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3

SFIDK.PS.029.V3.02 - 

521H0553

SITRANS F US SONOFLO

®

®

®

®

®

Introduction

The SITRANS F US SONOFLO

®

 ultrasonic flowmeter type SONOKIT mounting set is used for

installing one set of ultrasonic transducers type SONO 3200 in existing pipes made of steel or
concrete.

This manual only describes the SONOKIT installation in empty unpressurized pipes. When
installing SONOKIT

 

in pressurized pipes (hot tapping), please contact Siemens Flow Instruments

for further instructions.

SONOKIT is designed for measuring the flow velocity of liquids in full pipes. Satisfactory function
of the ultrasonic flowmeter depends on a low attenuation of the medium  and a well-defined and
stable flow profile.

The making of an ultrasonic flowmeter by means of the SONOKIT is divided into 4 steps:

1. Calculating and marking the transducer holder position
2. Installing the transducer holders
3. Marking the sensor geometry
4. Entering the sensor geometry into SONO 3000 (theoretical calibration)

To ensure optimum performance of the measuring equipment it is essential that the following
instructions are followed.

Location

The SONO 3200 sensor can be installed both
indoors  and outdoors, even in exposed
surroundings.

The sensor is suitable for media and ambient
temperatures from –50°C to +100°C, the high-
temperature version from –40°C to +200°C. The
temperature range is stated on the data plate on
the transducer. The enclosure rating is IP 67 or
better. Optionally, the SONO 3200 is available
with IP 68.

In case of large temperature differences be-
tween the medium and the environment the
sensor must be isolated to avoid 2-phase flow
which will result in inaccurate measuring re-
sults.

The space requirements around the pipe for
retrofitting a SITRANS F US SONOFLO

®

 ultra-

sonic flowmeter type SONOKIT are given be-
low:

Note:

 The above dimensions are minimum values.

Different space requirements apply when retrofitting takes place in pressurized pipes or when the
transducers are exchanged under pressure.

1.  Introduction

Potential Hazards

The ground wire must always be connected to the ground terminal in accordance with the
diagram.

- this page has been updated 2003.11

Summary of Contents for SITRANS F US SONOFLO

Page 1: ... 085R9381 Order no FDK 521H0553 SFIDK PS 029 V3 02 SITRANS F US SONOFLO Ultrasonic Flowmeter Type SONOKIT 1 track DN 100 DN 4000 Handbook s ...

Page 2: ...n 28 Wall or panel mounting 28 Remote installation of the signal converter 27 19 insert 28 Installation in 19 rack 28 Installation of the signal converter IP 65 version 28 Front of panel mounting 29 Back of panel mounting 29 Connection board 19 insert 30 IP 65 wall mounting box connection 30 Setting the voltage selector 19 insert 31 Location of the SENSORPROM memory unit 31 7 Electrical connection...

Page 3: ...Toensureoptimumperformanceofthemeasuringequipmentitisessentialthatthefollowing instructions are followed Location The SONO 3200 sensor can be installed both indoors and outdoors even in exposed surroundings The sensor is suitable for media and ambient temperatures from 50 C to 100 C the high temperature version from 40 C to 200 C The temperature range is stated on the data plate on the transducer ...

Page 4: ...nd on the sensor indicates direction of flow when the electrical connections correspond to the ones described in the manual Full pipes The sensor must always be completely filled with liquid The following installations should be avoided Installation at the highest point of the pipe system Installation in vertical pipes with free outlet With partially full pipes or pipes with free outlet the flowme...

Page 5: ...ntre the flowmeter in relation to pipe flanges and gaskets Valves must always be installed after the flow meter The only exception is installation of the sensor in a vertical pipe In this case a valve below the sensor is necessary to allow zero point adjustment It is important to select a valve which does not alter the flow when fully open Recommended inlet Fully open valve i e no flow restriction...

Page 6: ...ONO 3200 is used together with the mounting kit type SONOKIT O ring type The transducer has a screwed union for fitting in a counterflange welded onto the pipe The union and the pipe are sealed with an O ring The transducer holders are welded directly onto steel pipes or cast into the walls of concrete pipes and must be flush with the inside surface of the pipe ...

Page 7: ...mer Centre punch Spirit level Roll of adhesive tape Flame cutter or drill with ø 60 mm drill bit for making holes in steel pipes Electric or TIG welder for welding the mounting plate and the transducer holder Special drill unit for drilling ø 46 mm holes in concrete Filler A suitable filler or mortar does not shrink when setting A comparatively short setting time is preferred Tools etc Tools for i...

