IETG Intrinsically-Safe FlowHawk Installation, Operation, and Maintenance Manual October 2012 QR 775012 A4 IETG Ltd. Cross Green Industrial Estate Cross Green Way Leeds LS9 0SE England +44 (0)8450 179 333 www.ietg.co.
ii IETG FlowHawk Manual 2012 ADS LLC. All rights reserved. ADS , Profile, IntelliServe, FlowHawk , and Qstart are either trademarks or registered trademarks of ADS LLC. Enfora is a trademark of Enfora, Incorporated. Microsoft and Windows are registered trademarks of Microsoft Corporation. Scotchkote is a trademark of 3M. Teflon is a registered trademark of E.I. du Pont de Nemours and Company. Telog is a registered trademark of Telog Instruments.
Table of Contents iii Table of Contents Chapter 1 Introduction……… ................... 1-1 Intrinsic Safety ............................................................... 1-2 FlowHawk System Certification.............................. 1-2 Installation and IS Considerations ........................... 1-5 Special Conditions for Safe Use.............................. 1-5 Maintenance Restrictions ...............................................
iv IETG FlowHawk Manual Chapter 3 Sensor Installation and Connection………………… ................... 3-1 Investigating Site Characteristics ................................... 3-4 Flow Hydraulics ...................................................... 3-4 Pipe and Manhole Characteristics ........................... 3-5 Installing the Sensors in the Pipe.................................... 3-7 Standard Installation................................................ 3-7 Special Installations ........................
Table of Contents v Chapter 5 External Power…. .................... 5-1 Installation ...................................................................... 5-2 DC Power Requirements and Consumption ............ 5-3 Installing and Wiring the IETG-Supplied Power Supply to the EMU or EMUX ......................... 5-4 Chapter 6 Configuration and Activation .. 6-1 Hardware and Software Compatibility .................... 6-2 Configuring the Monitor Location .................................
vi IETG FlowHawk Manual Chapter 8 Maintenance and Troubleshooting…………...................... 8-1 Maintaining the System Components ............................. 8-2 Gathering Replacement Parts and Supplies ............. 8-2 Inspecting the Monitor ............................................ 8-3 Inspecting, Cleaning, and Handling the Sensors ... 8-17 Replacing the SIM Card and Desiccant in the GSM Module ................................................. 8-21 Replacing EMU Components ........................
Table of Contents vii Appendix D Modbus/EMUX Configuration and Diagnostics…………. ..................... D-1 Setting up PC-to-EMU Communication ................. D-2 Running the Onboard Diagnostics.......................... D-3 Modbus Data Registers .......................................... D-7 EMUX LED Window .......................................... D-10 Appendix E System Configuration and Setup to Support the Telog Ru-33 ....... E-1 Configuring the Monitor to Support the Ru-33 .......
1-1 CHAPTER 1 Introduction The IETG Intrinsically-Safe FlowHawk™ flow monitor (powered by ADS®) measures open channel flow in sanitary sewers, storm sewers, combined sewers, and other environments to assist municipalities and other industry in addressing the following issues: Planning sewer systems (sizing and rehabilitation) Reducing infiltration and inflow (I/I) Monitoring combined sewer overflows (CSOs) Detecting and monitoring surcharges Managing inter-agency billing Monitoring
1-2 IETG FlowHawk Manual Intrinsic Safety Intrinsic safety is an electronic hardware protection concept that ensures there are no conditions under which the equipment can operate that could cause a release of energy sufficient to ignite a hazardous gas or dust mixture. Devices that meet the low power, current-limited design criteria are deemed Intrinsically Safe (IS).
Introduction 1-3 Telog unit is not IS certified, the installation will not be considered intrinsically safe if the Ru-33 is installed in the manhole with the monitor. Sensors The FlowHawk monitor supports several approved IS sensors that vary in measurement methodology, redundancy, and other features. The monitor is approved for accommodating up to two of the same or different types of IS sensors.
1-4 IETG FlowHawk Manual Power The FlowHawk flow monitor can be powered by an internal 12-volt IS battery pack (p/n 8000-0043) or an external DC power source through an external modem unit (EMU, p/n 3800-0148) or EMU/multiplexer (EMUX, p/n 106226E)). Telemetry Wireless communication is available for the FlowHawk monitor via connection to an IS quad-band GSM/GPRS module (p/n 80000052), an EMU (p/n 3800-0148), or an EMUX (p/n 106226E).
Introduction 1-5 because the Telog unit does not possess IS certification, the installation will not be considered intrinsically safe if the Telog unit is installed in the manhole with the monitor. Installation and IS Considerations When installing the FlowHawk flow monitor, carefully follow any local regulations for the installation of IS equipment. For example, many clients only allow the use of special hazardous area tools (flashlights, radios, etc.) in manholes.
1-6 IETG FlowHawk Manual Note: The 8K-CS1 is no longer available; however, IETG will continue to provide support for this sensor. • As aluminum is used at the accessible surface of this unit, in the event of rare incidents, ignition sources due to impact and friction sparks may occur. This shall be considered when it is being installed, particularly in locations that require equipment with a Group II Ga level of protection.
Introduction 1-7 Maintenance Restrictions As mentioned earlier, all FlowHawk flow monitors are manufactured to meet IS standards. The monitor’s IS certification can be voided instantly if proper maintenance and service procedures are not followed. IETG must restrict certain maintenance tasks to IETG IS-certified technicians. IETG-certified technicians carefully inspect and document their repairs of IS monitors.
1-8 IETG FlowHawk Manual If you have any questions about the procedures, warranty information, or the level of service you are allowed to perform on a monitor, contact IETG through the contact information listed at the end of this chapter.
Introduction 1-9 Warnings, Certifications, GSM/GPRS Compliance, and Conformity Manhole and sewer system work involves confined space entry and is inherently dangerous. Therefore, installers and technicians should comply with all local and governmental regulations concerning confined space entry. In addition, personnel installing and maintaining this equipment should follow all guidelines presented in this manual concerning monitor installation and maintenance.
1-10 IETG FlowHawk Manual should be followed and carried out by at least two fully trained and qualified persons. Control Drawing This drawing depicts the interconnections allowed for the FlowHawk. It is intended for use by inspection professionals for audit certificate compliance; however, it is a good tool to understand the FlowHawk flow monitoring system structure. This drawing is divided in two sections with a match point indicated.
Introduction 1-11 Control Drawing – Part 2 (left side on 2 continues from drawing 1) Note: These are excerpts from an agency controlled document for illustration purposes only. Changes to the base controlled document require the approval of the certification body. For a full-size PDF copy of this drawing, please contact IETG and request drawing number 8000BK0009-CERT. Note: The Telog Ru-33 can be connected to the COMM port on the FlowHawk monitor using the Telog-Triton Comm Cable (p/n 8000-0054-01).
1-12 IETG FlowHawk Manual GSM/GPRS Modem Information Wireless telemetry is provided via attachment of the GSM Module to the FlowHawk monitor. The GSM Module contains a thirdparty, R&TTE-CE-certified, commercial GSM/GPRS modem. Integration of the modem into the GSM Module was performed in accordance with guidelines set forth in the third party’s Integration Manual in order to maintain the FCC approval.
Introduction 1-13 The equipment may be used with flammable gases and vapors with apparatus groups IIA and IIB and with temperature classes T3 (152oC), T4, T5, and T6. The equipment is only certified for use in ambient temperatures in the range of -20oC to +60oC and should not be used outside this range. The certificate number has an ‘X’ suffix, which indicates that special conditions apply to installation and use.
1-14 IETG FlowHawk Manual Sira FlowHawk Certification Label Sira Combo Sensor CSX Series Certification Label
Introduction 1-15 Sira Direct Connect Interface Certification Label Sira GSM Certification Label Sira Communication Interface (EMU/EMUX) Certification Label EC Type Examination Certificates Sira 09ATEX2027X, Sira 09ATEX2053X, and Sira 03ATEX2482 can also be used to substantiate conformance to applicable EU laws for IS equipment.
1-16 IETG FlowHawk Manual The following pages provide a copy of the first page of each certificate. Note: These copies were current at the time of publication of this manual. To access the latest version and entire content of each certificate, please contact IETG Ltd.
Introduction First page of the FlowHawk ATEX Certificate 1-17
1-18 IETG FlowHawk Manual First page of the GSM Module ATEX Certificate
Introduction 1-19 First page of the Communications Interface Unit (from the EMU/EMUX) ATEX Certificate
1-20 IETG FlowHawk Manual IECEx (International Electrotechnical Commission Explosive) Hazardous Area Compliance The FlowHawk is covered by certificates IECEx SIR 09.0020X (FlowHawk) and IECEx SIR 09.0021X (IS GSM modem). Reference IECEx standards IEC 60079-0 : 2004; IEC 60079-11 : 2006; and IEC 60079-26 : 2006. These IECEx certificates can also be used to substantiate conformance to applicable international standards for IS equipment.
Introduction First page of the FlowHawk IECEx Certificate of Conformity 1-21
1-22 IETG FlowHawk Manual First page of the GSM Module IECEx Certificate of Conformity
Introduction 1-23 Declaration of Conformity For European (EC member country) applications, a Declaration of Conformity (DoC) is required to be kept on file at the facility responsible for repair and maintenance of this equipment. A copy of the relevant DoC is also shipped with each product. If you have any questions about the Declaration of Conformity, contact IETG Ltd at the addresses given at the end of this chapter.
1-24 IETG FlowHawk Manual Sample FlowHawk Declaration of Conformity – Page 2
Introduction 1-25 Installation and Configuration Following is the general procedure for installing and configuring a FlowHawk monitor. Refer to Chapters 3 through 7 for more details.
1-26 IETG FlowHawk Manual comprehensive information on successfully conducting these tasks.
Introduction 1-27 Product Warranty This section includes the warranty information for the IETG FlowHawk™ flow monitor. New Product Warranty All new FlowHawk monitors and associated equipment provided by IETG will be free from defects in material and workmanship for up to one (1) year following the delivery date to the customer. During this warranty period, upon satisfactory proof of a defect, the product may be returned for repair or replacement, at IETG’s sole option.
1-28 IETG FlowHawk Manual Out-of-Warranty Product Repairs After the new product warranty expires, a product may be returned, at the owner’s prepaid expense, to IETG for repair. The owner will pay for all parts and labor associated with the repair. Any repair part will be covered by the new product warranty for 90 days from the date of shipment from IETG.
Introduction European Service Centre IETG Ltd Cross Green Way Cross Green Industrial Estate Leeds West Yorkshire LS9 0SE England Tel 0113 201 9700 Fax 0113 201 9701 Email flowhawk.support@ietg.co.uk Web www.ietg.co.
2-1 CHAPTER 2 System Overview The IETG FlowHawk™ flow monitor supports four flow measurement devices for gathering flow data: Peak Combo Sensor This sensor, which mounts at or near the bottom of the pipe, contains an upward-looking ultrasonic depth sensor, Doppler peak velocity sensor, and pressure depth sensor.
2-2 IETG FlowHawk Manual This data is available to the user for collection, further processing, analysis, and reporting. These reports include critical information that can assist municipalities and other industries in planning improvements and additions to sewer systems, improving the accuracy of billing information, and providing overall management of sewer systems. The FlowHawk monitor and sensors are primarily designed for monitoring flow in sanitary and storm sewers.
System Overview 2-3 Communication between the monitor and the user’s office or field computer can occur over TCP/IP (remote, wireless communication) or a direct connect interface cable (on-site communication). The FlowHawk is powered either by a 12-volt IS battery pack or through external power. Externally-powered units receive power from an independent source through an intermediate EMU (external modem unit) or EMUX (EMU/Multiplexer) and support wireless communication.
2-4 IETG FlowHawk Manual FlowHawk Flow Monitor The FlowHawk flow monitor is contained in a waterproof, airtight, cylindrical, high-impact ABS plastic canister housing. It contains a single processor board attached to the inside of the aluminum monitor top, a power regulator built into a protective dome, and a replaceable power source. Note: The FlowHawk also can receive power from an external DC source when used in conjunction with an EMU (External Modem Unit) or EMUX (EMU/ Multiplexer).
