User Manual

SONO-VARIO
SONO-VARIOLD for Moisture Measurements of Materials
with medium Density

IMKO Micromodultechnik GmbH Telefon: +49 - (0)7243 - 5921 - 0

Im Stöck 2 Fax: +49 - (0)7243 - 90856
D - 76275 Ettlingen e-mail: [email protected]
http: //www.imko.de

I:\publik\TECH_MAN\TRIME-SONO\ENGLISH\SONO-VARIO LD\Manual_SONO-VARIO-LD.docx
 Manual SONO-VARIO LD Version 2_3 2016-05-03

User Manual SONO-VARIO LD

Thank you for buying an IMKO moisture probe.

Please carefully read these instructions in order to achieve best possible results with your
SONO-VARIO LD probe for the in-line moisture measurement. Should you have any
questions or suggestions regarding your new probe after reading, please do not hesitate to
contact our authorised dealers or IMKO directly. We will gladly help you.

List of Content:

1. Instrument Description SONO-VARIOLD ................................................................................... 4

®
1.1.1. The patented TRIME TDR-Measuring Method ............................................................. 4
®
1.1.2. TRIME compared to other Measuring Methods ........................................................... 4
1.1.3. Areas of Application for the SONO-VARIOLD ................................................................. 4
1.2. Mode of Operation ................................................................................................................. 5
1.2.1. Measurement value collection with pre-check, average value and filtering ................... 5
1.2.2. Determination of the mineral concentration with EC-TRIME ......................................... 5
1.2.3. Material Temperature Measurement .............................................................................. 5
1.2.4. Temperature compensation of the internal SONO-electronic ........................................ 5
1.2.5. Analogue Outputs ........................................................................................................... 6
1.2.1. The serial RS485 and IMP-Bus interface ....................................................................... 7
1.2.2. The IMP-Bus as a user friendly network system ............................................................ 7
1.2.3. Error Reports and Error Messages ................................................................................ 7
2. Configuration of the Measure Mode ......................................................................................... 8
2.1. Cyclic operation modes CA, CF, CH, CC and CK ................................................................. 8
2.1.1. Average Time in the measurement mode CA and CF ................................................. 10
2.1.2. Filtering at material gaps in mode CA and CF ............................................................. 10
2.1.3. Mode CC – automatic summation of a moisture quantity during one batch process. 11
2.1.4. Mode CH – Automatic Moisture Measurement in one Batch ..................................... 13
2.2. Overview of single modes for different applications ............................................................ 14
3. Initial operation and installation .............................................................................................. 15
3.1. Adjustments for initial operation .......................................................................................... 15
3.2. Selection of the calibration curve Cal1 to Cal15.................................................................. 15
3.3. Calibration Set A for general bulk goods ............................................................................. 15
3.4. Calibration Set B for different grain types ............................................................................ 18
3.4.1. Selection and application of the reference method ...................................................... 20
3.4.2. Recording measurement data in trial operation ........................................................... 20
3.4.3. Setting the calibration curve (adjustment) .................................................................... 21
3.4.4. An example for an offset setting for wheat ................................................................... 21
3.5. Creating a linear Calibration Curve for a specific Material .................................................. 22
3.5.1. Calculation for a linear 2-point calibration curve .......................................................... 22
3.5.2. Calculation for a linear 1-point calibration curve .......................................................... 23
3.5.3. Calculation for a non-linear calibration curve ............................................................... 23
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4. Connectivity to SONO Probes .................................................................................................. 24

4.1.1. Connection Plug and Plug Pinning ............................................................................... 25
4.1.2. Analogue Output 0..10V with a Shunt-Resistor ............................................................ 26
4.1.3. Connection diagramm with SONO-VIEW ..................................................................... 26
5. Installation of the Probe ............................................................................................................ 27
5.1. Further important Assembly Instructions.............................................................................. 28
5.2. What to do if the Material Flow is not optimal? .................................................................... 29
5.3. Installation of SONO-VARIO LD inside a Screw Conveyor ................................................. 30
5.4. Protection of the Probe´s Connector against Abrasion ........................................................ 31
5.5. Assembly Dimensions .......................................................................................................... 32
5.6. Mounting in curved Surfaces ................................................................................................ 34
5.7. Gas- and waterproofed Installation in a Tube or Container ................................................. 34
5.8. Exchange of the Probe Head of the VARIOXtrem/LD ......................................................... 35
5.8.1. Basic Balancing of a new Probe Head.......................................................................... 36
6. Connection of the RS485 to the SM-USB Module from IMKO............................................... 37
7. Quick Guide for the Commissioning Software SONO-CONFIG ............................................ 39
7.1.1. Scan of connected SONO probes on the serial interface ............................................. 39
7.1.2. Configuration of Measure Mode and serial SONO-interface ........................................ 40
7.1.3. Set analogue outputs of the SONO probe .................................................................... 40
7.1.4. Selection of the individual Calibration Curves .............................................................. 41
7.1.5. “Test” run in the respective Measurement Mode .......................................................... 42
7.1.6. “Measure” Run in Datalogging-Operation ..................................................................... 42
7.1.7. Basic Balancing in Air and Water .................................................................................. 43
7.1.8. Offsetting the material temperature sensor .................................................................. 44
7.1.9. Compensation of the electronic temperature ............................................................... 44
8. Technical Data SONO-VARIO LD ............................................................................................. 45
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1. Instrument Description SONO-VARIOLD

®
1.1.1. The patented TRIME TDR-Measuring Method
The TDR technology (Time-Domain-Reflectometry) is a radar-based dielectric measuring procedure
at which the transit times of electromagnetic pulses for the measurement of dielectric constants,
respectively the moisture content are determined.
SONO-VARIO LD consists of a high grade steel casing with a wear-resistant sensor head with
ceramic window. An integrated TRIME TDR measuring transducer is installed into the casing. A
high frequency TDR pulse (1GHz), passes along wave guides and generates an electro-magnetic
field around these guides and herewith also in the material surrounding the probe. Using a new
patented measuring method, IMKO has achieved to measure the transit time of this pulse with a
-12
resolution of 1 picosecond (1x10 ), consequently determine the moisture and the conductivity of
the measured material.
The established moisture content, as well as the conductivity, respectively the temperature, can
either be uploaded directly into a SPC via two analogue outputs 0(4) ...20 mA or recalled via a
serial RS485 interface.

®
1.1.2. TRIME compared to other Measuring Methods
®
In contrary to conventional capacitive or microwave measuring methods, the TRIME technology
(Time-Domain-Reflectometry with Intelligent Micromodule Elements) does not only enable the
measuring of the moisture but also to verify if the mineral concentration specified in a recipe has
been complied with. This means more reliability at the production.
TRIME-TDR technology operates in the ideal frequency range between 600MHz and 1,2 GHz.
Capacitive measuring methods (also referred to as Frequency-Domain-Technology) , depending on
the device, operate within a frequency range between 5MHz and 40MHz and are therefore prone to
interference due to disturbance such as the temperature and the mineral contents of the measured
material. Microwave measuring systems operate with high frequencies >2GHz. At these frequencies,
nonlinearities are generated which require very complex compensation. For this reason, microwave
measuring methods are more sensitive in regard to temperature variation.
SONO probes calibrate themselves in the event of abrasion due to a novel and innovative probe
design. This consequently means longer maintenance intervals and, at the same time, more precise
measurement values.
The modular TRIME technology enables a manifold of special applications without much effort due
to the fact that it can be variably adjusted to many applications.

1.1.3. Areas of Application for the SONO-VARIOLD

SONO-VARIO LD is suited for moisture measurement of different materials with medium density
like grain types, wood pellets, animal food and others. An installation is possible into containers,
hoppers and above conveyor belts.
For wood chips and other very loose materials which show a bad flowability, an installation inside a
screw conveyor is recommended due to better and homogenuous densities inside a screw
conveyor.
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1.2. Mode of Operation

1.2.1. Measurement value collection with pre-check, average value and filtering
SONO probes measure internally at very high cycle rates of 10 kHz and update the measurement
value at a cycle time of 280 milliseconds at the analogue output. In these 280 milliseconds a probe-
internal pre-check of the moisture value is already carried out, i.e. only plausible and physically
checked and pre-averaged single measurement values are be used for the further data processing.
This increases the reliability for the recording of the measured values to a downstream programmable
control system PLC significantly.
In the Measurement Mode CS (Cyclic-Successive), an average value is not accumulated and the
cycle time here is 200 milliseconds. In the Measurement Mode CA, CF, CH, CC and CK, not the
momentarily measured individual values are directly issued, but an average value is accumulated via a
variable number of measurements in order to filter out temporary variations. These variations can be
caused by inhomogeneous moisture distribution in the material surrounding the sensor head. The
delivery scope of SONO probes includes suited parameters for the averaging period and a universally
applicable filter function deployable for currently usual applications. The time for the average value
accumulation, as well as various filter functions, can be adjusted for special applications.