Page 8: ...king the drawing 1 Circumference C 2 Wall thickness t The circumference is determined using the measuring tape Make sure that the pipe s surface is plane and free of dirt etc The measuring tape must fit snugly around the pipe Read the circumference C Repeat the measurement several times to avoid inaccuracies The wall thickness is obtained by measuring a similar pipe whose wall thickness is accessi...

Page 9: ...2 521H0553 SITRANS F US SONOFLO Step 4 Draw a line X1 at right angles to x x Step 5 Mark a point P1 on line X1 The distance a from X1 to P1 is calculated as follows a 0 25 x C Step 3 Mark a point X1 on line x x X1 should be approx 5 cm from the edge of the paper ...

Page 10: ...oint X2 on the line x x at a distance b from point X1 b is calculated using the formula DN 100 150 b 1 x Du DN 200 4000 b 0 577 x Du Du outer diameter of the pipe C π C Circumference of the pipe Step 7 Repeat steps 4 5 as shown above The drawing on the paper is now finished this page has been updated 2005 11 ...

Page 11: ...the pipe When it is perfectly balanced in horizontal position it intersects the top line Mark 4 5 points on the pipe s top line using the above method Draw a line X X through the marked top points using the length of angle iron Positioning the paper on the pipe Step 2 Place the paper on the pipe in such a way that the line X1 X2 on the paper coincides with the top line X X on the pipe Fix the pape...

Page 12: ...ith the centre punch Make sure that the lines dissecting the points can be redrawn once the paper is removed When preparing a steel pipe it is useful to draw a circle with a radius of 60 mm around points P again using the centre punch as this will facilitate cutting the holes with a flame cutter Remove the paper and start making the holes ...

Page 13: ...and free of dirt etc The measuring tape must fit snugly around the pipe Read the circumference C Repeat the measurement several times to avoid inaccuracies The wall thickness is obtained by measuring a similar pipe whose wall thickness is accessible or by consulting the relevant standard Step 2 Remove any rust or dirt from the surface of the pipe Find the top line X X using a spirit level Place th...

Page 14: ... through point X1 To construct the line through X1 place a strip of metal foil around the pipe thus ensuring that the line is at right angles to the pipe Step 4 Mark point P1 on the line at a distance a from X1 Point P1 is on the side of the pipe Therefore distance a is calculated as follows a 0 25 x C Mark a point X1 on top line X X Step 3 ...

Page 15: ...int X2 on line X X at a distance b from point X1 b is calculated using the formula DN 100 150 b 1 x Du DN 200 4000 b 0 577 x Du Du outer diameter of the pipe C π C Circumference of the pipe Step 6 Repeat steps 4 5 on the opposite side of the pipe The drawing is now finished this page has been updated 2005 11 ...

Page 16: ...553 SITRANS F US SONOFLO Place a set of transducer holders and mounting plates on the mandrel supplied with the kit without permanently fixing them Step 2 Step 1 Cut or drill 2 holes centred on P Dimension of the holes ø 60 mm 5 0 Installation of the transdu cer holders ...

Page 17: ...IDK PS 029 V3 02 521H0553 SITRANS F US SONOFLO Remove transducer holders and mandrel and weld the mounting plates completely onto the pipe Step 3 Tack weld the mounting plates in at least 3 places with transducer holders and mandrels mounted Step 4 ...

Page 18: ...the pipe wall The unit is fastened to the pipe wall by means of vacuum or clamping band Checkwhetherthemandrelcanstillpassthrough the transducer holders Correct the alignment of the transducer holders if necessary Use a 1 protection nut to protect the transducer holders thread and a hammer Step 6 The correctly positioned transducer holders are tack welded in at least 3 places with mandrels inserte...

Page 19: ... Remember to use O rings to seal the transducer holders Fix the transducer holder to the pipe by means of mortar Make sure that the mandrel is not exposed to the mortar as this might result in the mandrel getting stuck to the transducer holders The mandrel keeps the transducer holders in place until the mortar has set Step 4 a Concrete pipe b Repair mortar c Mandrel d Transducer holder ...

Page 20: ...inal axis of the pipe L Distance between transducer windows Di Inner diameter of the pipe The inaccuracies with which θ L and Di are measured directly influence the measuring accuracy of the finished system during theoretical calibration Be sure to choose measuring equipment with a suitable measuring accuracy The table shows the required measuring accuracy Step 1 Measuring the angle θ Measure the ...

Page 21: ...i can be calculated on the basis of the circumference C according to the following formula Di C π π π π π 2 x t The precise wall thickness t is measured with a sliding gauge after the holes have been made Enter Di into the measuring report Valid for standard 160 mm transducers With other transducer lengths set in dimen sions corresponding to these lengths ...