System Overview 2-5 efficient digital communication in areas with GSM/GPRS coverage using static IP address services. Remote communication with the monitor occurs over the network through one of three kinds of modems. GSM Module The GSM module (p/n 8000-0052) is typically installed in the manhole at the monitor location.
2-6 IETG FlowHawk Manual External Modem Unit (EMU) The EMU (p/n 3800-0148) is installed outside the manhole near an external power source. EMU EMUX (EMU/Multiplexer) The EMUX (p/n 106226E) is installed outside the manhole in a weatherproof enclosure or indoors near an RTU (remote terminal unit) and/or external power source.
System Overview 2-7 EMUX Direct Communication On-site (or direct) communication with all monitors is available through an IS PC communication direct connect cable (p/n 80000054). Modbus Modbus is a protocol that allows for communication to occur among multiple devices connected to the same network. It often is used to connect a supervisory computer with a remote terminal unit (RTU) in supervisory control and data acquisition (SCADA) systems.
2-8 IETG FlowHawk Manual Configuration and Setup to Support the Telog Ru-33, for more information. Processor Board FlowHawk top with processor board attached The processor board is the source of all monitor activity. The board is responsible for all of the monitor's high-level functions, including the following: Managing user communication with the monitor Controlling the timing at which the sensors fire (i.e.
System Overview 2-9 Storing the parameters required to accomplish the associated system operations Transmitting the stored and current data to the user's PC Initiating event notification through alarms The board allocates portions of memory to firmware (embedded software in the monitor that can be upgraded remotely) and data storage. The board also includes the monitor clock, random access memory (RAM), and Flash. The monitor uses RAM while taking readings and processing the flow data.
2-10 IETG FlowHawk Manual The connector ports located on top of the monitor can receive up to two sensors and one communication device: Channel 1 and Channel 2 Ports These ports can receive up to two of the following sensors: Peak Combo Sensor Surface Combo Sensor Ultrasonic Depth Sensor Slimline Peak Combo Sensor Note: The channel ports on the FlowHawk receive any combination of two sensors, including two of the same sensor type.
System Overview 2-11 Power Internal Power Internal power is supplied to the FlowHawk flow monitor by an internal 12-volt battery pack (p/n 8000-0043). The battery pack resides within the FlowHawk enclosure and powers monitor operations. An on-board backup battery sustains the monitor memory (RAM). FlowHawk 12-volt battery The power regulator, built into the dome assembly that covers and protects the processor board, is critical to intrinsically safe operation.
2-12 IETG FlowHawk Manual Power regulator dome with potted IS regulator board The user receives a warning when the internal 12-volt IS battery pack drops below a specified threshold (IETG recommends 7.5 volts). External Power The FlowHawk flow monitor also can receive power from an external DC source through an external modem unit (EMU, p/n 3800-0148) or external modem unit/multiplexer (EMUX, p/n 106226E) located outside the manhole near the power source.
System Overview 2-13 specifically designed for receiving external DC power that does not include the battery pack. Powering the monitor through an external source is particularly advantageous at a location that requires logging an extensive amount of data at a short interval and eliminates the periodic need for battery replacement and disposal.
2-14 IETG FlowHawk Manual Sensors The FlowHawk flow monitor can support up to 2 of the 4 sensor types available (3 combination sensors and a stand-alone ultrasonic depth sensor) at one time to gather raw flow data. It also can support 2 of the same sensor type at one time. Using independent measurement techniques, ultrasonic and pressure depth sensors collect information used to determine the depth of the flow. Velocity sensors use Doppler technology to determine the average or peak velocity of the flow.
System Overview 2-15 Peak Combo Sensor Ultrasonic Depth Sensor To provide the depth of the flow, the sensor sends an ultrasonic signal upward that bounces off the water surface – air interface. The travel time from the sensor to the flow surface and back is converted to distance, which translates into the depth of the flow. Ultrasonic upward depth signals bouncing off water surface Pressure Depth Sensor A pressure transducer in the Peak Combo Sensor also measures the depth of the flow over the sensor.
2-16 IETG FlowHawk Manual greater than full pipe that may extend up into the manhole during surcharges conditions. Water pressure impacts a diaphragm in the transducer that varies an electrical current. This current is digitized by a sensor processor board and the value is sent to the monitor processor board. A vent tube on the back of the diaphragm equalizes for atmospheric pressure. Three versions of pressure transducers are available with this combo sensor: 0 - 0.34 Bar (0 - 5 PSI), 0 - 1.
System Overview 2-17 the velocity sensor, and the signal received is the reflection of the sound wave (emitted by the velocity sensor) off the particles. Based on this information, the sensor determines the peak velocity of the oncoming flow. Profile calculates an average velocity from this peak by applying a user-defined average-to-peak ratio. Ultrasonic Depth Sensor The Ultrasonic Depth Sensor with a standard 9.
2-18 IETG FlowHawk Manual sound in the air using the temperature recorded by a temperature sensor housed within the ultrasonic depth sensor. Ultrasonic depth sensor sending signals to flow surface to determine range Quadredundancy The sensor contains four ultrasonic transducers for taking readings to give the sensor quadredundancy, which ensures greater sensor reading reliability. To take a reading, one transducer transmits a sound wave while a second transducer listens for the returning echo.
System Overview 2-19 This method of processing data in the monitor also replaces the need for a separate data-scrubbing process to eliminate random pops in the data. If not identified and discarded, these outliers— created by pipe and manhole noise, turbulent or wavy flow, a foamy flow surface, side connections, rungs, broken pipes, or drop connections—can make it more difficult to determine the true depth of flow.
2-20 IETG FlowHawk Manual Surface Combo Sensor Note: The new version of the Surface Combo Sensor (shown above) referenced here and throughout this manual is undergoing final testing and evaluation and will be available toward the end of 2012. However, the existing version of the Surface Combo Sensor (p/n 8K-CS3-V2XX-30) is currently available through IETG.
System Overview 2-21 Ultrasonic Depth Sensor This sensor first transmits an ultrasonic signal downward from one of the crystals on the sensor face that bounces off the flow surface and returns to the other crystal. The monitor measures the travel time elapsed between transmission and reception of the reflected sound signal. Based on the elapsed time and the speed of sound, the monitor determines the range. The range represents the distance between the sensor face and flow surface.
2-22 IETG FlowHawk Manual SURFACE VELOCITY FLOW Measuring velocity using the surface velocity sensor Surcharge Peak Velocity Sensor This sensor measures the velocity of the flow during surcharge conditions using the same methodology as the Peak Combo Velocity Sensor. It will measure velocity only when the pipe is full. The surcharge peak velocity sensor resides in the angled, front portion of the sensor in front of the ultrasonic depth crystals.
System Overview 2-23 Slimline Peak Combo Sensor The Slimline Peak Combo Sensor with a standard 35-foot (10.6-m) cable (p/n 8K-CS4-35) typically mounts at the bottom of the pipe and measures ultrasonic depth and peak velocity using two independent sensors. Slimline Peak Combo Sensor Ultrasonic Depth Sensor This sensor measures ultrasonic depth using the same method as the corresponding sensor in the Peak Combo Sensor.
3-1 CHAPTER 3 Sensor Installation and Connection The IETG FlowHawk™ flow monitor and sensors are primarily designed for monitoring flow in sanitary, storm, and combined sewers. The monitor mounts to the manhole wall or rim slightly below the manhole cover or to a rung in the manhole. A sewer system’s hydraulics are much more stable and uniform in the incoming pipe than in the manhole invert or outgoing pipe.
3-2 IETG FlowHawk Manual Install the Sensors in the Pipe This process primarily includes assembling the ring (for standard installations) or preparing the bands (for special installations) to which the sensors attach, mounting the sensors to the ring or band, securing the sensor cables to the ring or band, and installing the ring or bands in the pipe.
Sensor Installation and Connection space entry. IETG is not responsible for any injuries, damages, claims, or liability resulting directly or indirectly from the use of this installation guide or the installation of any IETG equipment.
3-4 IETG FlowHawk Manual Investigating Site Characteristics Before beginning installation activities, conduct a thorough investigation of hydraulic and site conditions. Flow Hydraulics The hydraulics of a site directly affect the monitor's ability to accurately measure flow depth and velocity.
Sensor Installation and Connection 3-5 Flow Traveling at Least 0.3 Meters per Second Slower flows enable debris to settle in the pipe, limiting the accuracy of flow measurements. Higher Elevation than High Water Level that Occurs in Wet Well at Downstream Pump Station Pipes that are below the high water level of the pump station wet well could experience frequent backup and surcharging. This will increase sensor maintenance and possibly reduce data accuracy.
3-6 IETG FlowHawk Manual Pipe Shape Taking the appropriate measurements that precisely reflect the exact pipe shape is essential to obtaining accurate flow calculations. Therefore, irregularly-shaped pipes will require additional measurements. Refer to the Profile User’s Guide #950015 (version B4 or greater) for more information. Note: All relevant pipe dimensions and measurements are required for entry in the Profile software during monitor configuration and activation.
Sensor Installation and Connection Installing the Sensors in the Pipe This section includes the procedures for performing sensor installations using one of the following methods: Standard Installations Special Installations Note: When installing a monitor with wireless communications, it is very important to test the FlowHawk and GSM module, EMU, or EMUX with the SIM Card installed to be sure the entire system functions and to verify network quality of service before installation.
3-8 IETG FlowHawk Manual Gathering Parts and Supplies Obtain the following supplies before installing the ring and sensors to prevent any costly delays. When ordering, specify the FlowHawk flow monitor installation hardware for ring-mounting.
Sensor Installation and Connection 3-9 Quantity Description Part Number Up to 2 (1 per monitoring point) Slimline Peak Combo Sensor – upward ultrasonic depth sensor & peak velocity sensor w/ M3 x 6mm stainless steel, flathead screws 8K-CS4-35 (10.
3-10 IETG FlowHawk Manual Quantity Description As needed 10mm stainless washer 15 5mm x 300mm cable tie 25 2mm x 100mm cable tie 15 4mm x 200mm cable tie 15 7mm x 400mm anchor cable tie 1 457-mm stainless steel crank handle Part Number I10–0012 1 IS pressure depth transducers (indicated by -xx- in the part number) are available in Peak Combo Sensors, Surface Combo Sensors, and Ultrasonic Depth Sensor with a Pressure Option in 0 - 0.34 Bar (0 - 5 psi) and 0 – 1.
Sensor Installation and Connection 3-11 Metric nut driver or socket set Metric wrenches Screwdrivers (flathead and Phillips head of assorted sizes) Thread tap compatible with the thread spec on the monitor mounting stud Diagonal wire cutters Folding carpenter’s rule with a brass slide Mastic tape (p/n 507193) or rubber coaxial stretch tape Assembling the Ring The flow sensors mount to a stainless steel ring for installation in the pipe.
3-12 IETG FlowHawk Manual Ring stabilizer with spreader mechanism screw 2. Slide the open end of the ring (end without the welded metal band) through the flanges in the ring stabilizer, making sure the flanges face the outside of the ring and the spreader mechanism screw faces the inside of the ring. Sliding the ring stabilizer onto the ring 3. Slide the ring stabilizer all the way around the ring until it is about 102 mm from the welded metal band at the other end of the ring.
Sensor Installation and Connection 3-13 Moving the ring stabilizer into position 4. Position the ring with the downstream edge (edge with the holes) facing you. 5. Install the sensor mounting plate on the ring in the following way based on the sensor type. These sensors use slightly different mounting hardware. Surface Combo Sensor Slide the Surface Combo Sensor mounting plate onto the open end of the ring with the back of the mounting plate (side with the slots) facing the outside of the ring.
