Sonotec Sonaphone User manual

Operating Manual
SONAPHONE
Ultrasonic testing device for preventive maintenance
Translation of the German original
Revision: 2.0 | 2023-04-03

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Content
1Notes on this documentation ...........................................................................................4
1.1 General .............................................................................................................................4
1.2 Representations in this documentation........................................................................4
1.3 Identification of warning instructions ...........................................................................5
2Safety instructions............................................................................................................6
2.1 Introduction......................................................................................................................6
2.2 Basic hazards...................................................................................................................6
2.3 Personnel and qualifications..........................................................................................7
2.4 Safety-conscious working practices ............................................................................8
2.5 Use of the product ..........................................................................................................9
2.6 Modifications and alterations.......................................................................................10
2.7 Data security..................................................................................................................10
3Description of the device.................................................................................................11
3.1 Intended use ...................................................................................................................11
3.2 Prohibited use.................................................................................................................11
3.3 Range of functions ........................................................................................................ 12
3.4 Working principle...........................................................................................................13
3.5 Device labeling ..............................................................................................................14
3.6 Connections, interfaces, device elements ................................................................. 15
3.7 Status display and device buttons.............................................................................. 17
3.8 Home screen.................................................................................................................. 19
3.9 SONAPHONE Software.................................................................................................20
3.10 Operating keys of the headphones............................................................................. 21
4Commissioning................................................................................................................22
4.1 Charging the battery.....................................................................................................22
4.2 Fastening the carrying strap to the device ............................................................... 23
4.3 Switching the device on/off .........................................................................................25
4.4 Setting user interface language, date and time ........................................................26
5Managing SONAPHONE apps .........................................................................................28
5.1 Internet portal “mySONAPHONE.com” .......................................................................28
5.2 Installing or updating ....................................................................................................28
5.3 Uninstalling and removing............................................................................................29
6Preparing a work order .................................................................................................. 30
6.1 Starting the app............................................................................................................ 30
6.2 Adjusting the display brightness ................................................................................ 30
6.3 Connecting the sensor .................................................................................................31
6.4 Using headphones ....................................................................................................... 33
6.5 Adjusting the volume ................................................................................................... 34
7Performing measurements ............................................................................................ 36
7.1 Using SONAPHONE apps ............................................................................................ 36

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7.2 Creating screenshots....................................................................................................37
8Concluding a work order................................................................................................ 38
8.1 Reading PDF files on the device................................................................................. 38
8.2 Hiding or closing an app.............................................................................................. 39
9Managing data................................................................................................................ 40
9.1 Directory structure....................................................................................................... 40
9.2 Transferring data from the device to a PC.................................................................41
9.3 Using the microSD card................................................................................................41
10 Using SONAPHONE DataSuite....................................................................................... 43
10.1 Managing data.............................................................................................................. 43
10.2 Collecting data.............................................................................................................. 43
11 Cleaning and maintenance ............................................................................................ 44
11.1 Cleaning......................................................................................................................... 44
11.2 Maintenance ................................................................................................................. 45
12 Troubleshooting ..............................................................................................................47
13 Technical data ................................................................................................................ 48
14 Disposal .......................................................................................................................... 50
14.1 Recycling and taking back of used equipment..........................................................50
14.2 Removing the battery ................................................................................................... 51
15 Warranty ......................................................................................................................... 53
16 Manufacturer information.............................................................................................. 54

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1Notes on this documentation
1.1 General
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 of at the current point of time.
1.2 Representations in this documentation
Illustrations
Illustrations used in this document 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.
 Indicates the use of a tool.

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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.
ATTENTION
Warns of dangers, which, if ignored, may lead to damage to property – including damage
to property due to operational interruptions.