Page 22: ...22 4 Measuring the sensor Measuring the sensor SFIDK PS 029 V3 02 521H0553 SITRANS F US SONOFLO ...

Page 23: ... lock as shown in the figure After installation of the SW lock the SENSORPROM unit is placed on the electronics of the signal converter as described in chapter 6 Installation of the signal converter Electronics unit and SENSORPROM unit are programmed with the sensor geometry data entered into the measuring report see pipe geometry chapter 8 Commissioning Important Remove the SW lock from the elect...

Page 24: ...e internal walls The terminal box is fastened to the transducer holder by means of a union Stress on the connection wires must be avoided when passing them through the terminal box The wire without a spade terminal is connected to terminal 2 The wire with a spade terminal is connected to the transducer by means of screw 3 The inner wire is connected to terminal 1 and the transducer cable and scree...

Page 25: ...the terminal box at the bottom of signal converter as shown 2 To protect the pins place the signal con verter in the packaging base supplied 3 Set the signal converter as described un der Commissioning The SENSORPROM unit has now been programmed with the required settings 4 Remove the battery and replace the SEN SORPROM unit in the terminal box The flowmeter is now ready for operation Turning the ...

Page 26: ...etween feeler and remote signal converter 2 Mount the wall bracket 3 Remove the connection board and loosen the earth cable 4 Connect track 1 transducer to terminals 85 88 and track 2 transducer to terminals 81 84 Signal wires to even screen to odd numbers 5 Reinstall the earth cable and snap in the connection board 6 Connectcurrentandsignalcablesandtighten all cable entries to ensure optimum seal...

Page 27: ...stallation of the signal converter SFIDK PS 029 V3 02 521H0553 SITRANS F US SONOFLO Remote installation of the signal converter Tighten the cable unions to obtain optimum sealing The gaskets must be visible above the cable ...

Page 28: ...gnal converter and close the cover 19 insert The 19 insert is designed for a 19 rack system The insert has a width of 28 TE 142 mm a height of 3 HE 128 mm and a module depth of 160 mm The insert can be mounted directly in a 19 rack system or on a wall IP 65 version An optional mounting kit for front of panel mounting or for back of panel mounting is available The various mounting options are illus...

Page 29: ...verter s connection board 4 Insert the signal converter into the frame and fasten with the four screws accessible from the front 5 Connect the cables as shown in Electrical connections Back of panel mounting 1 Mount the connection board at the back of the panel using four screws 2 Place the SENSORPROM unit on the connection board 3 Connect the cables as shown in Electrical connections 4 Fasten the...

Page 30: ...tallation SFIDK PS 029 V3 02 521H0553 SITRANS F US SONOFLO Connection board for 19 insert IP 65 wall mounting box connection The number of connection possibilities depends on the version With the 1 track meter only transducers C D can be connected ...

Page 31: ...of the SENSORPROM memory unit 19 insert The SENSORPROM unit is placed on the connection board see figure For identification purposes each SENSORPROM unit is labelled with the sensor type On the SONO 3000 the identification can also be read in the menu SENSOR CHARACTERISTICS During commissioning it should always be checked whether the pipe data settings in the menu correspond to the values in the s...

Page 32: ...ected to terminal 2 The wire with a spade terminal is connected to the transducer by means of screw 3 The inner wire is connected to terminal 1 and the transducer cable and screen are fixed to cable clip 4 Note When disassembling the terminal box the wires must be loosened from the connection board It is not necessary to remove the transducer cable Support the terminal box while loosening the unio...

Page 33: ... 3 current outputs 2 frequency pulse outputs Connect screen to 85 and 87 Supply voltage 230 V a c 115 to 230 V a c is connected to terminals 1 and 2 The ground wire must be connected to the ground terminal on the terminal plate If the ground wire is not connected personnel can be exposed to 115 V 230 V this page has been updated 2003 11 ...

Page 34: ... OFF ON Connection between De energized Energized terminal no 45 46 44 46 Error Error Normal Direction Forward Reverse Sound limit Inside range Outside range Relay mode signal converter 19 insert Relays shown in de energized position Relay 1 OFF ON Connection between De energized Energized terminal no 44 45 45 46 Error Error Normal Direction Forward Reverse Sound limit Inside range Outside range R...

Page 35: ...rd through the menus CHANGE KEY This key changes the settings or numerical values SELECT KEY This key selects the digits to be changed LOCK UNLOCK KEY This key allows the operator to change settings and gives access to submenus Settings are stored automatically in the signal converter and the SENSORPROM memory unit The settings remain stored in the event of power failure and when the signal conver...