1.2.2. Determination of the mineral concentration with EC-TRIME

With the radar-based TRIME measurement method, it is now possible for the first time, not only to
measure the moisture, but also to provide information regarding the conductivity, respectively the
mineral concentration or the composition of a special material. Hereby, the attenuation of the radar
pulse in the measured volume fraction of the material is determined. This novel and innovative
measurement delivers a radar-based conductance value (EC-TRIME) in dS/m as characteristic value
which is determined in dependency of the mineral concentration and is issued as an unscaled value.
The EC-TRIME measurement range of the SONO probe is 0..12dS/m

1.2.3. Material Temperature Measurement

A temperature sensor is installed into the SONO-probe which establishes the casing temperature 3mm
beneath the sensor surface. The temperature can optionally be issued at the analogue output2. As the
TRIME electronics operates with a power of approximately 1.5 W, the probe casing does slightly heat
up. A measurement of the material temperature is therefore only possible to a certain degree. The
material temperature can be determined after an external calibration and compensation of the sensor
self-heating. The offset of the measured temperature value can be adjusted with help of the program
SONO-CONFIG.
Despite SONO probes show a generally low temperature drift, it could be necessary to compensate a
temperature drift in special applications. SONO probes offer two possibilities for temperature
compensation.

Temperature compensation for the measured material

Water and special materials like oil fruits and others, can show a dependency of the dielectric
permittivity when using SONO probes at high temperature ranges. The dielectric permittivity is the raw
parameter for measuring water content with SONO probes. If special materials show a very special
temperature drift, e.g. in lower temperatures a higher drift than in higher temperatures, than it could be
necessary to make a more elaborate temperature compensation. Therefore it is necessary to measure
in parallel the material temperature with the temperature sensor which is placed inside the SONO
probe. Normally this is related with high efforts in laboratory works. SONO probes offer the possibility
to set special temperature compensation parameters t0 to t5 for every calibration curve Cal1 of Cal15
(see chapter “Selection of the individual calibration curve”). Please contact IMKO should you need any
assistance in this area.

1.2.4. Temperature compensation of the internal SONO-electronic

With this method of temperature compensation, a possible temperature drift of the SONO-electronic
can be compensated. Because the SONO-electronic shows a generally low temperature drift, SONO
probes are presetted at delivery for standard ambient conditions with the parameter TempComp=0.2.
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Dependent on SONO probe type, this parameter TempComp can be adjusted for higher temperature
ranges (up to 120°C for special version) to values up to TempComp=0.75. But it is to consider that it
is necessary to make a Basic-Balancing of the SONO probe in air and water, if the parameter
TempComp is changed to another value as TempComp=0.2. The parameter TempComp can be
changed with the software tool SONO-CONFIG, in the menu "Calibration" and the window
"Electronic-Temperature-Compensation".
Attention: When changing the TempComp parameter, a new basic balancing of the
SONO probe is necessary!

1.2.5. Analogue Outputs

The measurement values are issued as a current signal via the analogue output. With the help of the
service program SONO-CONFIG, the SONO probe can be set to the two versions for 0..20mA or
4..20mA. Furthermore, it is also possible to variably adjust the moisture dynamic range e.g. to 0-10%,
0-20% or 0-30%. For a 0-10V DC voltage output, a 500R resistor can be installed in order to reach a
0..10V output.
Analogue Output 1: Moisture in % (0…20%, variable adjustable)
Analogue Output 2: Conductivity (EC-TRIME) or optionally the temperature.
In addition, there is also the option to split the analogue output 2 into two ranges: into
4..11mA for the temperature and 12..20mA for the conductivity. The analogue output
two hereby changes over into an adjustable one-second cycle between these two
(current) measurement windows.

For the analogue outputs 1 and 2 there are thus two adjustable options:
Analog Output: (two possible selections)
0..20mA 4..20mA

For very special PLC applications, the current output can be inverted into:
20mA...0mA or 20mA…4mA

Analogue Output Channel 1 and 2: The two analogue outputs of the SONO probe
can be adjusted into one to four possible selections.

1. Moist, Temp Analogue output 1 for moisture, output 2 for

material temperature.

2. Moist, Conduct Analogue output 1 for moisture, output 2 for

conductivity in ranges of 0..20dS/mS or
50dS/m

3. Moist, Analogue output 1 for moisture, output 2 for

both, temperature and conductivity (EC-
Temp/Conductivity TRIME) with an automatic current-window
change in cycles of 5 seconds.

4. Moist / Analogue output 1 for moisture, output 2 for

the standard deviation based on the single
MoistSTdDev moisture values. This function is useful in e.g.
fluid bed drier for air volume control.
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Adjustment for the Measurement Ranges

For analogue output 1 and 2 the moisture dynamic range and temperature dynamic
range can be variably adjusted. The moisture dynamic range should not exceed
100%

Moisture Range: Temp. Range:

Maximum: e.g. 20 for sand (Set in %) Maximum: 70 °C
Minimum: 0 Minimum: 0 °C
Conductivity Range: 0..20dS/m or 0…50dS/m
Dependent on probe type and moisture range, SONO probes can measure pore
water conductivities (EC-TRIME) in ranges of 5dS/m up to 50dS/m.

1.2.1. The serial RS485 and IMP-Bus interface

SONO-probes are equipped with a standard RS485 as well as the IMP-Bus interface to set and
readout individual parameters or measurement values. An easy to implement data transfer protocol
enables the connection of several sensors/probes at the RS485-Interface. In addition, SONO-probes
can be directly connected via the module SM-USB or the display module SONO-VIEW to the USB port
of a PC, in order to adjust individual measuring parameters or conduct calibrations.
Please consider: The initial default setting of the serial interface is pre-setted for the IMP-Bus. To
operate with the RS485 inside the SONO-probe, it is necessary to switch and activate the RS485
interface with help of the modul SM-USB or SONO-VIEW.
In the Support area of IMKO´s homepage www.imko.de we publish the transmission protocol of the
SONO-probes.

1.2.2. The IMP-Bus as a user friendly network system

With external power supply on site for the SONO probes, a simple 2-wire cable can be used for the
networking. By use of 4-wire cables, several probes can be also supplied with power.
Standard RS485-interfaces cause very often problems! The RS485 is usually not galvanically
isolated and therefore raises the danger of mass grindings or interferences which can lead to
considerably security problems. An RS485 network needs shielded and twisted pair cables, especially
for long distances. Depending on the topology of the network, it is necessary to place 100Ohm
termination resistors at sensitive locations. In practice this means considerable specialist effort and
insurmountable problems.
The robust IMP-Bus ensures security. SONO-probes have in parallel to the standard RS485
interface the robust galvanically isolated IMP-Bus which means increased safety. The serial data line
is isolated from the probe´s power supply and the complete sensor network is therefore independent
from single ground potentials and different grid phases. Furthermore the IMP-Bus transmit its data
packets not as voltage signals, but rather as current signals which also works at already existing
longer cables. A special shielded cable is not necessary and also stub lines are no problem.

1.2.3. Error Reports and Error Messages

SONO probes are very fault-tolerant. This enables failure-free operation. Error messages can be
recalled via the serial interface.
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2. Configuration of the Measure Mode

The configuration of SONO- probe is preset in the factory before delivery. A process-related later
optimisation of this device-internal setting is possible with the help of the service program SONO-
CONFIG. For all activities regarding parameter setting and calibration the probe can be directly
connected via the serial interface to the PC with SM-USB-Module or the SONO-VIEW display module
which are available from IMKO.

The following settings of SONO probes can be amended with the service program SONO-CONFIG:
Measurement-Mode and Parameters:
 Measurement Mode A-On-Request (only in network operation for the retrieval of measurement
values via the serial interface).
 Measurement Mode C Cyclic:
SONO-VARIO is supplied ex-factory with suited parameters in Mode CH for measuring
moisture of sand and gravel. For other applications, mode CA could be usable. Up to 6
different modes can be adjusted:

Mode CS: (Cyclic-Successive) For very short measuring processes (e.g. 2…10 seconds)
without floating average and without filter functions, with internal up to 100 measurements per
second and a cycle time of 250 milliseconds at the analogue output. Measurement mode CS
can also be used for getting raw data from the SONO-probe without averaging and filtering.
Mode CA: (Cyclic-Average-Filter) For relative short measuring processes with continual
average value, filtering and an accuracy of up to 0.1%
Mode CF: (Cyclic-Float-Average) for continual average value with filtering and an accuracy of
up to 0.1% for very slowly measuring processes, e.g. in fluidized bed dryers, conveyor belts,
etc.
Mode CK: (Cyclic-Kalman-Filter with Boost) Standard setting for SONO-MIX for use in fresh
concrete mixer with continual average value with special dynamic Kalman filtering and an
accuracy of up to 0.1%.
Mode CC: (Cyclic Cumulated) with automatic summation of a moisture quantity during one
batch process.
Mode CH: (Cyclic Hold) similar to Mode CC but without summation.
Mode CH is recommended for applications in the construction industry. If the SONO-
probe is installed under a silo flap, Mode CH can measure moisture when batch cycles are
very short, down to 2 seconds. Mode CH executes an automatic filtering, e.g. if dripping water
occurs.