3-14 IETG FlowHawk Manual Sliding the Surface Combo Sensor mounting plate onto the ring Note: The new version of the Surface Combo Sensor (p/n 8K-CS5-V2-XX-30) referenced here and throughout this manual is undergoing final testing and evaluation. Contact the IETG Service Centre for sensor availability. This new version includes a different mounting plate and involves a slightly different installation procedure, as described in this manual, than the existing Surface Combo Sensor (p/n 8K-CS3-V2-XX-30).
Sensor Installation and Connection 3-15 Ultrasonic Depth Sensor Slide the Ultrasonic Depth Sensor mounting plate onto the open end of the ring with the back of the plate (side with the slots) facing the outside of the ring. The side with the backstop should face the inside of the ring. Once the mounting plate is on the ring, the majority of the plate should be extending out from the upstream edge of the ring. Sliding the Ultrasonic Depth Sensor mounting plate onto the ring 6.
3-16 IETG FlowHawk Manual Moving the ring stabilizer into position 9. Perform the following based on the ring type: Overlapping Insert the spreader mechanism screw completely through the hole at the open end of the ring. Non-Overlapping Insert a spreader mechanism screw through the hole at the left end of the ring so that the end of the screw extends inside the ring. Ring stabilizer fully connected 10. Place the ring on a flat surface with the spreader mechanism screw facing up.
Sensor Installation and Connection 3-17 11. Orient the ring with the downstream edge (edge with small holes) facing you. 12. Lay the spreader mechanism across the inside of the ring with the downstream end of the mechanism (end with the large welded nut) facing you, the four spreader bars facing toward the inside of the ring, and the shoulder bolts pointed outside the ring. 13. Place a washer and then the downstream, left spreader bar over the spreader mechanism screw.
3-18 IETG FlowHawk Manual Attaching the spreader bars 16. Turn the ring until the spreader mechanism is in the 12:00 position. 17. Align the spreader mechanism screw so that the head is visible through one of the ring size adjustment holes. Aligning the screw head and adjustment hole 18. Tighten the screw through the hole using a Phillips-head screwdriver while holding the hex nut with a 12-mm (0.5-in.) nut driver.
Sensor Installation and Connection 3-19 Tightening the spreader mechanism screw and hex nut 19. Insert the second spreader mechanism screw through the following hole based on the ring type: Overlapping Appropriate ring size adjustment hole on the outside of the ring Non-overlapping Last hole on the other free end of the ring (inserting the screw from the outside of the ring) 20. Slip the large washer onto the screw on the inside of the ring.
3-20 IETG FlowHawk Manual Place the washers onto the second spreader mechanism screw 21. Place the spreader bars over the screw, and tighten a hex nut on the screw.
Sensor Installation and Connection 3-21 Although the spreader mechanism fits snugly against the inside of the ring, the spreader mechanism may seem loose on the hex nuts. Do not be concerned. The spreader mechanism will tighten once the ring is installed and tightened inside the pipe. The following picture displays how a properly assembled ring with the ultrasonic depth sensor mounting plate should look.
3-22 IETG FlowHawk Manual either side of the pipe (between the 5:30 and 6:30 positions). A physical offset measurement must be taken if this technique is used. Refer to Installing the Ring in the Pipe on page 3-25.
Sensor Installation and Connection 3-23 Mounting the Peak Combo Sensor or Slimline Peak Combo Sensor Mount the Peak Combo Sensor or Slimline Peak Combo Sensor to the ring in the following way: 1. Use two M3 X10-mm stainless steel flathead screws (do not substitute any other screws) to mount the sensor at the bottom of the ring (opposite the Surface Combo Sensor/Ultrasonic Depth Sensor) with the tapered end of the sensor facing upstream. 2.
3-24 IETG FlowHawk Manual Securing the Cables to the Ring Securing the Peak Combo Sensor or Slimline Peak Combo Sensor cable to the ring helps prevent debris from collecting between the cable and the ring or catching on the loose cable. It also prevents the loose cables from disrupting the flow. Secure the cable in the following way: 1.
Sensor Installation and Connection 4. 3-25 Use the diagonal cutters to cut off the excess portion of the cable ties. Mounting the Surface Combo Sensor or Ultrasonic Depth Sensor The Surface Combo Sensor/Ultrasonic Depth Sensor is not mounted prior to installation of the ring. The ring mechanism and sensor mounting plate are assembled as detailed in Assembling the Ring on page 3-11.
3-26 IETG FlowHawk Manual Installing the ring at least 305 millimeters upstream from the manhole invert Keep the following in mind: Be sure to the mount the Surface Combo Sensor/Ultrasonic Depth Sensor at the top (crown) of the pipe and to mount the Peak Combo Sensor/Slimline Peak Combo Sensor is as close as possible to the bottom center of the pipe, above any silt present and below the flow surface (during minimum flows).
Sensor Installation and Connection 3-27 The bottom sensor may be rotated off the bottom centerline up to 15 degrees up either side of the pipe (between the 5:30 and 6:30 positions). However, rotating the ring and sensor requires accurately measuring the physical offset. Rotating the Peak Combo Sensor or Slimline Peak Combo Sensor no more than 15 degrees up either side of the pipe (between 5:30 and 6:30 positions) If necessary, temporarily clear away silt to install the ring.
3-28 IETG FlowHawk Manual Notice how the elevated sensor provides a gap in which debris can collect Notice how deterioration in the pipe surface creates a space for debris to collect under the sensor 4. Expand the ring by turning the spreader mechanism nut counter-clockwise with the crank handle or socket. However, do not tighten the ring against the pipe completely at this point. 5.
Sensor Installation and Connection 3-29 with the depth crystals facing downward toward the inside of the ring (flow surface). SENSOR MOUNTING PLATE SURFACE COMBO SENSOR Mounting the Surface Combo Sensor to the mounting plate on the ring Note: The new version of the Surface Combo Sensor (p/n 8K-CS5-V2-XX-30) referenced here and throughout this manual is undergoing final testing and evaluation. Contact the IETG Service Centre for sensor availability.
3-30 IETG FlowHawk Manual SENSOR MOUNTING PLATE ULTRASONIC DEPTH SENSOR Mounting the Ultrasonic Depth Sensor to the mounting plate on the ring Note: Handle the Surface Combo Sensor/Ultrasonic Depth Sensor with care, and do not expose it to extreme temperatures for an extended period of time. Keep the sensor in its protective packaging until it is time for installation. Avoid contacting the metal connector at the end of the Surface Combo Sensor cable with the Teflon®coated crystals on the sensor. 6.
Sensor Installation and Connection 3-31 Leveling the Surface Combo Sensor or Ultrasonic Depth Sensor If necessary, adjust the level for either sensor in the following way: Remove the sensor from the mounting plate. Loosen the ring slightly to allow the plate to move on the ring. Tap the sensor mounting plate to the right or left with a rubber mallet until it is level. Warning: Tapping the mounting plate with the sensor attached could damage the sensor.
3-32 IETG FlowHawk Manual 7. Fully tighten the ring until it fits securely and completely flush against the pipe wall. Warning: Avoid over-tightening the ring. This could bend the crank assembly. 8. Install an anchor bolt in the manhole wall just above the pipe crown. Using an anchor cable tie, secure the Surface Combo Sensor/Ultrasonic Depth Sensor cable. It can be further secured up the manhole wall. 9.
Sensor Installation and Connection 3-33 Surface Combo Sensor/Ultrasonic Depth Sensor Physical Offset Measure the distance from the crown (top) of the pipe to the face of the sensor (horizontal surface with the two/four depth crystals to determine the physical offset. Note: These offsets are required when configuring the monitor using the Profile or Qstart software. 11. Secure the sensor cables from the ring to the location at which the monitor is mounted in the manhole.
3-34 IETG FlowHawk Manual depth and velocity. In addition, measure the horizontal and vertical pipe dimensions carefully. Even slightly inaccurate pipe dimensions can significantly skew and misrepresent flow data. Caution: Handle all sensors and cables with extreme care. The sensors and cables contain delicate mechanisms and electronics. Keep sharp objects away from sensor cables, and avoid stepping or placing heavy objects on the cable during installation.
Sensor Installation and Connection 3-35 Quantity Description Part Number Up to 2 (1 per monitoring point) Surface Combo Sensor – downward ultrasonic depth sensor, pressure depth sensor, surface velocity sensor, & surcharge velocity sensor 8K-CS5-V2-xx-30 1 (9.1m cable) Up to 2 (1 per monitoring point) Ultrasonic depth sensor (downward ultrasonic depth only) 8K-CS3-V0-00-30 2 (9.
3-36 IETG FlowHawk Manual Quantity Description Part Number 1 Antenna for the GSM Module 3800-0162 or 3800-0163 1 as needed Magnet (for activating diagnostic codes through GSM modem module) 8000-0140 1 as needed External Modem Unit (EMU) 3800-0148 1 as needed External power kit (includes EMU chassis cable and 3-meter external power cable) 3800-0181 1 as needed EMU/Multiplexer (MUX) 106226E 1 as needed 12V DC power supply 5000-0727 1 as needed Communication cable (from monitor to EMU) 4
Sensor Installation and Connection 3-37 2 Extension cables can be ordered to specific lengths up to 91 meters. Note the desired length (meters converted to feet) in the -xxx-- portion of the part number. Standard lengths are 3.0m (10 ft.), 7.6m (25 ft.), 15.2m (50 ft.), 22.8m (75 ft.), 30.5m (100 ft.), 38.1m (125 ft.), 45.7m (150 ft.), and 61.0m (200 ft.). All other lengths must be custom ordered. 3 Communication cables can be ordered in 3-, 26-, 30-, or 41-meter (10-, 85-, 100-, or 135-ft.) lengths.
3-38 IETG FlowHawk Manual Mounting Peak Combo Sensors and Slimline Peak Combo Sensors Two special installation methods are available for mounting the Peak Combo Sensor and Slimline Peak Combo Sensor. ¾-band mount ½-band mount Both mounts require almost identical installation methods. The only significant differences are that the ¾-band mount allows the installer to secure the band to both sides of the pipe wall and to position the sensor at the bottom center of the pipe.
Sensor Installation and Connection 3-39 ¾-Band Mount Perform the following procedure to mount the Peak Combo Sensor or Slimline Peak Combo Sensor (when applicable) in a pipe using the ¾ band mount: 1. Use a hacksaw to cut the band to the appropriate length. Cut the band so that, when installed, it will run approximately ¾ of the circumference of the pipe. 2. Determine which end of the band will be the long end (end extending almost completely up one side of the pipe).
3-40 IETG FlowHawk Manual 4. Mount the sensor onto the inside of the band with two M3 x 10mm countersink screws, making sure the tapered, stepped end of the sensor faces the upstream edge of the ring (edge opposite cable tie holes). If mounting holes do not exist on the band at or near the desired mounting location for the sensor, drill holes in the band using a 3mm drill bit. 5.
Sensor Installation and Connection 3-41 Run the sensor cables from the sensor location in the pipe to the monitor location in the manhole according to the instructions in Securing the Sensor Cables in the Pipe and Manhole on page 3-53. ½-Band Mount Perform the following procedure to mount the Peak Combo Sensor or Slimline Peak Combo Sensor in a pipe using the ½-band mount: 1. Use a hacksaw to cut the band to the appropriate length.
3-42 IETG FlowHawk Manual 8. Spot drill the pipe wall through the hole, install a M6 x 55-mm anchor bolt, and secure the band to the anchor bolt with a washer and nut. Note: Make sure the submerged portion of the band is flush with the pipe wall. If it is not, remove the band and conform the band to the pipe. 9. Install a M6 x 55-mm anchor bolt, washer, and nut below the flow surface 30 to 80 mm away from the Peak Combo Sensor or Slimline Peak Combo Sensor on each side.
Sensor Installation and Connection 3-43 Note: This value will be necessary when configuring the monitor using the Profile or Qstart software. 12. Run the sensor cables from the sensor location in the pipe to the monitor location in the manhole according to the instructions in Securing the Sensor Cables in the Pipe and Manhole on page 3-53. Note: If the pipe is large and the sensor cable cannot reach the pipe crown, attach the sensor cables to 12-mm PVC tubing and anchor the tubing to the wall.