Page 36: ... reserved for the following symbols see keypad layout F If a fault develops two flashing triangles appear M The symbols indicate the following RESET MENU SERVICE MODE LANGUAGE SETUP OPERATOR MENU SETUP CONVERTER SETUP L Indicates the function of the LOCK key by the following symbols Ready for change Value locked Access to submenu RESET MODE Zero setting of totalizers and initialization of settings...

Page 37: ... CHANGE mode Enter the USER CODE press the LOCK key and page through the main menu using the PAGE FORWARD key until the required menu is reached Access the submenu by pressing the LOCK key CONVERTER SETUP MODE contains 3 submenus BASIC SETTINGS OUTPUT SETUP SENSOR CHARACTERISTICS In BASIC SETTINGS selection of flow direction measuring range measuring units totalizer units and low flow cut off can ...

Page 38: ...38 8 Commissioning Commissioning SFIDK PS 029 V3 02 521H0553 SITRANS F US SONOFLO ...

Page 39: ...nformation regarding the SERVICE MENU is located in the section Trouble shooting FLOW DIRECTION The flow direction is defined for volume and mass flow simultaneously VOLUME FLOW Choose measuring unit and the maximum volume flow For SONO 3000 not fitted with a SENSORPROM memory unit the display indication must be formatted It is done as follows a Sensor DN 2000 In the menu MAX RANGE the value 10 x ...

Page 40: ...density mass flow measuring units and the maximum mass flow range If the relay and density output is set to indicate sound limit the relay will make if the actual sound velocity is outside the range given by SOUND VELOCITY 1 and SOUND VELOCITY 2 i e indicating that the mass flow is calculated with a density outside the defined range CRYOGENICS Select cryogenic mass flow measuring unit and the maxi...

Page 41: ...elocity and density respectively The meter determines the density by measuring the sound velocity and interpolation of the relation between density and sound velocity TOTALIZER internal Select flow direction and measuring units By selecting bidirectional flow the net flow i e the difference between the positive and the negative flows will be displayed LOW FLOW CUT OFF Low flow cut off can be set w...

Page 42: ...53 SITRANS F US SONOFLO CURRENT OUTPUT CURRENT OUTPUT CHARACTERISTICS Bidirectional Unidirectional CURRENT OUT CURRENT OUT OFF VOLUME FLOW MASS FLOW SOUND VELOCITY CURRENT OUT TIME CON XX XS CURRENT OUT 4 20 mA 0 20 mA CURRENT OUT BIDIRECTIONAL UNIDIRECTIONAL ...

Page 43: ...MASS FLOW SOUND VELOCITY PULSE UNIT m3 UNIT m3 10 UNIT m3 100 UNIT UG 0 1 UNIT UG UNIT UG 10 UNIT UG 100 UNIT MUG UNIT L UNIT L 10 UNIT L 100 FRQ PULSE BIDIRECTIONAL UNIDIRECTIONAL FRQ PULSE PULSE OUTPUT FRQ OUTPUT FRQ OUTPUT TIME CON xx xs PULSE WIDTH XXXX UUUU FRQ PULSE MAX xxxx Hz VOLUME PULSE XXXXXXXX UUUU PULSE UNIT PULSE UNIT UNIT kg UNIT kg 10 UNIT kg 100 UNIT ton UNIT lb UNIT lb 10 UNIT lb...

Page 44: ...rror output is only available on relay no 1 The sound limit is defined in the MASS FLOW submenu Select SCALED mass flow and enter SOUND VELOCITY 1 and SOUND VELOCITY 2 The relay will make when the sound velocity exceeds the range defined by SOUND VELOCITY 1 and SOUND VELOCITY 2 SOUND VELOCITY min and max are part of the error message when ERROR has been selected ...

Page 45: ...se of auto calibration Wet calibration The calibration factor can also be changed by inserting the terminal supplied with the set into the bottom of the electronics unit Remove the terminal after programming if the signal converter is fitted with a SENSORPROM memory unit With no SENSORPROM unit the calibration factor must be set is manually Auto calibration Selecting AUTOMATIC will allow the conve...

Page 46: ...ily be used as one track system or in special cases as a three or four track system Using the SONO 3000 as a three or four track system is beyond the scope of this manual Please contact Siemens Flow Instruments for further information There is a connection between the number of tracks and which tracks may be set If installed as a one track meter the meter uses only the values set in track 1 Furthe...