Each of these settings will be preserved after shut down of the probe and is therefore stored on a
permanent basis.

2.1. Cyclic operation modes CA, CF, CH, CC and CK

For the cyclic modes the SONO probes are supplied ex-factory with suited parameters for the
averaging time and with a universally deployable filter function suited for most currently applications.
The setting options and special functions of SONO probes depicted in this chapter are only rarely
required. It is necessary to take into consideration that the modification of the settings or the
realisation of these special functions may lead to faulty operation of the probe!
For applications with non-continuous material flow, there is the option to optimise the control of the
measurement process via the adjustable filter values Filter-Lower-Limit, Filter-Upper-Limit and the time
constant No-Material-Keep-Time. The continual/floating averaging can be set with the parameter
Average-Time.
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Parameters in the Function

Measurement Mode CA, CF,
CC, CH and CK
Average-Time CA/CF: Time (in seconds) for the generation of the average value
Standard Setting: 2s can be set with this parameter.
Setting Range: 1…20 CC/CH/CK: Setting of the time for calculation of the trend or
Unit: Seconds expectation value for the Boost & Offset function.
Filter-Upper-Limit-Offset CA/CC/CF/CH/CK: Too high measurement values generated due
Standard Setting: 25% to metal wipers or blades are filtered out. The offset value in % is
Setting Range: 1….20 added to the dynamically calculated upper limit.
Unit: % Absolut
Filter-Lower-Limit-Offset CA/CC/CF/CH/CK: Too low measurement values generated due
Standard Setting: 25% to insufficient material at the probe head are filtered out. The
Setting Range: 1.….20! offset value in % is subtracted from the dynamically calculated
Unit: % Absolut lower limit with the negative sign.

Upper-Limit-Keep-Time CA/CC/CF/CH/CK: The maximum duration (in seconds) of the

Standard Setting: 10 filter function for Upper-Limit-failures (too high measurement
Setting Range: 1...100 values) can be set with this parameter.
Unit: % Absolut

Lower-Limit-Keep-Time CA/CC/CF/CH/CK: The maximum duration (in seconds) of the

Standard Setting: 10 filter function for Lower-Limit-failures (too low measurement
Setting Range: 1...100s values) for longer-lasting "material gaps", ie the time where no
Unit: Seconds material is located on the probe´s surface can be bridged.
Moisture Threshold CA/CF/CK: inactive
(start threshold in %-moisture) CC/CH: The accumulation of moisture values starts above the
Standard Setting: 0.1% „Moisture Threshold“ and from here the analogue signal is
Setting Range: 0….100% outputted. The accumulation pauses and will be frozen if the
Unit: % Absolut moisture level is below the threshold value. The No-Material-
Delay time starts and material gaps (disturbance) can be
eliminated.
No-Material-Delay CA/CF/CK: inactive
(period time) CC/CH: The accumulation stopps if the moisture value is below
Standard Setting: 10s the Moisture Threshold. The accumulation pauses for the period
Setting Range: 1….100s of the setted delay time and will be frozen if the moisture level is
Unit: Seconds below the threshold value. The SONO probes starts again in a
new batch with a new accumulation after the setted time span of
the “No-Material-Delay” is completely exceeded.
Boost CA/CF: inactive
Standard Setting: 35nn CC/CH/CK: Defines, how strong single measurement values are
Setting Range: 1….100nn weighted dependent on deviation to the current expected average
Unit: without unit! value. With e.g. Boost=35, a single measurement value is
weighted with only 65% (100-35) for a new average value.
Offset CA/CF: inactive
Standard Setting: 0.5% CC/CH/CK: Non-linearities in the process can be compensated
Setting Range: 0 ….5% by higher weighting of higher values. Can be used e.g. in fluid bed
Unit: % Absolut dryers or under silo flaps where non-linearities can occur due to
changes in the material density during process. “Offset” works
together with the parameter “Average-time”.
Weight CA/CF/CK: inactive
Standard Setting: 5 values CH: Smoothing factor for analog output setting. This parameter
Setting Range: 0 …..50 influences the reaction/response time with factor 3. E.g. 15 values
 Manual SONO-VARIO LD Version 2_3 2016-05-03

Unit: Measurement Values responds to a reaction time of 15/3=5 seconds.

CK: The reaction/response time works nearly 1:1.
E.g. 15 values responds to a reaction time of 15 seconds.

Invalid Measure Count CA/CF/CK: inactive

Standard Setting: 2 values CC/CH: Number of discarded (poor) measurement values after
Setting Range: 0….. 10 the start of a new batch, when „No-Material-Delay“ has triggered.
Unit: Measurement Values The first measurement values will be rejected, e.g. due to dripping
with 3 single values per second. water.

Moisture Std. Deviation Count CA/CC/CF/CH/CK: If the parameters Temperature or EC-TRIME

Standard Setting: 5 values (RbC) are not needed, the analogue output 2 can be setted tot he
Setting Range: 0….. 20 mode Moist/Moist Std. Deviation. In this mode the standard
Unit: Measurement Values deviation of all single moisture values can be outputted. With this
with 3 single values per second. function the homogeneity of the single measurement values can
be determined and it is possible to control a regulating process,
e.g. pressure regulation.
Quick und Quick-Precision CA/CC/CF/CH/CK/CS: Recommended is Quick Precision with
With Meas Time (no. values) Meas Time=2 where the TDR pulse is detected precisely. For still
a little better accuracies, Meas Time can be increased, however
Unit: without unit!
the single measurement cycle is increased by 60 milliseconds per
step (e.g. from 280ms to 340ms). Older SONO probe versions do
not have this Quick Precision function!

2.1.1. Average Time in the measurement mode CA and CF

SONO probes establishes every 200 milliseconds a new single measurement value which is
incorporated into the continual averaging and issues the respective average value in this timing cycle
at the analogue output. The averaging time therefore accords to the “memory” of the SONO probe.
The longer this time is selected, the more inert is the reaction rate, if differently moist material passes
the probe. A longer averaging time results in a more stable measurement value. This should in
particular be taken into consideration, if the SONO probe is deployed in different applications in order
to compensate measurement value variations due to differently moist materials.
At the point of time of delivery, the Average Time is set to 4 seconds. This value has proven itself to be
useful for many types of applications. At applications which require a faster reaction rate, a smaller
value can be set. Should the display be too “unstable”, it is recommended to select a higher value.

2.1.2. Filtering at material gaps in mode CA and CF

A SONO probe is able to identify, if temporarily no or less material is at the probe head and can filter
out such inaccurate measurement values (Filter-Lower-Limit). Particular attention should be directed
at those time periods in which the measurement area of the probe is only partially filled with material
for a longer time, i.e. the material (sand) temporarily no longer completely covers the probe head.
During these periods (Lower-Limit-Keep-Time), the probe would establish a value that is too low. The
Lower-Limit-Keep-Time sets the maximum possible time where the probe could determine
inaccurate (too low) measurement values.
Furthermore, the passing or wiping of the probe head with metal blades or wipers can lead to the
establishment of too high measurement values (Filter-Upper-Limit). The Upper-Limit-Keep-Time
sets the maximum possible time where the probe would determine inaccurate (too high) measurement
values.
Using a complex algorithm, SONO probes are able to filter out such faulty individual measurement
values. The standard settings in the Measurement Mode CA and CF for the filter functions depicted
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in the following have proven themselves to be useful for many applications and should only be altered
for special applications.

It is appropriate to bridge material gaps in mode CA with Upper- and Lower-Limit Offsets and Keep-
Time. For example the Lower-Limit Offset could be adjusted with 2% with a Lower-Limit Keep-Time of
5 seconds. If the SONO probe determines a moisture value which is 2% below the average moisture
value with e.g. 8%, than the average moisture value will be frozen at this value during the Lower-Limit
Keep-Time of 5 seconds. In this way the material gap can be bridged. This powerful function inside the
SONO probe work here with a highpass filter where the higher moisture values are used for building
an average value, and the lower or zero values are filtered out. In the following this function is
described with SONO parameters.

Sufficient material for an

Material gaps over e.g. 3 seconds which must
accurately moisture
be bridged for an accurately measurement with
measurement value of e.g.8%
a Lower-Limit Keep-Time of 5 seconds.

The following parameter setting in mode CA fits a high pass filtering for bridging material gaps.

The Filter Upper-Limit is here deactivated with a value of 20, the Filter Lower-Limit is set to 2%.
With a Lower-Limit Keep-Time of 5 seconds the average value will be frozen for 5 seconds if a
single measurement value is below the limit of 2% of the average value. After 5 seconds the
average value is deleted and a new average value building starts. The Keep-Time function stops if
a single measurement value lies within the Limit values.