3-44 IETG FlowHawk Manual 2. Continue securing the cables until reaching the Surface Combo Sensor, Ultrasonic Depth Sensor, or the top of the pipe. 3. Pull the ties until they are taut. Warning: Do not over-tighten the cable ties or kink the sensor cables! The depth cable sheathes two components: the electrical cables that operate the sensor and an air tube that ventilates the sensor.
Sensor Installation and Connection 3-45 Standard Mount Mount the Surface Combo Sensor or the Ultrasonic Depth Sensor using this method in the following way: Note: Handle the sensor with care, and do not expose it to extreme temperatures for an extended period of time. Keep the sensor in its protective packaging until it is time for installation. Avoid contacting the metal connector at the end of the Surface Combo Sensor cable with the Teflon-coated crystals on the sensor. 1.
3-46 IETG FlowHawk Manual Securing one end of the sensor mounting band 6. Slide the sensor mounting plate onto the band in the following way based on the sensor type: Surface Combo Sensor Slide the plate onto the band with the end of the plate with the keyholes facing upstream and the two band slots facing up.
Sensor Installation and Connection 3-47 Note: The new version of the Surface Combo Sensor (p/n 8K-CS5-V2-XX-30) referenced here and throughout this manual is undergoing final testing and evaluation. Contact the IETG Service Centre for sensor availability. This new version includes a different mounting plate and involves a slightly different installation procedure, as described in this manual, than the existing Surface Combo Sensor (p/n 8K-CS3-V2-XX-30).
3-48 IETG FlowHawk Manual Securing the other end of the band Note: If the sensor mounting plate has too much side play, attach another anchor bolt approximately 25 mm from the plate. 10. Slide the sensor mounting plate along the metal band until it is level (from side to side) with the flow surface and pipe crown, and tighten the nuts securely with a nut driver. Refer to the instructions on leveling this sensor in Installing the Ring in the Pipe beginning on 3-25. 11.
Sensor Installation and Connection 3-49 SENSOR MOUNTING PLATE SURFACE COMBO SENSOR Fastening the Surface Combo Sensor to the mounting plate on the band Note: Remember, this new (available late 2012) version of the Surface Combo Sensor (p/n 8K-CS5-V2-XX-30) includes a different mounting plate and involves a slightly different installation procedure, as described in this manual, than the existing Surface Combo Sensor (p/n 8KCS3-V2-XX-30).
3-50 IETG FlowHawk Manual SENSOR MOUNTING PLATE ULTRASONIC DEPTH SENSOR Sliding the Ultrasonic Depth Sensor into the sensor mounting plate on the band 12. Confirm that the sensor is still level. 13. Determine the physical offset for the Surface Combo Sensor or the Ultrasonic Depth Sensor by measuring the distance from the crown (top) of the pipe to the face of the sensor (horizontal surface with the two/four ultrasonic crystals on either sensor).
Sensor Installation and Connection 3-51 Surcharge mount 1. Determine the appropriate height at which to mount the Ultrasonic Depth Sensor portion of the surcharge bracket (p/n I40-0010). The sensor slides into the groves of the mounting plate at the lower portion of the bracket. When making this determination, keep in mind that the maximum range of the sensor is 3.048 meters (10 ft). 2. Press the bracket firmly against the manhole wall. 3.
3-52 IETG FlowHawk Manual 7. Hold the bracket firmly in place against the manhole wall. 8. Identify the three pre-drilled holes on the bottom of the bracket, and spot drill the manhole wall through the middle hole with a drill. 9. Rotate the bracket 90, and drill and mount an M6 x 55-mm anchor bolt. 10. Secure the bottom of the bracket with a washer and nut. 11. Slide the sensor into the mounting plate on the bracket, and secure the cable with cable ties to keep the sensor in place. 12.
Sensor Installation and Connection 3-53 Securing the Sensor Cables in the Pipe and Manhole Securing the sensor cables from the ring (or band, when applicable), along the pipe crown, and up the manhole helps prevent debris from collecting on sagging cables or between the cables and the pipe crown. Do not allow sensor cables to hang down in the pipe or sag in the manhole. Loose cables could present a safety hazard in the manhole or increase the potential for sensor or monitor damage to occur.
3-54 IETG FlowHawk Manual Warning: Do not over-tighten the cable ties or kink the sensor cables! The depth cable sheathes two components: the electrical cables that operate the sensor and an air tube that ventilates the sensor (when applicable). Overtightening the ties or kinking the cable can damage or restrict the air tube, causing incorrect pressure depth readings. 2.
Sensor Installation and Connection Securing the sensors cables along the pipe and into the manhole 3-55
3-56 IETG FlowHawk Manual Connecting the Sensors to the Monitor After installing the ring and sensors and securing the sensor cables to the pipe and manhole wall, connect the sensor cables to the appropriate ports on the top of the monitor. The ports that receive the sensors are labeled Channel 1 and Channel 2. The FlowHawk supports the connection of two sensors in any combination, including two of the same sensor type, to the channel ports.
Sensor Installation and Connection A CH NN E L A CH 2 NN E L 3-57 1 0518 II 1 G Ex ia IIB T4 Ga Sira 09ATEX2027X MODEL: 8000 - FHK/FST ST ONLY TE M AX . 82 kP Use only battery pack 106152 a FLOWHAWK TM IETG CO M M W W W. I E T G .C O . U K Cable connector ports 2. Visually inspect each sensor connector and monitor connector port for damaged or broken pins. Replace a monitor or sensor with defective ports or connectors. 3.
3-58 IETG FlowHawk Manual 7. Seal any unused connectors with a cap. If necessary, obtain additional caps from IETG. Note: An air valve is present in the monitor top. This valve exists only for testing purposes during the manufacturing process.
Sensor Installation and Connection 3. 3-59 (applies only when a second dryer tube is present) Repeat steps 1 through 3 for the other dryer tube, but attach it to the other vertical portion of the handle on the opposite side of the monitor.
4-1 CHAPTER 4 Communication After installing the sensors in the pipe and connecting the sensors to the IETG FlowHawk™ monitor, it is necessary to establish communication with the monitor through wireless communication (remote) or direct connection (on-site). Both methods of communication require a field (laptop) computer or office computer equipped with the Profile® or Qstart™ software.
4-2 IETG FlowHawk Manual EMUX enables the RTU to obtain real-time monitor data through a serial connection and the Profile software (a user) to communicate with the monitor through a wireless connection. Direct, on-site communication with the monitor is possible through an IS serial connection between the monitor and a laptop computer.
Communication 4-3 GSM-Based Wireless Communication The IETG FlowHawk monitor system supports GSM wireless communication through a GSM/GPRS module over TCP/IP using static IP address network services. Both the Profile software and IntelliServe® hosted systems support TCP/IP communication. Wireless communications and the quality of service depend on local conditions and service providers. An optimal location for flow monitoring may not offer the best wireless network coverage.
4-4 IETG FlowHawk Manual higher) or the Profile or Qstart online help for further information on wireless setup and use.
Communication 4-5 Installing the GSM Module Establishing remote, wireless communications with the batterypowered FlowHawk monitor involves installing a GSM module in the manhole. The GSM Module (p/n 8000-0052) is a polycarbonate enclosure containing an electronic assembly comprised of a modem module and intrinsically safe isolation components. The enclosure has a clear, removable top to allow the user to access the SIM card holder.
4-6 IETG FlowHawk Manual network quality of service. Perform this validation before deploying to the field and again at the monitoring site before installing the monitor. Gathering Parts and Supplies Gather the following items to perform the installation: GSM module One of two wireless antennas available through IETG (p/n 3800-0162 or 3800-0163) (applicable only to off-road installations) Extension cables (4.6-m (15-foot): p/n 507165; 15.
Communication 4-7 Trowel or putty knife for scooping asphalt Hammer Carpenter’s rule Pen, pencil, or chalk for marking asphalt or concrete Shop vacuum Wire brush Alcohol wipes Leather work gloves Protective goggles Heavy-duty, high-quality caulking gun (for regular-sized tubes) Appropriate tools for cutting and removing tarmac or dirt for burying antenna Patching and sealing materials for tarmac and for sealing the cable hole into the manhole Cable ties f
4-8 IETG FlowHawk Manual Installing the Wireless Antenna Before installing the GSM Module into the manhole, install one of the following antennas: Wireless, slim, quad-band antenna (p/n 3800-0162) Wireless, mini-wing, quad-band antenna (p/n 3800-0163) Mini-wing antenna Install a wireless slim or mini-wing antenna in the road, in dirt, or under other paving materials in the following way: Note: While this section describes the process for installing these antennas, all wireless antennas provided t
Communication 4-9 Choose a location that is as flat as possible with stable base material. Select a location where the antenna will experience minimal direct impact from road traffic, where possible. Make sure the location exists beyond the manhole’s iron rim beneath the road surface. This will enable you to access the manhole corbel when drilling the channel for the antenna cable. Verify that no buried utility cables exist in the area in which drilling will occur for the antenna installation.
4-10 IETG FlowHawk Manual Hole running from antenna installation location to manhole 5. Level the bottom of the hole using the demolition hammer with the chisel and a bushing tool. 6. Thoroughly clean out the hole for the antenna of all debris using a brush. 7. If the protective cap is not present on the connector at the end of the antenna cable, clean the connector and tape it up with rubber stretch tape for protection against damage and debris while it is being fed through the channel. 8.
Communication 4-11 10. Apply a piece of white release tape onto the top of the antenna, and then seat the antenna into the bottom of the hole. Once the antenna is firmly seated, remove the release tape. 11. Apply cold patch asphalt on top of the antenna element. When using asphalt, scoop the warm material into the hole and then pound it in using a hammer. Place a piece of wood or metal between the asphalt and the hammer to prevent the hammer from sticking to the asphalt.
4-12 IETG FlowHawk Manual Installation with antenna cable coiled in manhole 14. Seal the space between the antenna cable and the corbel hole with electrical duct sealant or as required to prevent infiltration into the manhole. Note: Do not connect the antenna cable to the GSM Module until after the SIM card is installed.
Communication 4-13 Installing the SIM Card The GSM Module requires a standard SIM card provisioned for static IP address operation to establish communication. Since the global list of providers changes over time, as well as the features available via the GSM infrastructure, IETG will provide additional documentation addressing the selection and testing of SIM cards for use with the GSM module. Please contact IETG for specific information on procuring SIM cards for use in the specific geographic area.
4-14 IETG FlowHawk Manual Cover removed from GSM Module 3. Slide back the clip on the SIM card carrier to unlock the carrier. The clip indicates the proper direction for unlocking the carrier.
Communication 4. 4-15 Swing up the hinged clip to the carrier and gently insert the SIM card into the slot. Orient the card so that the beveled corner of the card will align with the beveled corner of the carrier once locked into place. Swinging up hinged clip and inserting card; notice beveled edge of card 5. Close the clip to the carrier, and slide the clip forward to secure the SIM card into place. The clip indicates the proper direction for locking the carrier.
4-16 IETG FlowHawk Manual 6. Inspect the gasket and all edges of the module enclosure seal to be sure they are free of any debris. 7. Position the desiccant pack (p/n 507995) in the GSM module above or to the right of the LED window. Make sure the desiccant is fresh by inspecting the center strip on the pack. The center strip on a new, fresh pack should be blue in color. Replace the pack if a pink color is visible through the center strip. Desiccant pack properly seated and positioned in GSM module 8.
Communication 4-17 10. Wrap electrical tape tightly over the seam (between the cover and the case) of the GSM module enclosure to enhance the seal and to simplify the removal of debris when the module is opened. Installing the GSM Module Note: IETG recommends installing the antenna prior to securing the GSM module to the monitor. Note: The following instructions address a standard installation that involves mounting the GSM module inside the manhole.