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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 device may lead to injuries.
•Do not open the device.
•Protect the device 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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ATTENTION
Possible damage of the device display!
Improper use may damage the device display.
•Do not use scratching or sharp objects to operate the device by touch screen.
Commercially available pens for touch screens are suitable.
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.
Requirements on ultrasonic testing
Operators of the device must have thorough expertise, skills and experience to avoid errors
that may lead to unforeseeable consequences.
Ultrasonic testing with the SONAPHONE may only be carried out when the following
(minimum) conditions are met:
•Selection of suitable accessories
•Complete and correct configuration of the device parameters
•Selection of a suitable testing method
•Correct interpretation of measurement values
•Expertise for drawing conclusions on the condition of the plant.

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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.
•Carry the device by the carrying strap when climbing up and down ladders and stairs.
Always carry the device by the carrying strap in such a way that the carrying strap
does not get caught or entangled in moving parts.
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. Use the carrying
case to transport and store the product.
•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.
•Do not use scratching or sharp objects to operate the touchscreen. Apart from
operation by finger touch, commercially available touchscreen pens or touchscreen
gloves are suitable.

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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.
2.7 Data security
Data loss
The loss of measurement data may lead to incomplete measuring chains or
misinterpretations.
•Always make sure to backup measurement data regularly on external data media.
•Back up your measurement data before updating the software or resetting the device
to factory settings.
Cyber security measures
Based on analysis of vulnerabilities according to IEC 62443-4-1 and IEC 62443-4-2, no
cyber security measures are necessary for the product.
However, a cyber attack on the product and its environment can never be completely ruled
out. Thus, we strongly recommend to implement safety measures (e.g. anti-virus programs,
firewalls, access restrictions) against potential cyber attacks within the product
environment.

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3Description of the device
This section describes use, connections and controls of the SONAPHONE.
3.1 Intended use
The SONAPHONE is a testing device for the verification, recording and evaluation of
ultrasonic signals.
Ultrasound can be created during a wide range of processes, including:
•at leaks in compressed air, steam and vacuum systems,
•during the operation of steam traps,
•at leaking valves, gates, barriers or taps in pipe systems,
•during the normal function of slide or rolling bearings,
•during cavitation caused by pumps and compressors,
•in the event of flashovers or corona discharges in electrical systems.
Depending on the device version and equipment, there are many other possible applications
for the device for processes where ultrasonic signals can be verified.
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
Operating or using the product incorrectly and/or not in the sense of its intended use may
lead to risk of death and personal injury.

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3.3 Range of functions
The SONAPHONE can be used for the evaluation of system conditions wherever ultrasonic
signals are created and wherever the evaluation of these signals allows for conclusions to
be drawn regarding correct functioning. Applications range from "simple" leak detection
through to monitoring tasks for complex processes.
The device concept of the SONAPHONE has been developed to support the user with
evaluation for a range of different processes by means of an adapted sensor system and
flexibility in the output of the recorded data.
The basis of the system is the mobile testing device, which has various sensor connections
and interfaces. Function and application software is installed on the device. The LevelMeter
app (basic version) already includes functionalities for testing, recording and display.
With this, many basic tasks can already be realized:
•Planning testing work
•Recording signal curves
•Saving and playing back signal curves
•Making ultrasonic signals audible
•Documenting (photographing) test points and marking damage areas
For special tasks, the system can be expanded by the addition of the following:
•Sensors that meet the special requirements of the testing work
•Application-specific software with extended functions allowing for the recording,
evaluation and management of testing and measurement data for special tasks.