2.1.3. Mode CC – automatic summation of a moisture quantity during one batch process
Simple PLCs are often unable to record moisture measurement values during one longer batch
process with averaging and data storage. Furthermore there are applications without a PLC, where
accumulated moisture values of one batch process should be displayed to the operating staff for a
longer time. Previously available microwave moisture probes on the market show two disadvantages:
1. Such microwave probes need a switching signal from a PLC for starting the averaging of the
probe. This increases the cabling effort.
2. Material gaps during one batch process will lead to zero measurement values which falsify the
accumulated measurement value considerably, recipe errors can occur.
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Unlike current microwave probes, SONO probes work in mode CC with automatic summation, where it
is really ensured that the measured material has contact with the probe. This increases the reliability
for the moisture measurement during one complete batch process. The summation is only working if
material fits at the probe. Due to precise moisture measurement also in the lower moisture range,
SONO probes can record, accumulate and store moisture values during a complete batch process
without an external switching or trigger signal. The SONO probe “freezes” the analogue signal as long
as a new batch process starts. So the PLC has time enough to read in the “freezed” moisture value of
the batch. For applications without a PLC the “freezed” signal of the SONO probe can be used for
displaying the moisture value to a simple 7-segment unit as long as a new batch process will start.
With the parameter Moisture Threshold, the SONO probe can be configured to the start moisture
level where the summation starts automatically. Due to an automatic recalibration of SONO probes, it
is ensured that the zero point will be precisely controlled. The start level could be variably set
dependent to the plant. Recommended is a level with e.g. 0.5% to 1%.
With the parameter No-Material-Delay a time range can be set, where the SONO probe is again
ready to start a new batch process. Are there short material gaps during a batch process which are
shorter than the “No-Material-Delay”, with no material at the probes surface, then the SONO probe
pauses shortly with the summation. Is the pause greater as the “No-Material-Delay” then the probe is
ready to start a new batch process.
Please note: If the PLC already accumulates single moisture values in higher cycle rates, than an
additional automatic summation of a moisture quantity inside the SONO-probe during one batch
process will produce errors. Here mode CS is recommended.

How can the mode CC be used, if the SONO probe cannot detect the „moisture threshold“ by
itself, e.g. above a conveyor belt if there is constant material covering above the probe head
over a longer time: In this case, a short interrupt of the probe´s power supply, e.g. for about 0.5
seconds with the help of a relay contact of the PLC, can restart the SONO probe at the beginning of
the material transport. After this short interrupt the SONO probe starts immediately with the
summarizing and averaging.

Please note: It should be noted that no material sticks on the probes surface. Otherwise the moisture
zero point detection of the probe will be shifted up and the probe would not be detect a moisture low
value below the “Moisture-Threshold”.
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Time chart for mode CC

2.1.4. Mode CH – Automatic Moisture Measurement in one Batch

Mode CH can be used for applications in the construction industry. If the SONO-probe is installed
under a silo flap, Mode CH can measure moisture when batch cycles are very short, down to 5
seconds (and perhaps shorter). Mode CH executes an automatic filtering with Invalid Measure
Count, e.g. if dripping water occurs or for filtering out the first false measurements after opening the
silo flap. The measurement cycle starts if the probe detects the Moisture Threshold value and freeze
the analogue output value until the next cycle.
Mode CH (Cyclic Hold) is identically to Mode CC but without summation.
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2.2. Overview of single modes for different applications

The following table gives an overview about possible parameter settings in different modes:
Application/ Sand/ Above a Inside a Inside a Gene- in a screw At the
Installation Gravel conveyor mixer fluid bed rally conveyor end of a
and specific under a belt dryer simple with screw
Parameters silo flap appli- filtering conveyor
cations options
due to Long
metal term
spiral process
Operating CH CH CK CK CA CK CF
Mode
Average- 2 2 5 5 10 10 30
Time
Filter- inactiv inactiv inactiv inactiv e.g. 20 inactiv e.g. 20
Upper-Limit 100 100 100 100 100
Offset
Filter- inactiv inactiv inactiv inactiv e.g. 10 inactiv e.g. 5
Lower-Limit 100 100 100 100 100
Offset
Upper- inactiv inactiv inactiv inactiv e.g. 10 inactiv e.g. 10
Limit-Keep- 10 10 10 10 10
Time
Lower- inactiv inactiv inactiv inactiv e.g. 10 inactiv e.g. 10
Limit-Keep- 10 10 10 10 10
Time
Moisture 0.1 0.1 0.1 0.1 - 0.1 -
Threshold
No-Material- 10 10 10 10 - inactiv -
Delay
Boost 35 35 20 20 - 20 -
Offset 0.5 0.5 1 1 - 1 -
Weight 5 5 25 25 - 50 -
Invalid 2 2 inactiv inactiv - inactiv -
Measure
Count

For very difficult applications, where it is not certain which mode is the best inside the SONO-probe,
we recommend to select mode CA with averaging time = 1 second. With help of the software SONO-
CONFIG a data record can be stored directly during process conditions. After forwarding this data set
to IMKO, we would be pleased to be at your disposal for finding the best suitable working mode.
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3. Initial operation and installation

3.1. Adjustments for initial operation
The term “adjustment” refers, in this case, to the correct setting of the calibration curve and zero offset
depending on material type and installation place where an absolute moisture value with an accuracy
of +-0,1% is important.
The SONO-VARIO LD can only be adjusted when installed in the plant as the location and the bulk
density of the material have a significant influence on moisture measurement. Adjustment must be
carried out separately for every dried product. Moisture measurement is dependent on the following
parameters:
 Location (e.g. metallic objects within the field of measurement)
 Bulk density of the material
 Type of material (product)
As soon as one of these parameters changes, another calibration curve or an adjustment must be
chosen. If all possible grain types are adjusted, it is only necessary to select the right calibration curve
when changing the grain type in the plant.

3.2. Selection of the calibration curve Cal1 to Cal15

Up to 15 different calibration curves (CAL1 ... Cal15) can be stored inside the SONO-VARIO LD.
Two calibration sets can be used for each set with Cal1 to Cal15:
Calibration Set A: for general bulk goods like wood chips, pellets, powder, pet food, etc.
Calibration Set B: for different types of grain and corn like maize, wheat, barley, soja, etc.

The different calibration curves CAL1 ... Cal15 can be activated in two ways:
A: With the stand alone module SONO-VIEW the calibration curve can be selected and activated.
B: The calibration curve (Cal1. .15) can be activated with the module SM-USB which is connected via
a PC. In the menu "Calibration" and in the window “Material Property Calibration" by selecting the
desired calibration curve (Cal1...Cal15) and with using the button “Set Active Calib”. The finally
desired and possibly altered calibration curve (Cal1. .15) which is activated after switching on the
probes power supply will be adjusted with the button "Set Default Calib”.

3.3. Calibration Set A for general bulk goods

The charts (Cal.1 .. 15) in the next two pages show different selectable calibration curves which are
stored inside the SONO probe.
Plotted is on the y-axis the gravimetric moisture (MoistAve) and on the x-axis depending on the
calibration curve the associated radar time tpAve in picoseconds. With the software SONO-CONFIG
the radar time tpAve is shown on the screen parallel to the moisture value MoistAve (see "Quick
Guide for the Software SONO-CONFIG). In air, SONO-probes measure typically 60 picoseconds
radar time, in water 1000 picoseconds.
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3.4. Calibration Set B for different grain types

If the installation is at the discharge hopper: For displaying correct moisture values it is to taken
into account that a suitable calibration curve is to adjust, depending on grain type. A zero offset of
SONO-VARIO LD could be also necessary due to installation place.
If the outfeed is continually and the SONO-VARIO LD is continually covered with grain, then the
calibration curve has to be selected “with TC” (Temperature Compensation). However if the outfeed
is batch by batch, then the calibration curve has to be selected “without TC”, because the
temperature sensor at SONO-probe measures most of the time the air temperature, not the grain
temperature, which would lead to measurement failures.

The following charts (Cal.1 .. Cal15) show different selectable calibration curves which are stored
inside the SONO-VARIO LD.
Plotted is on the y-axis the gravimetric moisture (MoistAve) and on the x-axis depending on the
calibration curve the associated radar time tpAve in picoseconds. With the software SONO-CONFIG
the radar time tpAve is shown on the screen parallel to the moisture value MoistAve (see "Quick
Guide for the Software SONO-CONFIG).

Calibration Recommended Bulk Application

Curve for grain type density of
grain type

Cal1 Maize, without TC 0,75 Installation at the discharge hopper. The outfeed is
(TC = batch by batch and it is not secured, that the SONO-
Temperature VARIO LD is continually covered with grain.
Compensation)

Cal2 Maize, with TC 0,75 A: An installation at the beginning of the heating zone
is not allowed due to high temperature range.
(pre-setted
after delivery) B: Installation at the discharge hopper. The outfeed is
continually and the SONO-VARIO LD is continually
covered with grain.