4-18 IETG FlowHawk Manual Communication cable connected to monitor with stretch tape properly applied 4. Attach the antenna cable connector to the antenna port on the GSM module. 5. Wrap rubber stretch tape around the entire cable connection, extending onto the cable approximately 50 mm (2 in) beyond the connection on the module. 6. Secure the communication cable of the GSM module to the short vertical portion of the monitor handle using a cable tie.
Communication 4-19 FLOWHAWK MONITOR COMMUNICATION CABLE CABLE TIES GSM MODULE ANTENNA CABLE Securing the GSM module to the monitor handle 7. Carefully coil and secure the remaining slack cabling as necessary. Slack enables the technicians to remove the GSM module from the manhole for maintenance or service activities. 8. Wrap rubber stretch tape around the entire cable connection, particularly over the gap between the connector and port, and up the cable 20 mm beyond the connector.
4-20 IETG FlowHawk Manual Installing an EMU Establishing remote, wireless communications with the externalpowered FlowHawk monitor involves installing an EMU (p/n 38000148) outside the manhole (in which the monitor is installed) at the location housing the external power source.
Communication 4-21 Consider the following when choosing the route for the cable: Choose a route that will not require running the communication cable underneath rough gravel roads. Constant traffic could cause damage to the cable. Verify that the communication cable trench will not damage an existing sprinkler system. Locate any sprinkler lines (These are not located by the locator service). Check with homeowner if necessary.
4-22 IETG FlowHawk Manual Gathering Tools and Materials Obtain the following items to perform the installation: Ratchet set with 11-millimeter (7/16-in) socket Pointed shovel Claw hammer Hammer drill Minimum 13-millimeter (½-in) diameter masonry bit at least 305 millimeters (12 in) in length to drill through the manhole wall or corbel Generator for hammer drill (if necessary) Installing the Communication Cable After finalizing the cable route, run the communication cable (p/n 10622
Communication 2. 4-23 Verify that the wire ends have been stripped correctly with only 6 millimeters (¼ in) exposed. If they have not been stripped or have been stripped incorrectly, prepare the wires in the following way: Wire ends stripped 6 mm Cut off the old stripped ends (when applicable) back to the jacket. Use the small side cutters to carefully remove 102 millimeters (4 in) of the jacket, and cut away the tension strands and any other unnecessary jacket materials.
4-24 IETG FlowHawk Manual Forming a thin taper using vinyl tape 4. Excavate a trench at least 305 mm (12 in) deep and 102 millimeters (4 in) wide from the EMU/power source location to the monitor location. Consult local regulations to verify the required trench depth for the area. 5. Drill a 13-milllimeter (½-in) (minimum) hole through the corbel (structural foundation holding the manhole cover) or manhole wall to provide a smooth transition for the cable into the trench. 6.
Communication 4-25 Running the cable and conduit from the manhole to the EMU/power source 7. Provide enough slack in the cable at the manhole end to allow removal of the monitor from the manhole during service activities. Note: Do not connect the cable to the monitor at this time! 8. Provide approximately 1016 mm (40 in) of excess cabling at the EMU/power source location. 9.
4-26 IETG FlowHawk Manual Installing the EMU Installing the wireless EMU involves wiring the communication cable to the Communication Interface/Barrier box and mounting the EMU at the power source location. EMU Components The wireless EMU (p/n 3800-0148) houses the following major components: Communication Interface/Barrier PCB Modem Reset PCB Quad-Band TCP/IP Wireless Modem Mini-wing Antenna IETG ships the wireless EMU preassembled.
Communication 4-27 Front of EMU Gathering Tools and Materials Obtain the following items before initiating installation: Medium (No.
4-28 IETG FlowHawk Manual Wiring the Communication Cable Once the communication cable has been installed and at least 1016 millimeters (40 in) of communication cable extends from the ground, wire the communication cable to the EMU and install the external power kit: 1. Unscrew the 4 large plastic screws with the Phillips head screwdriver and remove the cover to the EMU. Carefully set the cover aside to avoid damage and prevent dirt from contacting the cover gasket.
Communication 4-29 Opening the communication cable entry fitting 3. Run the communication cable through the fitting and into the box. Pull enough of the cable through the hole to allow room to hold the cable while attaching the wires to the connector. Communication cable inserted through the entry fitting Warning: Verify that the communication cable is NOT attached to the flow monitor.
4-30 IETG FlowHawk Manual 4. Terminate the 12 wires into the orange connector, using the 3mm (1/8-in) flat head screwdriver, as shown on the label affixed to the inside cover of EMU box. Make sure all screws are tight.
Communication 4-31 Note: The port on the Communication Interface/Barrier Box may be difficult to access because of its close proximity to the modem. Therefore, it may be necessary to remove the box from the EMU before connecting the orange connector. Release the box from the back plate of the EMU by grasping the rear edge (next to back plate) and gently, but firmly, pulling to release the Velcro® grips.
4-32 IETG FlowHawk Manual Inserting the SIM card into the modem in the EMU SIM card seated in the EMU modem 8. Slide the SIM lock to the left to secure the card in place.
Communication 9. 4-33 Install the External Power Kit (p/n 3800-0181) in the EMU in the following way: External Power Kit includes an external power cable (top) and a chassis cable (bottom) Remove the plug at the top of the EMU to the right of the communication cable entry fitting. Remove the nut from the metal connector on the chassis cable (from the kit), and lubricate the O-ring on the connector with Parker-O-Lube.
4-34 IETG FlowHawk Manual Inserting the chassis connector through the hole in the EMU Thread the nut back onto the connector on the outside top of the EMU to secure the connector in the hole, and tighten the nut securely with a wrench. Threading the nut onto the connector from the outside of the EMU Connect the plastic white connector from the chassis cable to the corresponding connector on the cable attached to the Communication Interface/Barrier Box in the EMU.
Communication 4-35 Connecting chassis connector to the Communication Interface/Barrier Box Attach the metal connector from the 10-foot power cable to the chassis cable connector.
4-36 IETG FlowHawk Manual Note: If additional cable is required to cover the distance to the DC source, select an appropriate gauge of cable to complete the run. The existing cable is 6 millimeters (¼ in) in diameter and has an ethylene/propylene copolymer jacket. If the cable requires splicing, use a junction box or other method suitable for the environment in which the cable will be installed. 10. Replace the cover onto the EMU, and securely tighten the four plastic screws.
Communication 4-37 One of the holes through which to secure the EMU to the panel 2. (applicable only to FlowHawk monitors containing the 12-volt IS battery pack) Disconnect the battery pack cable from the regulator dome cable in the FlowHawk or disconnect and remove the 12-volt IS battery pack completely from the canister.
4-38 IETG FlowHawk Manual Communication cable from EMU connected to monitor with stretch tape properly applied 4. Run and connect the external power cable to the power supply, and then connect to the power source. Refer to Chapter 5, External Power, for information and instructions on installing the power supply and connecting to the power source. 5. Contact a remote support analyst (with access to the Internet and the Profile or Qstart software).
Communication 4-39 Note: The material of which the enclosure housing the EMU is made may impact the strength of the signal available. If the material is significantly reducing the signal strength, consider installing the wireless antenna (currently mounted inside the EMU) outside the enclosure.
4-40 IETG FlowHawk Manual Installing an EMUX Establishing remote, wireless communications with an externallypowered FlowHawk monitor that also will be connected serially to a SCADA or other process control system through an RTU (Remote Terminal Unit) requires installation of an EMUX (p/n 106226E).
Communication 4-41 Installing the EMUX Installing the wireless EMUX primarily involves installing the SIM card in the EMUX, connecting the communication cable to the EMUX, and mounting the EMUX near the RTU and/or external power source. Gathering Tools and Equipment Obtain the following items before initiating installation: Medium (No.
4-42 IETG FlowHawk Manual EMUX with cover SIM card clip Inside of EMUX with cover removed 3. Slide the SIM card into the SIM card clip on the board inside the EMUX until it is seated securely in place. Orient the card so that the beveled edge of the card corresponds with the beveled edge on the lower right edge of the clip.
Communication 4-43 Sliding the SIM card into the clip 4. Replace the cover onto the EMUX, and replace and tighten the screws. Connecting the Communication Cable to the EMUX Connect the communication cable to the EMUX in the following way: 1. (applies only to monitors installed in manholes) Verify that the communication cable has been installed and at least 1016 mm (40 in) of communication cable extends from the ground at the EMUX location. 2.
4-44 IETG FlowHawk Manual Terminal Wire Color Gauge Wire 1 Yellow 22 2 Blue (small) 22 3 Black (small) 22 4 White 22 5 Red (small) 22 6 Green (small) 22 7 Brown 22 8 Orange 22 9 Red (large) 18 10 Blue (large) 18 11 Black (large) 18 12 Green (large) and bare shield drain wire 18 (green)/ 22 (drain wire) Note: The wires can become loose while moving the cable. Therefore, after terminating the wires, verify once again that each wire is secure.
Communication 4-45 on the cable entry fitting until the cable is secure and cannot be moved in or out of the fitting. Inserting communication cable connector into the port on the EMUX Mounting the EMUX IETG recommends installing the EMUX in the same location or in close proximity to the RTU and/or power source. This minimizes the distance required for the serial cable connecting the EMUX to the RTU and, therefore, maintains a strong signal. It also limits power degradation in transmission.
4-46 IETG FlowHawk Manual 2. Clean the inside, rear wall of the enclosure with alcohol, and then adhere two mating pieces of Velcro to the wall. 3. Secure the EMUX to the inside of the enclosure with the Velcro. Connecting the Communication Cable to the Monitor Connect the communication cable running from the EMUX into the manhole or other monitor location to the monitor in the following way: 1.
Communication 4-47 Communication cable from EMUX connected to the monitor with stretch tape properly applied Installing a Wireless Antenna The EMUX supports the use of both IETG and customer-supplied wireless antennas. Two wireless antenna options are available through IETG: mini-wing (p/n 3800-0163) and slim (p/n 38000162). Customer-supplied antennas must meet the following specifications: 50 ohms VSWR < 1:1.
4-48 IETG FlowHawk Manual Attach the antenna connector to the gold ANTENNA connector on top of the EMUX. Connecting antenna cable to ANTENNA port on EMUX EMUX in Metallic Enclosure When housing the EMUX in a metallic enclosure, the antenna must extend outside the enclosure to ensure adequate reception. Run the cable through a pre-drilled or existing hole in the enclosure.
Communication 4-49 Connecting the RTU to the EMUX Connect the RTU to the MODBUS port (male pins) on the EMUX using a customer-supplied serial cable with a female DB-9 connector configured to an RS-232 connection specification. It also must support 8 data bits, 1 stop bit, no parity.
4-50 IETG FlowHawk Manual Wiring external power cable and ground to connector on EMUX 3. Reseat the connector (with the cable now attached) into the 4pin port on the EMUX. 4. Run and connect the external power cable to the power supply and then connect to the power source. Refer to Chapter 5, External Power, for information and instructions on installing a power supply and connecting to the power source. 5. Contact a remote support analyst (with access to the Internet and the Profile software).
Communication 4-51 installing the wireless antenna outside the enclosure. If this requires drilling holes in the enclosure, take the appropriate measures to seal the holes around the cable once the antenna is installed to ensure protection for the internal components against the elements. 7. Backfill the trench between the manhole and the location at which the EMUX is installed, and restore the landscape as necessary.
4-52 IETG FlowHawk Manual Connecting to the Monitor in the Field (Direct Connection) The Direct Connect Cable (p/n 8000-0054) allows you to connect directly to the FlowHawk with a laptop computer for on-site communications. Direct Connect Cable Connect to the monitor with a laptop computer in the following way: 1. Attach the potted cable connector from the Direct Connect Cable to the corresponding COMM port on the top of the monitor.