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3.4 Working principle
For a variety of different processes, ultrasonic signals are created in different frequency
ranges, which the SONAPHONE makes visible and audible:
For tests carried out with the SONAPHONE, a distinction is made between two types of
ultrasound with regard to the use of sensors:
Airborne sound – these sound waves spread via air, and can be verified in leak detection on
compressed air lines, for example.
Structure-borne sound – these sound waves occur in mechanical processes, spread via
solid structures, and can be used to verify bearing wear, for example.
The SONAPHONE can be used to evaluate ultrasonic signals that inevitably occur in the
observed processes (leaks in compressed air or vacuum systems).
Alternatively, the SONAPHONE can be used to record ultrasonic signals that are actively
generated by a corresponding transmitter. This procedure is used for leak detection in non-
pressurized systems and containers, for example.
The level curve is depicted by averaging the ultrasound with very short time intervals. The
level data is output in the form of a level graph. The spectra are calculated directly from the
high-resolution ultrasound data, and are displayed as a function of time (spectrograms). Up
to 5 additional level values can be output via the display in order to meet individual
requirements.
At the same time, the signals are made audible via the integrated speaker or the
headphones (for working in areas with high levels of background noise). The volume can be
adjusted using the buttons on the device or on the sensors.
For documentation purposes, voice memos can be recorded for each test, and text
comments can be added. Photos can also be taken, with damage areas marked.
The saved data and additional information can be used to create PDF reports within the
device. There is also the option of transferring all data (individual data as well as reports) to
other devices for further processing via the USB interface.
Extended functionalities are possible in the form of adapted sensors and the associated
special software (see relevant documentation).

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3.5 Device labeling
Identification plate
No. Identification
1 Manufacturer’s address
2 Model ID
3 Serial number
4 CE marking
Disposal
The marking for disposal is located on the battery cover:

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3.6 Connections, interfaces, device elements
Structure
Description
No. Connection/interface/device element
1 Microphone
2 Slot for micro SD card
3 USB port
•Type: Micro-USB socket, type B
•for charger / power supply / data transfer
4 Headphone jack (jack socket 3.5 mm)

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No. Connection/interface/device element
5 Speaker
6 Sensor cable socket
•Type: LEMO 0B (4-pin)
•with marked plug-in position
7 Camera and flash
8 Battery with cover
9 Carrying strap bracket

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3.7 Status display and device buttons
Structure
Description
No. Component Description/function
1 Status LED SONAPHONE Shows the current device status:
•Green: Device is starting.
•Red: Measurement value recording is active.
2 Status-LED state of charge Shows the current state of charge:
•Orange: Battery is charging.
•Green: Battery is charged.
3 Increase volume Increases the volume of the acoustic playback.
4 Decrease volume Decreases the volume of the acoustic playback.

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No. Component Description/function
5 Configurable hardware
button
Activation/deactivation of the display lock when tilting or
turning the SONAPHONE handheld unit.
If the display lock is activated, it may be deactivated by
pressing the hardware button.
The assignment of the hardware button can be set in the
SONAPHONE apps.
6 Home button •Short pressing:Switches to the home screen.
•Long pressing:Opens the overview of active apps.
7 On/Off button •Keeping pressed (2 s): Turning the device on or off.
•Short pressing:Activate/deactivate standby mode.

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3.8 Home screen
Structure
Desciption
No. Description/function
1 Status bar: Shows volume, charge level and time.
With a swipe gesture from top to bottom, further information/settings can be displayed.
2 Time and date (digital clock widget)
3 Quick access (up to 6 apps can be placed)
4 Opens the overview of all installed apps and widgets.
5 Multitasking: Opens the overview of active apps.
6 Home: Closes the current window and shows the home screen (activated apps remain
active).
7 Back:Closes the current screen and returns to the previous one.

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3.9 SONAPHONE Software
Operating system
The SONAPHONE's operating system is based on Android 4.4.2. The source code can be
disclosed upon request.
SONAPHONE Apps
Icon Name Application
Software Manager App to manage (install, update, uninstall) SONAPHONE apps
and app licenses.
Factory pre-installed
Hardware Manager Highly specialized app for updating the firmware of
SONAPHONE sensors BS10, BS20, BS30 and BS40
Factory pre-installed
SONAPHONE Setup Quick setting for interface language, date and time
Factory pre-installed
Measurement Core Measurement core app
Factory pre-installed
LevelMeter Versatile app for essential maintenance tasks
Factory pre-installed
SteamExpert Highly specialized app for testing steam traps
Optional
LeakExpert Highly Specialized App for localization and documentation of
compressed air leakage
Optional
AssetExpert Highly specialized app for route-based data collection
Optional
Licenses for third-party software
Licenses for third-party software used in the respective SONAPHONE apps can be
displayed in the corresponding SONAPHONE app.