Cal3 Wheat without TC 0,75 Pre-installed like Cal1

Cal4 Wheat with TC 0,75 Pre-installed like Cal2
Cal5 Rye without TC 0,72 Pre-installed like Cal1
Cal6 Rye with TC 0,72 Pre-installed like Cal2
Cal7 Barley without TC 0,63 Special calibration curve
Cal8 Barley with TC 0,63 Special calibration curve
Cal9 Rape and oilseeds 0.65 ? No temperature compensation necessary!
without TC
Cal10 Sunflower seeds 0,30 No temperature compensation necessary!
without TC
Cal11 Soya without TC 0,65 Special calibration curve
Cal12 Soya with TC 0,65 Special calibration curve
Cal13
Cal14
Cal15 1/10 tp Radar time and reference calibration for test
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3.4.1. Selection and application of the reference method

In order to adjust the SONO-VARIO LD for precise absolute measurements at the discharge, an off-
line measurement method must be available to serve as a reference. It must provide a high degree of
absolute precision and function with large sample volumes
Most commercially available grain-moisture measuring systems leave a great deal to be
desired regarding both of these aspects!
The SONO-VARIO LD measures the average value continuously over a volume of 1-2 litres. In moving
grain, the measurement volume acquired in the averaging time increases many times over. It therefore
requires a lot of time and effort to check this very representative value with a reference instrument that
shows a sample quantity in the millilitre range. There are also factors that can affect measurement,
such as temperature and conductivity, that can be ignored when using SONO-VARIO LD due to the
TDR radar method of measurement.
Thus, the most suitable method for determining the exact moisture of the grain is to use a drying oven.
Here, too, the sample volume is of decisive importance and should be at 0.5 litres.
When extracting the sample and taking reference measurements, the following must be observed:
 The samples for the reference measurements should be extracted from as close as possible
to the probe. The distribution of moisture in the grain dryer can vary greatly.
 When using a calibrated instrument with small sample volumes, several samples must be
extracted and their arithmetical average calculated.
 Please note that calibrated instruments can also produce incorrect measurements that can lie
between 2% in the lower and even 5% in the upper moisture range.
After the dryer or the silo has been filled, the SONO-VARIO LD moisture value must show a valid
reading.

3.4.2. Recording measurement data in trial operation

The selection of the calibration curve can only be adjusted in real operation or in realistic trial
operation. The following description is based on the implementation of the SONO-VARIO LD at the
discharge, in the delivery or in the storage area.
As a general rule, only the moisture range close to the reference input is of significance for trial
operation, i.e. when determining the switch position for maize, checking should be done at about 15%.
It is more important that the SONO-VARIO LD is exactly correct in the lower area of measurement. It
is of less importance whether SONO-VARIO LD measures 26% instead of 28% in the upper range!
When extracting a sample or checking the lower reference input (e.g. 15% ), a single sample is of
course insufficient. A single sample, possibly even extracted from quite a different point than in the
direct vicinity of the probe, is not at all representative, i.e. several samples must be taken directly at
the probe and averaged!
At the start of trial operation, the suitable calibration curve can be set.
When all the preparations for extracting samples and measuring them have been made, the grain
dryer can be started up. Now, a sample of grain must be taken continuously, ideally every 15 minutes.
The SONO-VARIO LD reading and the selected calibration curve are to be noted simultaneously
with every extracted sample. This is compared with the appropriate offline-determined reference value,
which is also to be noted. As soon as the moisture is near the target moisture, the calibration curve
should be set to the best possible value, which is the nearest to the reference value.
In the following you will find a ready-to-use form for entering the measurements.
 Where continuous-flow dryers are concerned, at least 10 to 20 measurements should be
available in the range between the minimum and maximum permissible moisture content after
drying. The measurements from the still very damp discharged grain during the charge phase
should be noted but not used for the purposes of adjustment.
 For rotary dryers, only the measurements take towards the end of the drying process are of
relevance to adjustment. Here, too, at least 10 measurements are to have been documented.
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Density and moisture distribution effects in the grain can cause too low measurements during
the first one to two hours. These values should not be used for the adjustment.

3.4.3. Setting the calibration curve (adjustment)

The appropriate setting of the calibration curve should be determined on the adjustment protocol. Only
the measurements near the target moisture should be taken into account.

3.4.4. An example for an offset setting for wheat

Note: SONO-VARIO LD is pre-installed to calibration curve … for wheat.
A continuous-flow dryer is to be set for wheat. A SONO-VARIO LD has been installed whose probe is
located in the direct vicinity of the discharge point. To start with, the calibration curve is set to Cal….
for wheat. The dryer is started up and measurement recording commences. It is not until the moisture
at the discharge point falls below 18% that the measurements become of real interest and can be
used for the adjustment process. Analysis can start as soon as about 10 to 20 measurements are
available in the range from 12% to 18%.

Reference measurement TRIME-GW, Level 1 TRIME-GW deviation

17.9% 24.6% 1
17.3% 17.6% 8
17.8% 17.3% 8
17.1% 16.8% 8
16.8% 16.2% 8
16.5% 15.8% 8
15.8% 16.0% 7
15.1% 15.6% 7
14.5% 14.7% 7
13.9% 14.0% 7
13.3% 13.5% 7
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3.5. Creating a linear Calibration Curve for a specific Material

The calibration curves Cal1 to Cal15 can be easily created or adapted for specific materials with help
of SONO-CONFIG. Therefore, two measurement points need to be identified with the probe. Point P1
at dried material and point P2 at moist material where the points P1 and P2 should be far enough
apart to get a best possible calibration curve. The moisture content of the material at point P1 and P2
can be determined with laboratory measurement methods (oven drying). It is to consider that sufficient
material is measured to get a representative value.
Under the menu "Calibration" and the window "Material Property Calibration" the calibration curves
CAL1 to Cal15 which are stored in the SONO probe are loaded and displayed on the screen (takes
max. 1 minute). With the mouse pointer individual calibration curves can be tested with the SONO-
probe by activating the button "Set Active Calib". The measurement of the moisture value
(MoistAve) with the associated radar time tpAve at point P1 and P2 is started using the program
SONO-CONFIG in the sub menu "Test" and "Test in Mode CF" (see "Quick Guide for the Software
SONO- CONFIG").

Step 1: The radar pulse time tpAve of the probe is measured with dried material. Ideally, this takes
place during operation of a mixer/dryer in order to take into account possible density fluctuations of the
material. It is recommended to detect multiple measurement values for finding a best average value
for tpAve. The result is the first calibration point P1 (e.g. 70/0). I.e. 70ps (picoseconds) of the radar
pulse time tpAve corresponds to 0% moisture content of the material. But it would be also possible to
use a higher point P1´ (e.g. 190/7) where a tpAve of 190ps corresponds to a moisture content of 7%.
The gravimetric moisture content of the material, e.g. 7% has to be determined with laboratory
measurement methods (oven drying).

Step 2: The radar pulse time tpAve of the probe is measured with moist material. Ideally, this also
takes place during operation of a mixer/dryer. Again, it is recommended to detect multiple
measurement values of tpAve for finding a best average value. The result is the second calibration
point P2 with X2/Y2 (e.g. 500/25). I.e. tpAve of 500ps corresponds to 25% moisture content. The
gravimetric moisture content of the material, e.g. 25% has to be determined with laboratory
measurement methods (oven drying).

Step 3: With the two calibration points P1 and P2, the calibration coefficients m0 and m1 can be
determined for the specific material (see next page).

Step 4: The coefficients m1 = 0.0581 and m0 = -4.05 (see next page) for the calibration curve Cal14
can be entered directly by hand and are stored in the probe by pressing the button “Set”. The name of
the calibration curve can also be entered by hand. The selected calibration curve (e.g. Cal14) which is
activated after switching on the probes power supply will be adjusted with the button "Set Default
Calib”.

Attention: Use “dot” as separator (0.0581) in SONO-CONFIG, not comma !