Communication 2. 4-53 Attach the serial connector end of the cable to the proper serial port on the laptop computer. Note: If your computer has a USB port and no serial port, run a USB-to-serial adapter cable (and driver software) between the Direct Connect Cable and the computer to perform serial communications. IETG recommends the following USB adapters: Dynex (model DX-UBDB9) and Keyspan (model USA-19S). 3.
5-1 CHAPTER 5 External Power The IETG FlowHawk™ can receive power from an external DC power source. However, any connection of external power to the monitor must occur through a standard external modem unit (EMU, p/n 3800-0148) or an EMUX (EMU/multiplexer, p/n 106226E) for compliance with IS certification. Note: When installing an externally-powered EMU or EMUX, IETG recommends locating the EMU or EMUX in close proximity to the DC power source to maximize the net power available to the EMU/EMUX.
5-2 IETG FlowHawk Manual Installation A typical installation involving external power includes the following: An AC mains power line terminated at a pole or post close to the manhole in which the monitor is installed An AC distribution device (i.e.
External Power 5-3 DC Power Requirements and Consumption To run on external power, the FlowHawk requires a power source capable of supplying a minimum of 1 ampere of 12-volt regulated DC power (12 V +/-10% as measured/available at the EMU or EMUX, not at the power source output). When long cable runs are required, size the supply and cabling to ensure that line losses do not reduce the net power available to the EMU or EMUX. IETG offers a power supply (p/n 5000-0727) for this application.
5-4 IETG FlowHawk Manual GSM Modem During Communication, Active 230 mA average (for 360 seconds (6 minutes) while collecting 90 blocks of data) Sleep Current with GSM Modem Continuously On 32 mA Sleep Current with GSM Modem Continuously Off 2 mA EMUX Following are the power requirements for monitors that communicate wirelessly through an EMUX: Monitor Operating in Standby 156 mA average (includes EMUX, monitor, and GSM modem standby currents) Monitor Firing the Peak Combo Sensor 238 mA average
External Power 1. 5-5 Mount the power supply (p/n 5000-0727) to the panel or other mounting surface in the enclosure housing the EMU or EMUX using appropriate fasteners through the four 4.4-millimeter (0.175-in) holes located under the corner cover screws. Note: Do not drill new holes through the power supply housing! This will expose the internal components of the power supply to moisture, creating unsafe operating conditions. It also will void the product warranty. Power Supply 2. Verify that the 1.
5-6 IETG FlowHawk Manual 3. Remove the front cover from the power supply by loosening the 4 plastic screws. 4. Run the external power cable (from the EMU or EMUX) through the entry hole cable grip entry on the side of the power supply case opposite the AC power cord. 5. Terminate the wires from the external DC power cable in the following way: Connect the –DC In wires from the cable to the –V terminal in the power supply.
External Power 5-7 Wiring the external power cable to the IETG-supplied power supply 6. Verify the following before connecting to the power source: Battery pack has been disconnected and removed from the monitor. Communication cable is connected to both the monitor and the EMU or EMUX.
5-8 IETG FlowHawk Manual External power cable is connected to the EMU or EMUX and the power supply 7. Connect the power supply to the AC distribution device (i.e., the disconnect, fuse, or breaker box). 8. Ensure the DC ON LED is illuminated and the DC LOW LED is out. 9. Securely tighten the cable grip fittings and replace the enclosure cover. Make sure the cover properly aligns with the gasket and that all screws are tightened equally (i.e., snug, but not over-tightened).
6-1 CHAPTER 6 Configuration and Activation After installing the IETG FlowHawk™ flow monitor and sensors and establishing communications, it is necessary to configure and activate the monitor to begin taking flow measurements and recording data at the monitor location.
6-2 IETG FlowHawk Manual monitors quickly in the field. It also includes several other features and functions, such as data collection, archival, and display. Refer to the Profile User's Guide #950015 (version B4 or higher) for more detailed instructions on installing the software, collecting monitor data, and configuring, activating, and confirming the monitor.
Configuration and Activation 6-3 Configuring the Monitor Location To ensure the most efficient and useful results for each monitor location, the user must activate the FlowHawk flow monitor with the proper configuration information to satisfy the specific monitoring needs of the project and to reflect actual site conditions.
6-4 IETG FlowHawk Manual Starting the Profile Software Before traveling to the field for installation, configuration, and activation activities, install the Profile software on the field computer and register the software using a Profile license key provided by IETG. Once installed, start the Profile software from an office or field computer by selecting Start > Programs > ADS Corporation > Profile from the Microsoft® Windows® start menu or doubleclicking on the Profile icon on the Windows desktop.
Configuration and Activation 6-5 The left pane displays all the levels and current details for the selected database on a tree. These levels and details are accessible by expanding and collapsing the entries on the tree. Click the plus symbol (+) next to an entry to display the items contained under that level of the tree; click on the minus symbol (-) next to an entry to collapse the items under that entry level.
6-6 IETG FlowHawk Manual Properties dialog for the new location 3. Enter the new Location Name. Do not duplicate more than the first 7 characters of the monitor names for multiple locations, unless the 8th character is followed by an underscore (_) and a unique character(s). For example, you cannot use the names FlowHawk1 and FlowHawk2. However, you could use the names FlowHawk_1 and FlowHawk_2. 4. Enter the new location Description. 5. Select FlowHawk from the Series drop-down list.
Configuration and Activation 6-7 Properties dialog for a new FlowHawk location 6. Select the method by which you will communicate with the monitor from the Connect Using drop-down list. TCP/IP Choose this option for wireless, remote communication. Selecting this option also requires entering the monitor’s IP address for the wireless connection in the IP Address field. Note: Do not use leading zeros before or within the IP address. For example, an IP address of 166.213.006.
6-8 IETG FlowHawk Manual transfer), and most countries are phasing out CSD services. Therefore, ADS strongly discourages using this communication option with the FlowHawk. Serial Choose this option for direct, on-site communication. 7. Enter the monitor’s Serial Number. 8.
Configuration and Activation 6-9 Note: The Scan and Fast designations apply when implementing the Dual Data Rate feature in MLI. The Scan rate also pertains to applications involving Modbus and Telog® Ru-33 operations. Fast Select the accelerated rate at which you want the monitor to take and store readings once the threshold defined in MLI has been exceeded. The monitor will remain in this state until the flow conditions at the monitoring point return to normal, as defined in MLI.
6-10 IETG FlowHawk Manual slave IDs used by the RTU or Telog unit when referencing other devices. For Telog Ru-33 operations, IETG recommends using 55 as the identifier through which to request data from the monitor. Delay Response Enter the amount of time, in milliseconds, following a request before the monitor returns the requested data to the RTU (through the EMUX) or the Telog Ru-33. The maximum delay allowed is 2000 ms. The default delay response is 10 ms. 13.
Configuration and Activation 6-11 Creating an Installation Table Creating an installation table involves defining the size, shape, and physical characteristics of the monitoring point in order to allow the software to properly calculate the correct depths and corresponding quantities at the monitoring point. One installation table must be created for each monitoring point. The user can create an installation table using the Installation Generator in the Profile software in the following way: 1.
6-12 IETG FlowHawk Manual Create Installation – Introduction dialog in the wizard 3. Select the New radio button and then click on the Next button. Create Installation – Installation dialog 4. Select the Pipe radio button, and then click on the Next button.
Configuration and Activation 6-13 Create Installation – Type dialog 5. Select the type or shape of the pipe from the drop-down list, and then click on the Next button. Create Installation – Dimension/Parameters dialog 6. Enter the proper pipe dimensions in the corresponding fields, and then click on the Next button.
6-14 IETG FlowHawk Manual Create Installation – Name dialog 7. Enter an appropriate name for the installation in the text field, and then click on the Next button.
Configuration and Activation 8. 6-15 Review the installation table selection summary, and then click on the Finish button. Select the Back button to return to previous dialogs to edit any of the existing selections. Option to save pipe table dialog 9. Click on the Yes button to save the installation table to the Profile database for the selected location. Installation Generator dialog 10. Enter 0.9 in the VGain field or the average-to-peak ratio, if other than 0.9. 11. Select File > Exit.
6-16 IETG FlowHawk Manual Option to store coefficients 12. Click on the Yes button. Store dialog displaying coefficients 13. (optional) Edit Start Time field to indicate the date and time at which you want to implement the designated Gain. 14. Click on the OK button. Note: Repeat steps 1 through 14 to create an installation table for a second monitoring point corresponding to the location, when applicable.
Configuration and Activation 6-17 Selecting and Editing Devices Select and edit the devices corresponding to the new monitor location to log the desired data. Devices generally represent sensors, but not always. Editing the devices involves setting specific parameters to ensure the monitor and Profile properly obtain and process the data. Perform the following steps to properly select and edit devices: 1. Select the location for which you want to select and edit devices from the database. 2.
6-18 IETG FlowHawk Manual Edit Devices dialog 4. Select the monitoring point to which you want to assign the devices from the Monitoring Point drop-down list. 5. Select the checkboxes corresponding to the devices you want to assign to the designated monitoring point from the Available Devices selection box. A checkmark must display beside a device in the Monitoring Point Devices section to ensure Profile includes the device in the LIF.
Configuration and Activation 6-19 device during data collection. In addition, IETG recommends assigning a device to a monitoring point of the same number. For example, assign Peak Combo 1 only to Monitoring Point 1 and Peak Combo 2 only to Monitoring Point 2. Note: The Smart Depth 1 and Smart Depth 2 devices represent stand-alone ultrasonic depth sensors. Note: The MLI 1 and 2 and Modem Setup devices are not associated specifically with a sensor.
6-20 IETG FlowHawk Manual Select the OK button after editing the device parameters and any associated sensor/tools. Repeat the three previous steps from step 6 for each device that requires new settings or modification. Note: Each Edit [device type] Parameters dialog contains default settings. 7. (applicable only to locations with a second monitoring point) Repeat steps 4 through 6 to assign a device(s) to the other monitoring point and edit the device(s) parameters. 8.
Configuration and Activation 6-21 Edit Peak Combo 1 Parameters dialog showing the Ultrasonic tab
6-22 IETG FlowHawk Manual Edit the following Device Parameters at the bottom of the dialog, and then edit the individual tabs as described in the following sections. Physical Offset Enter the physical offset for the sensor at the time of installation if it was installed offset from the bottom center of the pipe. Refer to Chapter 3, Sensor Installation and Connection, for instructions on measuring the physical offset. The default physical offset is 0.
Configuration and Activation 6-23 Usually Dry Pipe typically remains dry, except under wet weather conditions. Electronic Offset Enter the difference that exists between the depth sensor readings and the manually measured depth. The default value is 0. Deadband Select the distance from the sensor face within which readings received will be ignored. The default value (Auto) represents a percentage of the flow depth and should be sufficient under normal circumstances.
6-24 IETG FlowHawk Manual Note: Modifications made to the Advanced Parameters should be performed only by or under the guidance of trained IETG personnel. Therefore, IETG recommends leaving the default settings (Auto) in place. Modify the parameters as necessary, and then select OK once complete.
Configuration and Activation 6-25 Edit Peak Combo 1 Parameters dialog displaying the Pressure tab Enable Select this checkbox to ensure the monitor begins taking pressure depth readings at the designated interval once activated. Electronic Offset Enter the difference that exists between the pressure depth sensor readings and the manually measured depth. The default value is 0.
6-26 IETG FlowHawk Manual Store Data Select this checkbox to ensure the monitor logs pressure depth data to memory. This option is selected by default.
Configuration and Activation 6-27 Note: The velocity parameters corresponding to the Peak/Slimline Peak Combo Sensor typically should not require editing. However, if modifications are necessary, IETG does not recommend making changes to these parameters without proper training or assistance.
6-28 IETG FlowHawk Manual Velocity Direction Select one of the following options that reflects the general direction of the flow at the monitoring point and position of the velocity sensor. The default is Forward. Bidirectional Choose this option for monitoring points that potentially experience reverse flows. The Peak/Slimline Peak Combo Sensor typically is positioned facing upstream into the flow.
