S
3.0 ... ca. 8.5 mm
L
8.0 ... ca. 17.0 mm
Dimensions of sensor and cover depend on diameter, wall thickness
and flexibility of tube.
If possible, provide a short piece of tube for an optimal selection!
Materials

Housing/cover: plastics/POM/black
Measuring cell: plastics/PMMA/black
Potting: PUR
Note: Other materials are available on request.
Mounting
2 x holes M4 on the rear side of the sensor
Operating Temperature
+5 °C ... +60 °C
Storage Temperature
-20 °C ... +70 °C
Degree of Protection
IP67
Power Supply Voltage
+12 ... 30 VDC, ripple max. 10 %,
protection against reverse connection
Power
Max. 50 mA (without switching current)
Switching Output
PNP, max. switching current 150 mA
No fuse inside the sensors!
Pay attention to max. switching current!
Load
Input
PNP-
Output
+UB
CONTROL
SENSOR
Ground
+UB
Ground

SONOCHECK – Air Bubble Detector Type ABD06.xx
ABD 06.xx 10
Output Specification
(Standard)
State
Level of PNP-Output
Air/bubble
+24 V
Liquid
Ground
Internal error (self-test)
+24 V
The state of output can be configured according to the application by means of
the ABD Monitor.
Measuring Cycle
200 µs
Response Time
Hold Time
minimal < 0.5 ms
The Response Time can be adjusted in a wide range. Furthermore, the Hold
Time can be set in order to increase the duration of the output signal.
CE Compliance
Compliance with DIN EN 61326-1: 2006
EN 61000-4-3 EMC, Radiated radio-frequency - Electromagnetic field
immunity, Test Result A, Test with 10 V/m (0.15 ... 1000 MHz)
EN 61000-4-4 EMC, Electrical fast transient/burst immunity test, Test Result A
(see restrictions below)
EN 61000-4-6 EMC, Immunity to conducted disturbances, induced by radio-
frequency fields, Test Result A, Test with 10 V/m
EN 55011 Electromagnetic disturbance characteristics, Limit 30 dBµV/m
For testing typical settings for bubble detection
have been
applied. The immunity depends on a reasonable configura
tion.
Operating with very high bubble sensitivity combined with a
very
short response time can
cause disturbances of the system,
induced by electromagnetic disturbing, pressure changing,
mechanical vibration, etc.
Scope of Delivery
Bubble detector type ABD06, model and dimensions adjusted to tube of
customer
Cover with screws, dimensions adjusted to sensor and tube
Technical datasheet
Accessories/Options
M12 sensor cable, 3 poles, length 2m/5m/10m
ABD Monitor, consisting of:
USB data converter
M12 sensor cable, 5 poles, length 2m
USB cable type A-B, length 1.5m
CD with software ABD Monitor
Snap-in cover, dimensions adjusted to sensor and tube (cannot be
retrofitted)
Table 3: Technical data of the sensor SONOCHECK - type ABD06.xx

SONOCHECK – Air Bubble Detector Type ABD06.xx
ABD 06.xx 11
4 Technical Drawings
4.1 Dimensions Model S for an Outer diameter of the Tube of 3.0 ... approx. 8.5 mm
Figure 6. Drawing of sensor model S
Note: The drawings do not conform to real dimensions
Mounting Holes
M4, depth 8
M12 Sensor Connector

SONOCHECK – Air Bubble Detector Type ABD06.xx
ABD 06.xx 12
4.2 Dimensions Model L for an Outer Diameter of the Tube of 8.0 ... approx. 17.0 mm
Figure 7. Drawing of sensor model L
Note: The drawings do not conform to real dimensions
M12 Sensor Connector
Mounting Holes
M4, depth 8