3.5.1. Calculation for a linear 2-point calibration curve

1. Download the Excel-Sheet „SONO 2-Point LinearCalibration_Calculation“ from IMKO´s
Homepage under „Support Software“.
2. Enter into the Excel-Sheet both TP-values with the respective reference moisture values.
3. Read out both parameters m0 and m1 from the Excel-Sheet.
4. Enter, set and save both parameters m0 and m1 with help of the software „SONO-CONFIG“
in the menu „Calibration“ in the window „Material Property Calibration“ in the selected
calibration curve.
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3.5.2. Calculation for a linear 1-point calibration curve

In practice during commissioning of a SONO probe in process, it could be happen that the measured
material above the probe is only available with a single moisture value. So a 2-point calibration could
not be carried out.
The procedure described below is not as precisely like a 2-point calibration, but it could be a
compromise to achieve an acceptable result for a usable calibration curve.
Below you will find the basic steps which are necessary:

1. Measure the radar travel time Tp in the running process while the material lies or flows above the
SONO probe´s surface. Tp can be measured with help of the module SM-USB or with the display
module SONO-VIEW.
2. Determine the reference moisture M in % of the measured material which lies above the SONO
probe. Unless the material moisture is already known, the reference moisture can be determined
with an infrared- or microwave oven in the laboratory.
3
3. Determine the bulk density D of the material in kg per dm . Unless the bulk density is already
known this can be done by weighing of exactly 1 liter volume of the material.
4. Download the Excel-Sheet „SONO 1-Point LinearCalibration_Calculation“ from IMKO´s
Homepage under „Support Software“. Enter the three determined parameters Tp (Radar
travel time), M (Moisture) und D (bulk density) into the Excel-Sheet. As result you get the two
calibration curve coefficients m0 and m1.
5. Enter, set and save both parameters m0 and m1 with help of the software „SONO-CONFIG“ in the
menu „Calibration“ in the window „Material Property Calibration“ in the selected calibration
curve. The three parameters Tp, M and D can be also entered without a PC with the module
SONO-VIEW (see manual SONO-VIEW).

3.5.3. Calculation for a non-linear calibration curve

SONO probes can work also with non-linear calibration curves with polynomials up to 5th grade.
For a non-linear calibration it is necessary to calibrate with 4…8 different calibration points with
different Tp values and the related moisture values in %. To calculate nonlinear coefficients for
polynomials up to 5th grade, an EXCEL software tool from IMKO can be used.
1. Download the Excel-Sheet „SONO_NonlinearCalibration_Calculation“ from IMKO´s
Homepage under „Support Software“.
2. Enter the TP-values with the respective reference moisture values into the Excel-Sheet.
3. Read out the parameters m0 to m5 from the Excel-Sheet.
4. Enter, set and save the parameters m0 to m5 in the selected calibration curve with help of the
software „SONO-CONFIG“ in the menu „Calibration“ under the window „Material Property
Calibration“.
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4. Connectivity to SONO Probes

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4.1.1. Connection Plug and Plug Pinning

SONO-VARIO LD is supplied with a 10-pole MIL flange plug.

Assignment of the 10-pole MIL Plug and sensor cable connections:

Plug-PIN Sensor Connections Lead Colour Lead Colour

A +7V….24V Power Supply red red

B 0V Power Supply Blue Blue
D 1. Analogue Positive (+) Moisture Green Green
E 1. Analogue Return Line (-) Moisture yellow yellow
F RS485 A white white
G RS485 B brown brown
C (rt) IMP-Bus grey/pink grey/pink
J (com) IMP-Bus blue/red blue/red
K 2. Analogue Positive (+) Pink Pink
E 2. Analogue Return Line (-) Grey Grey
H Screen transparent transparent
(is grounded at the sensor. The plant
must be properly grounded!)
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4.1.2. Analogue Output 0..10V with a Shunt-Resistor

There are PLC´s which have no current inputs 0..20mA, but voltage inputs 0..10V. With the help of a
shunt resistor with 500 ohm (in the delivery included) it is possible to generate a 0..10V signal from the
current signal 0..20mA. The 500 ohm shunt resistor should be placed at the end of the line resp. at the
input of the PLC. Following drawing shows the circuit principle.

4.1.3. Connection diagramm with SONO-VIEW

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5. Installation of the Probe

The installation conditions are strongly influenced by the constructional circumstances of the
installation facility. The ideal installation location must be established individually. For measuring
bulk goods, the SONO-VARIO should ideally be installed under a silo valve, which has many
advantages (see below).

Installation of the SONO-VARIO for measuring bulk goods under a silo valve or on a conveyor belt.
Dependent on material, it is important to find the suitable angle of the mounting plate. It should
be not too steep, but also not too flat and the flowing material should cover the probes surface
completely during flowing.

The installation inside a silo could be also possible, but it must be observed, that during filling and
emptying, no material (e.g. sand) can be stick on the probes surface, which could be result in
measurement errors. The following instructions should be followed when installing the probe:
The SONO-VARIO LD should be installed ideally under a valve of the silo, which has many
advantages:
1. The material flows constant and therefore the material density is constant which guarantees
more precise measurement values.
2. Due to higher material pressure, the probe´s surface is cleaned continously. Material sticking
and therefore measurement errors are be prevented.
3. The SONO-VARIO can detect clearly the start and the end of a batch process. So the SONO-
VARIO can calculate an automatic summation of the moisture quantity during one batch
process in mode CC. Even short batches with few material can be precisely measured.
Further advantage is that the PLC programming can be made more simple without switching
signals.
Unfavourable conditions for moisture probes occur if the probes are installed inside silos or
inside the outlets.
There are materials which are sticky and adhere, even at near-vertical walls. Such an installation
place inside a silo can lead to measurement failures because the SONO probe cannot be
controlled visually.
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5.1. Further important Assembly Instructions

The following instructions should be followed when installing the probe:
 The universal holder should be installed direct under a silo flap, so that the flowing material
covers the moisture probe completely.
 The installation locations may not be situated beneath the inlets for additives.
 In case of an uneven base, the probe must be installed at the highest point of the base. No water
may accumulate at the probe head as this could falsify the measurement.
 With the universal holder, deliverable by IMKO, the SONO-VARIO can be placed above a
conveyor belt. Particularly with inhomogeneous or loose sand, the material can be constantly
condensed, which leads to higher measurement results.
 Areas with strong turbulences are not ideal for the installation. There should be a continuous
material flow above the probe head.
 For special installations inside mixing containers it should be noted that the stirring movement of
blades should be conducted without gaps above the probe head.
 The probe should not be installed in the direct vicinity of electrical disturbing sources such as
motors.
 In case of curved installation surfaces in containers, the centre of the probe head should be flush
with the radius of the container wall without disturbing the radial material flow in the container.
The probe may not project and come in contact with blades or wipers.
 The probe connector should be protected against splashing water after installation.

Attention! Risk of Breakage!

The probe head is made of hardened special steel and a very wear-resistant ceramic in order to
warrant for a long life-span of the probe. In spite of the robust and wear-resistant construction, the
ceramic plate may not be exposed to any blows as ceramic is prone to breakage.

Attention! Risk of Overvoltage!

In case of welding work at the plant, all probes must be completely electrically disconnected.
SONO-probes need a stabilized power supply with 7V-DC to max. 24 V-DC. With unstabilzed power
supply there is the risk of overvoltage. We strongly suggest not to use unstabilized power supplies.

Attention! Risk of Malfunction!

1. In larger concrete plants it could be possible, that there are different mass potentials for different
power lines in use, especially if the PLC is installed in larger distances to the moisture probe. Here
it could come to problems that the analogue moisture signal 0(4)..20mA could not be measured
correctly in the PLC. With such a problem we recommend to use an isolated powerbox for the
SONO probe. Available upon request by IMKO.
2. Take care that there are no other electromagnetic fields nearby the SONO probe. E.g. another
moisture probe installed beside or in opposite of the SONO probe could influence the
measurement field.

Any damage caused by faulty installation is not covered by the warranty!

Abrasive wear of sensor parts is not covered by the warranty!

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5.2. What to do if the Material Flow is not optimal?

But even the best sensor technology can deliver good results, if special limits are respected
concerning installation place, environmental conditions and the associated bulk density of the
measured material.

There are plants where the material flow is so bright, that the material height is too less above the
probes surface. Following picture shows a funnel chute where guiding plates left and right and also
above the probe are bundling the material flow. Especially with sticky sand or other sticky materials it
is recommended that the guiding plates are coated with PTFE.

Please consider: The minimum material height above the probes surface is 30mm.

It is also possible to implement filter functions in the SONO probe with Upper- and Lower Limit (please
take a look under chapter „Operation Mode…“).
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5.3. Installation of SONO-VARIO LD inside a Screw Conveyor

The installation of SONO-VARIO LD inside a screw conveyor ensures optimum conditions concerning
material flow and material density, because the measured material is not loose but is condensed by
the screw.

The SONO probe can be installed along the screw conveyor. It is recommended to attain a mounting
angle with a limit value of 30°, to ensure that enough material lies above the probe´s surface.
Optionally the spiral conveyor can be cutted, so that a plug formation ensures that enough materials
lies above the probes´s surface.
It is also possible to install the probe at the end of the screw conveyor, where it is also ensured that
enough material, in a backlog with a relative constant density lies above the probe´s surface.
It is recommended to use measurement mode CF if the spiral is cutted out of if the probe is installed
at the end of the screw conveyor.