Page 47: ...s 0 ZERO ADJUSTMENT The factory setting is applicable in most cases but if the user requires a very high accuracy at low flow an application dependent zero adjustment NEW AUTO ZERO is recommended Zero adjustment is initiated when the LOCK key is pressed The zero adjustment will take approx 60 seconds During the process the text BUSY and a countdown from 300 is displayed When the process is finishe...

Page 48: ... h xx Mass flow max 1300 Totalizer 1 Off Volume flow Mass flow Off Totalizer 1 direction Pos Pos Neg Bidirectional Totalizer 1 unit m3 Totalizer 2 Off Volume flow Mass flow Off Totalizer 2 direction Pos Pos Neg Bidirectional Totalizer 2 unit m3 Low flow cut off 1 5 0 9 9 Force control Off Off Max Min OUTPUT SETUP Current 1 Off Volume flow Mass flow Sound Velocity Off Current 1 direction Unidirecti...

Page 49: ...1 2000 Cable length 1 Viscosity unit mm2 s mm2 s cSt Viscosity 1 Pipe diameter 0 398 Pipe geometry unit m m inch Pipe surface roughness 0 0004 0 0000 0 0100 No of tracks 2 1 2 4 Track 1 track On On Off Track 1 track length 0 46 Track 1 track angle 60 Track 1 displacement 0 179 Track 2 track On On Off Track 2 track length 0 46 Track 2 track angle 60 Track 2 displacement 0 179 Track 3 track Off On O...

Page 50: ... h 100 l m3 60 2 60 480 ton h 100 kg ton 100 4 100 9 380 m3 h 100 l m3 100 4 20 800 ton h 100 kg ton 125 5 150 13 550 m3 h 100 l m3 150 6 50 1 200 ton h 1 t ton 150 6 220 18 850 m3 h 1 m3 m3 220 9 00 1 800 ton h 1 t ton 200 8 380 32 1 400 m3 h 1 m3 m3 380 16 3 000 ton h 1 t ton 250 10 600 48 2 200 m3 h 1 m3 m3 600 24 4 800 ton h 1 t ton 300 12 850 70 3 200 m3 h 1 m3 m3 850 34 7 000 ton h 1 t ton 3...

Page 51: ...PROM memory unit the sensor is automatically configured st at DN 400 mm Error 42 is shown for a short while The signal converter will display the corresponding flow rate 3 For correct flow measurement the following parameters must be set CONVERTER SETUP MODE BASICSETTINGS The dimension dependent settings are listed in table 2 OUTPUT SETUP Set the required output signals SENSOR CHARACTERISTICS CALI...

Page 52: ...ers Current faults are stored in ERROR PENDING and current and past faults are stored in ERROR LOG The faults are stored in the form of an error code with indication of elapsed time since error registration Power off erases the content of the ERROR LOG ERRORhandling Fault ERROR PENDING ERROR LOG 1 Error no time 1 Error no time 2 2 3 3 4 4 5 5 The first 5 faults 6 are stored here 7 8 9 10 The last ...

Page 53: ...tion in the pipe The meter detects flow in the pipe 22 ON Actual sound velocity outside the Check the setting of track length and min and max sound velocity measuringrange 23 Hardwarefault SONO 3000 defective 24 Replace the signal converter 33 34 25 ON 1 Defective power supply 1 ReplaceSONO3000 2 Supply voltage too low 2 Check supply voltage No flow 26 Force output Fatalmeasuringerror Usually appe...

Page 54: ...NT 2 NORMAL FORCED CURRENT 3 FORCE CURRENT 3 NORMAL FORCED FREQUENCY 1 NORMAL 1 Hz FREQUENCY 2 NORMAL 1 Hz RELAY 1 NORMAL FORCED RELAY 1 ON OFF RELAY 2 NORMAL FORCED RELAY 2 ON OFF MAX MAX MAX MAX SIGNAL INFORMATION In the SIGNAL INFORMATION menu it is possible to read information regarding the ultrasonic signals the flow signals and the transducers TIME FLOW In the TIME FLOW menu it is possible t...

Page 55: ... caused by variation in the attenuation due to e g air bubbles The S N RATIO is a number between 1 and 40 The typical value for water is between 20 and 35 SIGNAL TRANSDUCER The quality of the transducer and liquid oscillation is indicated by the RESONANCE LEVEL A number higher than 100 indicates satisfactory operation A value below 100 indicates mis match between transducer and liquid A value belo...

Page 56: ...rovement are always welcomed Technical data subject to change without prior notice The reproduction transmission or use of this document or its contents is not permitted without express written authority Offenders will be liable for damages All rights including rights created by patent grant or registration of a utility model or design are reserved Copyright Siemens AG 11 2005 All Rights Reserved ...

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