Configuration and Activation 6-29 second (mps) on a regular basis, ADS recommends choosing the 4.572 mps option for this parameter. Transmit Frequency Select the frequency at which to transmit the signal. IETG recommends leaving the default setting (Normal) for older Peak Combo Sensors (serial numbers of 8xxxx) and selecting the High setting for newer Peak Combo Sensors (serial numbers of 1xxx) and existing Slimline Peak Combo Sensors.
6-30 IETG FlowHawk Manual Advanced Parameters dialog Note: Modifications made to the Advanced Parameters should be performed only by or under the guidance of trained IETG personnel. Therefore, IETG recommends leaving the default settings (Auto) in place. Modify the parameters as necessary, and then select OK once complete.
Configuration and Activation − 6-31 Manual Select this option to enter the percentage of full amplification at which to transmit the signal. Enter a percentage between 10 and 100 percent, where 100 percent represents maximum amplification. Temperature tab The temperature sensor measures the temperature of the flow at the location at which the sensor is installed. The temperature is logged at the same interval as the other entity data.
6-32 IETG FlowHawk Manual Edit Peak Combo 1 Parameters dialog displaying the Temperature tab Sensor Select the source from which to measure the temperature used when compensating for temperature in Peak/Slimline Peak Combo Sensor readings. The channels correspond to the sensors connected to those channels (ports) on the monitor. The option selected here should be consistent with the option selected for the Channel in the Device Parameters section at the bottom of the dialog.
Configuration and Activation 6-33 Note: The stored temperature value is the actual water temperature reading from the Peak/Slimline Peak Combo Sensor. Store Data Select this checkbox to ensure the monitor logs the temperature data to memory. This option is selected by default. Editing the Surface Combo Sensor Device The following section provides descriptions for the parameters corresponding to the Surface Combo Sensor device.
6-34 IETG FlowHawk Manual Edit Surface Combo 1 Parameters dialog displaying the Smart Depth tab Edit the following Device Parameters at the bottom of the dialog, and then edit the individual tabs as described in the following sections: Physical Offset Enter the physical distance from the face of the sensor to the crown (top) of the pipe.
Configuration and Activation 6-35 Sensor Installation and Connection, for instructions on measuring the physical offset. Channel Select the channel number of the port on top of the monitor to which this device is connected. Pipe Height This field displays the pipe height at the monitor location, based on the installation table. This parameter is not editable from this location.
6-36 IETG FlowHawk Manual Store Data Select this checkbox to ensure the monitor logs the smart depth data to memory. This option is selected by default. Advanced Select this button to access the Advanced Parameters dialog. Advanced Parameters dialog Note: Modifications made to the Advanced Parameters should be performed only by or under the guidance of trained IETG personnel. Therefore, IETG recommends leaving the default settings (Auto) in place.
Configuration and Activation 6-37 Surcharge Detection Select the Disable checkbox to prevent the monitor from implementing the Surcharge Detection function when processing smart depth data. For locations that typically do not experience surcharges, disabling Surcharge Detection eliminates the processing time required for this function and, as a result, conserves monitor power.
6-38 IETG FlowHawk Manual Surface Velocity tab Edit the parameters corresponding to the surface velocity sensor in the Surface Combo Sensor.
Configuration and Activation 6-39 Enable Select this checkbox to ensure the monitor begins taking velocity readings at the designated interval once activated. Transmit Frequency Select the frequency at which to transmit the signal. IETG recommends leaving the default setting (Normal) for most applications. However, if hydraulic conditions at the site are resulting in questionable or erroneous readings, consider applying one of the other frequency options. Contact IETG for assistance when necessary.
6-40 IETG FlowHawk Manual application in which this would be the preferable option would be for measuring velocity in an outgoing line following two incoming lines in the manhole. Backward Bidirectional Choose this option when the Surface Combo Sensor is installed facing downstream and to ensure the monitor analyzes flows moving both away from and toward the face of the sensor. This option would be beneficial, for example, when using a weir to measure overflows with the potential of river intrusion.
Configuration and Activation 6-41 measurements. This parameter is editable through the Installation Generator or the Quantity Coefficient Generator. Cross Check Gain Enter the value by which to multiply raw velocity readings in the monitor to determine average velocity for comparison purposes in the monitor. The default is 0.90. Store Data Select this checkbox to ensure the monitor logs the velocity data to memory. This option is selected by default.
6-42 IETG FlowHawk Manual Ping Amplitude Choose the method for managing the amplification of the analog signal that is sent out, or transmitted from, the sensor. Smaller pipes typically require weaker (quieter) amplification; larger pipes typically require stronger (louder) amplification. − Auto Select this option to allow the monitor to automatically optimize the amplification of the signal. − Manual Select this option to enter the percentage of full amplification at which to transmit the signal.
Configuration and Activation 6-43 Peak Velocity tab Edit the parameters corresponding to the peak (surcharge) velocity sensor in the following way: Edit Surface Combo 1 Parameters dialog displaying the Peak Velocity tab
6-44 IETG FlowHawk Manual Note: When using a Peak Combo Sensor and Surface Combo Sensor at the same monitoring point, ADS recommends maintaining the same settings for all of the parameters corresponding to both Peak Velocity (Velocity tab on the Edit Peak Combo Parameters dialog) and Surcharge Peak Velocity (Peak Velocity tab in the Edit Surface Combo Parameters dialog) to ensure consistency between the velocity readings.
Configuration and Activation 6-45 Backward Choose this option for monitoring points at which the Surface Combo Sensor has been positioned facing downstream and to ensure the monitor only analyzes flows moving away from the face of the sensor. One application in which this would be the preferable option would be for measuring velocity in an outgoing line following two incoming lines in the manhole.
6-46 IETG FlowHawk Manual Note: The Cross Check Gain parameter does not apply to the Peak (Surcharge) Velocity Sensor; therefore, it is not available on the Peak Velocity tab. Store Data Select this checkbox to ensure the monitor logs the velocity data to memory. This option is selected by default. Advanced Select this button to access the Advanced Parameters dialog. Advanced Parameters dialog Modify the parameters as necessary, and then select OK once complete.
Configuration and Activation 6-47 Ping Amplitude Choose the method for managing the amplification of the analog signal that is sent out, or transmitted from, the sensor. Smaller pipes typically require weaker (quieter) amplification; larger pipes typically require stronger (louder) amplification. − Auto Select this option to allow the monitor to automatically optimize the amplification of the signal.
6-48 IETG FlowHawk Manual Edit Surface Combo 1 Parameters dialog displaying the Pressure tab Enable Select this checkbox to ensure the monitor begins taking pressure depth readings at the designated interval once activated.
Configuration and Activation 6-49 Electronic Offset Enter the difference that exists between the pressure depth readings and the value equal to the pipe height minus the physical offset of the Surface Combo Sensor. However, ADS recommends leaving this value at zero. Store Data Select this checkbox to ensure the monitor logs pressure depth data to memory.
6-50 IETG FlowHawk Manual Edit Smart Depth 1 Parameters dialog Parameters Note: Under normal conditions, the parameters in this section (Parameters) should not require modification. However, if additional adjustments are necessary, refer to the detailed description of each parameter.
Configuration and Activation 6-51 Electronic Offset Enter the difference that exists between the smart depth sensor readings and the manually measured depth, when applicable. The default value is 0. Note: An electronic offset is rarely needed. An offset greater than +/- 13 millimeters typically indicates that the physical offset or pipe height has been measured or recorded incorrectly.
6-52 IETG FlowHawk Manual Modify the parameters as necessary, and then select OK once complete. DAC Gain Choose the method for managing the amplification of the analog signal that returns to the sensor: − Auto Select this option to allow the monitor to automatically optimize the amplification of the signal. − Manual Select this option to enter a fixed value between -12db (lower amplification) and +12db (high amplification) at which to amplify the signal.
Configuration and Activation 6-53 Temperature The temperature sensor measures the air temperature in the pipe to apply when calculating the speed of sound in air. Note: Under normal conditions, the parameters in the Temperature section should not require modification. However, if additional adjustments are necessary, refer to the detailed description of each parameter.
6-54 IETG FlowHawk Manual Modem Setup dialog Fill in the parameters corresponding to the Modem Setup device in the following way, when applicable: Parameter 1 Enter the carrier that you estimate will ensure the highest, most consistent level of success in performing wireless communication.
Configuration and Activation 6-55 in each field until you have indicated all of the possible carrier options corresponding to your monitor location. Enable Debug IETG reserves this option for internal diagnostic use only. Editing the Data Delivery Device Edit data delivery setup dialog The Data Delivery device enables the monitor to upload flow data stored in the monitor memory to an IntelliServe database or an FTP site at a user-designated interval.
6-56 IETG FlowHawk Manual Interval Select the rate at which you want the monitor to upload data to the selected destination. Determine the appropriate interval based on the sample rate for the monitor and the number of entities for which the monitor records data. A faster sample rate and/or a greater number of entities may require a more frequent interval for data delivery. Note: The remaining parameters apply only when uploading data to an FTP site.
Configuration and Activation 6-57 monitor to calculate QContinuity. Edit the flow device in the following way: Flow Type Select QContinuity from the drop-down list. Note: The options available for Depth Type and Velocity Type correspond to the devices assigned to the monitoring point. Depth Type Select the depth sensor from which you want to apply depth data in calculating QContinuity from the dropdown list.
6-58 IETG FlowHawk Manual Setting the Communication Parameters Setting the communication parameters involves designating the communication ports and temperature thresholds to ensure proper communication, measurement, and maintenance of the FlowHawk flow monitor. Modify the communication parameters as necessary. Note: Typically, the default settings should not require modification. 1.
Configuration and Activation Monitor Diagnostics dialog The Select Communication Parameters dialog displays. Note: The Communication Parameters screen is common to all monitor types serviced by the Profile software. As a result, some fields and default values are not relevant to the FlowHawk and, therefore, will not affect monitor operation.
6-60 IETG FlowHawk Manual Select Communication Parameters dialog 3. Select or enter the communication parameters as necessary: Modem Name Select the modem you want to use during modem communication from the drop-down list. This list should include all available modems on your computer. Modem Port Select the proper port for modem communication from this drop-down list. This list should include all available ports on your computer.
Configuration and Activation 6-61 DMI Port (This parameter does not apply to the FlowHawk) Timeout Enter the number of seconds you want your local computer to wait for a response from the monitor once communication has been initiated. Attempts Enter the number of times you want your local PC to request data from the monitor following a failed attempt while the monitor is still on line.
6-62 IETG FlowHawk Manual Low Battery FlowShark IS Internal (This parameter does not apply to the FlowHawk) Low Battery FlowShark IS External (This parameter does not apply to the FlowHawk) Low Battery FlowAlert/RainAlert II (This parameter does not apply to the FlowHawk) Low Battery Triton/FlowHawk Enter the voltage below which you want Profile to provide notification for the internal battery in FlowHawk monitors. IETG recommends entering 7.5 to ensure successful communication and operation.
Configuration and Activation 6-63 Activating the Monitor After configuring the monitor, activate the monitor to initiate the flow monitoring process based on the monitor configuration. Monitor activation involves generating the activation data using the Profile software, downloading this data to the monitor, and initiating flow data measurement and logging.
6-64 IETG FlowHawk Manual Selecting the Activate option from the Functions section on the Monitor Diagnostics dialog Profile downloads the configuration and installation information, activates the monitor, and begins logging data based on the selected configuration. 4. Select Update Connection Type from the Functions dropdown list, and then click on the Perform button. Note: The FlowHawk is configured in the factory for Serial (i.e., on-site) communication upon receipt.
Configuration and Activation 6-65 Selecting Update Connection Type from the Functions drop-down list The Update Connection Type dialog displays. Update Communication Type dialog 5. Select the method through which communication with the monitor will occur from the Communication Type drop-down list, and then click on the OK button.