Furthermore it is possible to install the SONO probe in the middle of the screw conveyor without a cut
out of the spiral. Here it is necessary to set appropriate filter algorithms, because the metal of the
spiral has an influence of the measurement. The appropriate parameters have to be found, dependent
on screw velocity.
It is recommended to use measurement mode CK if the probe is installed in the middle of the screw
conveyor without a cut out of the spiral.
Please take also a look the chapter “Overview of single modes for different applications”.
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5.4. Protection of the Probe´s Connector against Abrasion

If sand and gravel flows above the buffle plate and could touch the probe connector of the SONO-
probe, than it is recommended to mount an extra protection for the probe´s connector. This is feasible
e.g. with a commercial flexible garden hose with an inner diameter of 27mm. The hose can be slotted
longitudinally and can be mounted around the connector and the cable. It could be fixed with cable
ties. The following picture shows this solution for protection of the probe´s connector.

Alternatively, the included shrink sleeve over the cable can be used. After installation of the SONO-
probe and connection of the MIL-connector, the shrink sleeve can be shrinked with a hot air blower.
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5.5. Assembly Dimensions

SONO-VARIO LD can either be installed at the base or the side wall of containers. One fact to
consider is that the installation into the container base also enables the measurement of smaller
material quantities. A mounting flange is available for SONO-VARIO LD. The flange can both be
welded on to the base and the side wall of the container. The probe can be adjusted to the
correct position, respectively correct installation height.

SONO-VARIOLD
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Dimensions of the Mounting Flange

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5.6. Mounting in curved Surfaces

In order to prevent the probe head from projecting and interfering with wipers, the centre of the
probe head should be flush with the radius of the wall. The ceramic must be laterally aligned to
the rotational axis as the gap towards the wipers is smallest in this position.
In order to ensure that the probe head is completely covered with material, the probe is best
positioned near the base. In order to prevent water from accumulating above the sensor head,
which could falsify the measurement, an installation angle of approximately 30° above the base
centre is recommended.

5.7. Gas- and waterproofed Installation in a Tube or Container

For a pressure-tight installation of a SONO probe in a vessel or a tube, a flange installation is
recommended. For such applications we recommend to use IMKO´s moisture probe SONO-
FLANGE.

Information upon request.

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5.8. Exchange of the Probe Head of the VARIOXtrem/LD

At the SONO-VARIO LDXtrem and VARIOLD not only the ceramic plate but the whole metal/ceramic
wear-resistant probe head can be exchanged.
This is how easy it is to exchange the wear-resistant probe head:
- Loosen the 4 fastening screws (look for the right sequence of washer and gasket rings).
- Lift off the probe head carefully so that the robust spring contacts in the interior are canted as
little as possible.
- Clean the surface inside the probe body for the O-Ring.
- Place the probe head so that the two spring contacts are inserted in the contact bushings.
- Screw the 4 fastening screws back on. It is to consider, that the 4 screws “find” the 4 holes in the
green epoxy plate inside the probe.
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5.8.1. Basic Balancing of a new Probe Head

The probe heads are all identical and are manufactured to fit precisely. In spite of this fact, after an
exchange, it is necessary to make a basic calibration in air and water, that SONO-VARIO LDXtrem/LD
measures precise and accurate with the new probe head. Therefore some work-steps are required.
Basic calibration procedure:
1. Provide a small container with water in which the probe head can be plunged in. For the first
calibration point in air the probe head must be completely dry. If appropriate dry it with a towel.
2. Unplug the blind cap of the calibration connector and plug in the calibration connector.
3. Plug in the MIL-connector with power supply to the probe. The blue LED is on for 3 seconds and
start with a slow blinking for the next 10 seconds preparation time for the first calibration point in
air. Therefore the dry probe head must be free in air. When the LED is on continual for 5 seconds
the first calibration point is completed in air.
4. Now the blue LED starts with a quicker blinking during 10 seconds preparation time for the
second point in water. During this 10 seconds the probe head must be plunged in water. When
the LED is on continual for 5 seconds the calibration is completed in water. After that the LED is
off.
5. If the calibration should be failed, the blue LED will be blinking continual.
6. Unplug the MIL connector and the calibration connector. Plug in the blind cap of the calibration
connector. Plug in the MIL connector again. The blue LED should be active continual now.
SONO-VARIO LD is ready to use. With strong pressing of a hand to the probe head, the
analogue moisture output 4..20mA should be respond.

If necessary the basic balancing procedure could be repeated several times.

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6. Connection of the RS485 to the SM-USB Module from IMKO

The SM-USB provides the ability to connect a SONO probe either to the standard RS485 interface or
to the IMP-Bus from IMKO. In fact that the IMP-Bus is more robust and enables the download of
a new firmware to the SONO probe, the SONO probes are presetted ex-factory to the IMP-Bus.
So it is recommended to use the IMP-Bus for a serial communication. Both connector ports are
shown in the drawing below.
The SM-USB is signalling the status of power supply and the transmission signals with 4 LED´s. When
using a dual-USB connector on the PC, it is possible to use the power supply for the SONO probe
directly from the USB port of the PC without the use of the external AC adapter.

How to start with the USB-Module SM-USB from IMKO

 Install USB-Driver from USB-Stick.
 Connect the SM-USB to the USB-Port of the PC and the installation will be accomplished
automatically.
 Install Software SONOConfig-SetUp.msi from USB-Stick.
 Connection of the SONO probe to the EX9531 via RS485A, RS485B and 0V.
 Check the setting of the COM-Ports in the Device-Manager und setup the specific COM-Port with
the Baudrate of 9600 Baud in SONO-CONFIG with the button "Bus" and "Configuration" (COM1-
COM15 is possible).
 Start “Scan probes” in SONOConfig.
 The SONO probe logs in the window „Probe List“ after max. 30 seconds with its serial number.

Note 1:
In the Device-Manager passes it as follows:
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Control Panel  System  Hardware  Device-Manager

Under the entry “Ports (COM & LPT) now the

item “USB Serial Port (COMx)” is found.

COMx set must be between COM1….COM9

and it should be ensured that there is no
double occupancy of the interfaces.
If it comes to conflicts among the serial port or the USB-SM has been found in a higher COM-port, the
COM port number can be adjusted manually:
By double clicking on "USB Serial Port" you can go into the properties menu, where you see
"connection settings" – with "Advanced" button, the COM port number can be switched to a free
number.

After changing the COMx port settings, SONO-CONFIG must be restarted.

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7. Quick Guide for the Commissioning Software SONO-CONFIG

With SONO-CONFIG it is possible to make process-related adjustments of individual parameters of
the SONO probe. Furthermore the measurement values of the SONO probe can be read from the
probe via the serial interface and displayed on the screen.
In the menu "Bus" and the window "Configuration" the PC can be configured to an available COMx-
port with the Baudrate of 9600 Baud.

7.1.1. Scan of connected SONO probes on the serial interface

In the menu "Bus" and the window "Scan Probes" the serial bus can be scanned for attached SONO
probes (takes max. 30 seconds).
SONO-CONFIG reports one or more connected and founded SONO probes with its serial number in
the window “Probe List“. One SONO probe can be selected by klicking.
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7.1.2. Configuration of Measure Mode and serial SONO-interface

In "Probe List" with "Config" and "Measure Mode & Parameters” the SONO probe can be adjusted to the
desired measure mode CA, CF, CS, CK, CC or CH (see Chapter “Configuration Measure Mode”).
Furthermore the serial interface inside the SONO probe can be selected to IMP-Bus, RS485 or both
interfaces. Due to very robust behavior it is recommended to select the IMP-Bus.

7.1.3. Set analogue outputs of the SONO probe

In the menu "Config" and the window "Analog Output" the two analogue outputs of the SONO probe
can be configured (see Chapter “Analogue outputs..”).
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7.1.4. Selection of the individual Calibration Curves

In the menu "Calibration" and the window "Material Property Calibration" the calibration curves
CAL1 to Cal15 which are stored in the SONO probe are loaded and displayed on the screen (takes
max. 1 minute). With the mouse pointer individual calibration curves can be activated and tested with
the SONO-probe by activating the button "Set Active Calib". Furthermore, the individual calibration
curves CAL1 to Cal15 can be adapted or modified with the calibration coefficients (see Chapter
“Creating a linear calibration curve”).

The desired and possibly altered calibration curve (Cal1. .15) which is activated after switching on the
probes power supply can be adjusted with the button "Set Default Calib”.
The calibration name can be entered in the window “Calibration Name”.
The coefficients m0 to m1 (for linear curves) and m0 to m5 (for non-linear curves) can be entered and
adjusted directly by hand with the buttons “Set” and “Save”. Possible are non-linear calibration curves
with polynomials up to fifth order (m0-m5).

Attention: Use “dot” as separator not comma, for coefficients m0 to m5 !

Determination of the parameters m0 and m1 for a linear calibration curve (see also chapter
“Creating a linear calibration curve…”
1. Download the Excel-Sheet „SONO_LinearCalibration_Calculation“ from IMKO´s Homepage
in the dropdown menu „Support Software“.
2. Enter into the Excel-Sheet both TP-values with the respective reference moisture values.
3. Read out both parameters m0 and m1 from the Excel-Sheet.
4. Enter, set and save both parameters m0 and m1 in the selected calibration curve.
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7.1.5. “Test” run in the respective Measurement Mode

In the menu "Test" and the window "Test in Mode CA to CF" the measured moisture values “MoistAve”
(Average) of the SONO probe are displayed on the screen and can be parallel saved in a file. In the menu
"Test" and the window "Test in Mode CS" the measured single measurement values “Moist” (5 values per
second) of the SONO probe are displayed on the screen and parallel stored in a file. In „Test in Mode A“
single measurement values (without average) are displayed on the screen and can also be stored in a file.
Attention: for a test run in mode CA, CH, CC, CF, CS or A it must be ensured that the SONO
probe was also set to this mode (Measure Mode CA, CF, CS, A). If this is not assured, the
probe returns zero values.

Following measurement values are displayed on the screen:

MoistAve Moisture Value in % (Average)
MatTemp Temperature
EC-TRIME Radar-based-Conductivity EC-TRIME in dS/m (or mS/cm)
TDRAve TDR-Signal-Level for special applications.
DeltaCount Number of single measurements which are used for the averaging.
tpAve Radar time (average) which corresponds to the respective moisture value.

By clicking „Save“ the recorded data is saved in a text file in the following path:
\SONO-CONFIG.exe-Pfad\MD\Dateiname
The name of the text file Statis+SN+yyyymmddHHMMSS.sts is assigned automatically with the
serial number of the probe (SN) and date and time. The data in the text file can be evaluated with
Windows-EXCEL.

7.1.6. “Measure” Run in Datalogging-Operation

In the menu "Datalogging" it is possible to aquire and store measurement data from several SONO
probes with variable and longer cycle rates in a datalogger-operation, e.g. to store measurement data
during a long-term drying cycle.
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7.1.7. Basic Balancing in Air and Water

SONO probe heads are identical and manufactured precisely. After an exchange of a probe head it is
nevertheless advisable to verify the calibration and to check the basic calibration and if necessary to
correct it with a “Basic Balancing”.
With a “Basic Balancing” two reference calibration measurements are to be carried out with known set-
points ("RefValues"). For the reference media, different calibration materials are used, dependent on
the SONO probe type. For SONO probes with a ceramic measurement window, air and water (tap
water) is used. For other SONO probes like SONO-GS1 glass beads are used for basic calibrations
(on request).
Attention: Before performing a “Basic Balancing” it must be ensured that the SONO
probe was set to “Measure Mode” A. If this is not assured, the probe returns zero values.
After a “Basic Balancing” the SONO probe has to be set to “Measure Mode C” again,
because otherwise the probe would not measure continuously!
In the menu "Calibration" and the window "Basic Balancing" the two set-point values of the radar
time tp are displayed with 60ps and 1000ps.
1. Reference set-point A: tp=60ps in air (the surface of the probe head must be dry!!)
The first set-point can be activated with the mouse pointer by clicking to No.1. By activating
the button "Do Measurement" the SONO probe determines the first reference set-point in air.
In the column „MeasValues“ the measured raw value of the radar time t is displayed (e.g.
1532.05 picoseconds).
2. Reference set-point B: tp=1000ps in water. The SONO probe head has to be covered with
water in a height of about 50mm. The second set-point can be activated with the mouse
pointer by clicking to No.2. By activating the button "Do Measurement" the SONO probe
determines the second reference set-point in water. In the column „MeasValues“ the
measured raw value of the radar time t is displayed.
3. By activating the button „Calculate Coeffs“ and „Coeffs  Probe“ the alignment data is
calculated automatically and is stored in the SONO probe non-volatile. With a “Test run” (in
Mode A) the radar time tp of the SONO probe should be now 60ps in air and 1000ps in water.
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7.1.8. Offsetting the material temperature sensor

In the menu „Calibration“ and the window „Material Temp Offset“,

a zero point offset can be adjusted for the material temperatur sensor
which is installed inside the SONO probe. In this example a
temperature deviation of +5° C is produced by inside self-warming of
the SONO probe. The correction value -5 can be setted in the Coeff0
window.

The example shows the parameters for displaying the temperature

in the unit: Degree Fahrenheit.

7.1.9. Compensation of the electronic temperature

With this method of temperature compensation, a possible
temperature drift of the SONO-electronic can be compensated.
Because the SONO-electronic shows a generally low temperature
drift, SONO probes are presetted at delivery for standard ambient
conditions with the parameter TempComp=0.2. Dependent on
SONO probe type, this parameter TempComp can be adjusted for
higher temperature ranges (up to 120°C for special high
temperature version) to values up to TempComp=0.75. But it is to
consider that it is necessary to make a Basic-Balancing of the
SONO probe in air and water, if the parameter TempComp is
changed to another value as TempComp=0.2. The parameter
TempComp can be changed with the software tool SONO-CONFIG,
in the menu "Calibration" and the window "Electronic-
Temperature-Compensation".
Attention: When changing the TempComp parameter, a
new basic balancing of the SONO probe is necessary!
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8. Technical Data SONO-VARIO LD

SENSOR DESIGN
Casing: High Grade Steel V2A 1.4301
SONO-VARIOLD: The probe head surface consists of stainless steel with
abrasion-resistant special ceramic.

Available are high-temperature versions of the SONO-VARIO LD up to 150°C

with external measurement transformer SONO-ES upon request!

MOUNTING
Sensor Dimensions:
SONO-VARIOLD: 108 x 71mm (Diameter x Length)

The mounting flange can be screwed on to the rear side of any container, hopper or silo.

MEASUREMENT RANGE MOISTURE

The sensor measures from 0% up to the point of material saturation. Measurement
ranges up to 100% moisture (pure water) are possible with a special calibration.

MEASUREMENT RANGE CONDUCTIVITY

The sensor, as a material-specific characteristic value, delivers the radar-based conductance
(RbC – Radar-based-Conductance) in a range of 0…12dS/m. The conductivity range is reduced
in moisture measurement ranges >50%.

MEASUREMENT RANGE TEMPERATURE

Measurement Range: 0°C …70°C
The temperature is measured 3mm beneath the wear-resistant sensor head inside the
sensor casing and is issued at the analogue output 2. The material temperature can be
measured with an external calibration and compensation of the sensor intrinsic-heating.
On request: version with higher temperature range!

MEASUREMENT DATA-PREPROCESSING
MEASUREMENT MODE CA: (Cyclic-Average) For relative short measuring processes with
continual average value, filtering and an accuracy of up to 0.1%
MEASUREMENT CF: (Cyclic-Float-Average) For very slow measuring processes with
floating average value, filtering and an accuracy of up to 0.1%
MEASUREMENT MODE CS: (Cyclic-Successive) For very short measuring processes
without floating average with internal up to 100 measurements per second and a cycle time of
200 milliseconds at the analogue output.
Mode CC: (Cyclic Cumulated) with automatic summation of a moisture quantity during one
batch process.
Mode CH: (Cyclic Hold) similar to Mode CC but without summation.
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SIGNAL OUTPUT
2 x Analogue Outputs 0(4)…20mA
Analogue Output 1: Moisture in % (e.g. 0..20% variably adjustable)
Analogue Output 2: Conductivity (EC-TRIME/ RbC) 0..20dS/m, or optionally the
temperature or the standard deviation.
In addition, there is the option to split the analogue output 2 into two ranges: into
4..11mA for the temperature and 12..20mA for the conductivity. The analogue output
2 hereby changes over into an adjustable 5 second cycle between these two
(current) measurement windows.
The two analogue outputs can be variably aligned with the SONO-CONFIG software.
For a 0-10V DC voltage output, a 500R resistor can be installed.

CALIBRATION
A maximum of 15 different calibrations can be stored inside the probe. For special
th
materials, variable calibrations with polynomials up to the 5 order are possible. A
zero point correction can be performed easily with the SONO-CONFIG software.

COMMUNICATION
A RS485 interface enables network operation of the probe, whereby a data bus
protocol for the connection of several SONO probes to the RS485 is implemented by
default. The connection of the probe to industrial busses such as Profibus, Ethernet,
etc. is possible via optional external modules (available upon request).

POWER SUPPLY
+7V to max. +24V-DC, 1.5 W max.
Attention: Do not use unstabilized power supplies. Risk of overvoltage !

AMBIENT CONDITIONS
0 - 70°C
On request: High temperature version with external measurement transformer SONO-ES.

MEASUREMENT FIELD EXPANSION

SONO-VARIOLD: Approximately 70 - 100 mm, depending on material and moisture.

CONNECTOR PLUG
The sensor is equipped with a robust 10-pole MIL flange connector. Readymade connection
cables with MIL connectors are available in cable lengths of 4m, 10m, or 25 m.
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Precise Moisture Measurement

in hydrology, forestry, agriculture, environmental and earth science,

civil engineering, as well as individual applications!