6-66 IETG FlowHawk Manual Communication options available 6. Click on the Disconnect button once activation is successful (designated in the Results section) and complete and the communication type has been designated. The local computer disconnects from the monitor. 7. Click on the Close button to exit the Monitor Diagnostics dialog.
Configuration and Activation 6-67 Setting Up the RTU to Retrieve the Current Data through Modbus Following monitor activation, you must program the RTU with the appropriate Modbus register addresses corresponding to the current entity and monitor data you want to retrieve from the monitor. IETG also recommends verifying that the RTU is retrieving the desired output data shortly following monitor activation.
6-68 IETG FlowHawk Manual 2. Allow the FlowHawk monitor to take log data for an appropriate amount of time to obtain an adequate amount of data. Please note the interval at which the monitor takes readings for Modbus output is based on the Scan rate. 3. Collect the data from the monitor. Refer to Collecting Data from the Monitor on page 6-86 for detailed instructions. 4. Compare the data collected from the monitor to the output values obtained through Modbus.
Configuration and Activation 6-69 Running Sensor Diagnostics Profile’s diagnostics tool enables the user to verify the proper operation of sensors, obtain current readings and status, adjust settings, and identify, diagnose, and troubleshoot potential problems with ultrasonic depth, velocity, and pressure sensors. Run diagnostics for the system sensors in the following way: 1.
6-70 IETG FlowHawk Manual 2. Select the Connect button to establish communication with the monitor. Profile initiates communication with the monitor and establishes a connection. 3.
Configuration and Activation 6-71 Ultrasonic Depth Diagnostics This section provides instructions on running diagnostics on the upward-looking depth sensors found in both the Peak Combo Sensor and Slimline Peak Combo Sensor once connected to the monitor through the Monitor Diagnostics dialog. Run diagnostics on the upward ultrasonic depth sensor in the following way: 1. Select the Upward Ultrasonic 1 sensor from the Diagnose Device drop-down list, and then select the Diagnose button.
6-72 IETG FlowHawk Manual Upward Ultrasonic Diagnostics dialog showing current parameters for the Upward Ultrasonic 1 device 2. Click on the Read button. The Results section displays the current depth and temperature readings measured by the upward ultrasonic depth sensor in the Upward Ultrasonic Diagnostics dialog.
Configuration and Activation 6-73 Upward Ultrasonic Diagnostics dialog displaying the results after firing the Upward Ultrasonic 1 device 3. Verify the accuracy, consistency, and quality of the readings, and edit the configuration parameters as necessary. Electronic Offsets can be used to make monitor depth readings coincide with depths measured in the field. Field Depth = UpDepth1 + Electronic Offset If the sensor reading is Low, add a positive (+) electronic offset.
6-74 IETG FlowHawk Manual Advanced Parameters dialog 5. Select the Store button to save any changes made in the device parameters to the LIF in the database. Note: When running diagnostics on multiple devices for the same monitor, finish all device diagnostics before reactivating the monitor with the updated LIF. Store the changes for each device to the LIF as you complete them and before you exit the device window.
Configuration and Activation 6-75 Pressure 3 represents the pressure sensor in both the Surface Combo Sensor and the Ultrasonic Depth Sensor with the pressure option. The Pressure Diagnostics dialog displays the current configuration parameters stored in the LIF for the Pressure 1/3 sensor. Pressure Diagnostics dialog showing current parameters for the Pressure 1 device 2. Click on the Read button.
6-76 IETG FlowHawk Manual Pressure Diagnostics dialog showing the results for the Pressure 1 device following sensor firing 3. Verify the accuracy of the pressure depth and temperature readings, and edit the configuration parameters as necessary. 4. Select the Store button to save any changes made in the device parameters to the LIF in the database. 5. Select the Close button to exit the Pressure Diagnostics dialog and return to the Monitor Diagnostics dialog.
Configuration and Activation 1. 6-77 Select the Velocity 1, Peak Velocity 3, or Surface Velocity 3 from the Diagnose Device drop-down list, and then select the Diagnose button. Velocity 1 represents the velocity sensor in both the Peak Combo Sensor and the Slimline Peak Combo Sensor, Peak Velocity 3 represents the surcharge peak velocity sensor in the Surface Combo Sensor, and Surface Velocity 3 represents the surface velocity sensor in the Surface Combo Sensor.
6-78 IETG FlowHawk Manual Velocity Diagnostics dialog displaying the current velocity readings and other data after firing the Velocity 1 device 3. (optional) Click on the Advanced button to view more detailed diagnostic information. Advanced Parameters dialog 4. Verify the accuracy of the reading, and edit the configuration parameters as necessary.
Configuration and Activation 5. 6-79 Select the Store button to save any changes made in the sensor parameters to the LIF in the database. Note: When running diagnostics on multiple devices for the same monitor, consider waiting to reactivate the monitor with the new LIF until after completing the device diagnostics on all the selected devices. However, save the changes to the database before exiting each device window. 6.
6-80 IETG FlowHawk Manual Ultrasonic Diagnostics dialog displaying the current parameters for the Smart Depth 3 device 2. Click on the Read button. The Results section displays the current depth of the flow, range, and other factors measured by the Smart Depth ultrasonic sensor.
Configuration and Activation 6-81 Ultrasonic Diagnostics dialog displaying results for the Smart Depth 3 device after firing the sensor 3. Verify the accuracy, consistency, and quality of the readings, and edit the configuration parameters as necessary. Note: You can use an electronic offset to compensate for small differences between the depth readings from the monitor and depths measured in the field.
6-82 IETG FlowHawk Manual Advanced Parameters dialog 5. Select the Store button to save any changes made in the sensor parameters to the LIF in the database. Note: When running diagnostics on multiple devices for the same monitor, finish all device diagnostics before reactivating the monitor with the updated LIF. Store the changes for each device to the LIF once complete and before exiting the device window. Reactivate the monitor with the new LIF after completing diagnostics on all the selected devices.
Configuration and Activation 1. 6-83 Select the Temperature [1 or 3] sensor from the Diagnose Device drop-down list, and then select the Diagnose button. Temperature 1 represents the temperature sensor in both the Peak Combo Sensor and the Slimline Peak Combo Sensor; Temperature 3 represents the temperature sensor in the Surface Combo Sensor and the Ultrasonic Depth Sensor. The Temperature Diagnostics dialog displays. Temperature Diagnostics dialog for Temperature 1 device 2. Click on the Read button.
6-84 IETG FlowHawk Manual Temperature Diagnostics dialog displaying the temperature from the Temperature 1 device 3. Verify the accuracy of the reading. This reading represents the water temperature. 4. Click on the Close button to exit the Temperature Diagnostics dialog and return to the Monitor Diagnostics dialog. Activating the Monitor If a change has been made to any of the sensor parameters, reactivate the monitor through the Diagnostics mode.
Configuration and Activation 6-85 Note: IETG also recommends performing confirmations to verify the accuracy of the data and equipment. Confirmations involve comparing manual flow depth, temperature, and velocity measurements taken in the field against monitor readings taken electronically. The technician or analyst confirms the accuracy of the data based on the difference between the monitor and field readings. For more information, refer to the Profile User’s Guide #950015 (version B4 or higher).
6-86 IETG FlowHawk Manual Collecting Data from the Monitor The data collection function available through Diagnostics provides enhanced features for viewing and analysis. Once the collection process is complete, Profile displays the data in both hydrograph and scattergraph formats based on the entities collected. In addition to the scattergraph displaying the depth-to-velocity relationship, it also displays a scattergraph illustrating the correlation between depth entities.
Configuration and Activation 6-87 Monitor Diagnostics dialog 2. Select the Connect button to establish communication with the monitor. Profile initiates communication with the monitor and establishes a connection. 3. Select Collect from the Functions drop-down list, and then select the Perform button.
6-88 IETG FlowHawk Manual Selecting the Collect option from the Functions drop-down list on the Monitor Diagnostics dialog Profile displays the Collect the Specified Data dialog.
Configuration and Activation 6-89 Collect the Specified Data dialog 4. Designate the range of data you want to collect from the monitor by editing the Start and End Time fields in the Collect Information in the section. Edit these fields directly by selecting the portion of the date or time stamp you want to change and then entering the appropriate designation or using the arrows to scroll up and down in the range.
6-90 IETG FlowHawk Manual Collect The Specified Data dialog indicating data collection was a success 6. Click on the Next button. The View Hydrograph – [location name] dialog displays the collected data in hydrograph format.
Configuration and Activation 6-91 View Hydrograph – [location name] dialog 7. Review the data on the hydrograph, and then click on the Next button. Under optimal conditions, the depth and velocity data should reflect a consistent diurnal pattern. The View Depth and Velocity Scattergraph – [location name] dialog displays the collected depth and velocity data in scattergraph format.
6-92 IETG FlowHawk Manual View Depth and Velocity Scattergraph – [location name] dialog 8. Review the data on the scattergraph, and then click on the Next button. Under optimal conditions, the data on the graph should reveal velocity increasing with depth. The View Ultrasonic and Pressure Scattergraph – [location name] dialog displays the collected ultrasonic and pressure depth data in scattergraph format.
Configuration and Activation 6-93 View Ultrasonic and Pressure Scattergraph – [location name] dialog 9. Review the data on the scattergraph, and then click on the Next button. A properly performing pressure depth sensor should display a one-to-one relationship with the UNIDEPTH data. The Site DR Analysis – [location name] dialog displays the results of the site data review analysis of the collected data and any recommendations for resolving identified issues.
6-94 IETG FlowHawk Manual Site DR Analysis – [location name] dialog 10. Review any issues identified and the suggested actions, and then click on the Finish button. 11. Click on the Close button. The Monitor Diagnostics dialog displays. The Results section displays the recommendations from Site DR Analysis when applicable.
Configuration and Activation 6-95 Upgrading the Monitor Firmware Profile enables you to download updated firmware to the FlowHawk flow monitor that may include new features and capabilities or performance improvements and enhancements in functions such as data processing, analysis, or communications. IETG strongly recommends collecting the data from the monitor before updating the firmware in the monitor to avoid losing the flow data stored in the monitor memory.
6-96 IETG FlowHawk Manual Selecting the Update Firmware option from the Functions drop-down list on the Monitor Diagnostics dialog The Form Firmware Download dialog displays.
Configuration and Activation 6-97 4. Select the Browse button corresponding to Firmware field to locate and designate the file applicable to the firmware download. This program file represents the firmware containing the updated code for data processing activities. 5. Select the OK button. Profile downloads the new firmware to the monitor. 6. Disconnect from the monitor using Profile.
6-98 IETG FlowHawk Manual Viewing Diagnostic and Data Logs Profile generates detailed logs for many activities performed through Diagnostics, such as monitor activation, data collection, and firmware downloading. These logs are available immediately following the activity and for future access to historical information. 1. Select the monitor location for which you want to view a diagnsotic or data log from the Profile main screen, and then click on the Diagnostics toolbar button.
Configuration and Activation 6-99 Selecting the Logs option from the Functions drop-down list on the Monitor Diagnostics dialog 4. Click on the Perform button. The View Logs dialog displays.
6-100 IETG FlowHawk Manual View Logs dialog 5. Select the type of log you want to view from the Log Type drop-down list. The Logs section displays all logs available for the selected location and log type. 6. Select the specific log you want to view, and select the View button. The View Logs dialog displays the logs available for viewing corresponding to the selected log type. 7. (optional) Select the Print button to print the log file contents.
7-1 CHAPTER 7 Monitor Installation After installing the sensors and establishing communications, install the IETG FlowHawk™ monitor in the manhole. The monitor mounts inside the manhole by a mounting bracket attached to the monitor and bolted to the manhole wall or using a hook attached to a manhole rung. The following procedures for monitor installation apply to most sites.
7-2 IETG FlowHawk Manual Mounting the Monitor on Manhole Rung The simplest way to mount a monitor in a manhole is to attach it to a rung. FlowHawk monitors come with a standard hook for this purpose. Make sure the rungs are capable of holding the weight of the monitor and cables. The monitor weighs 13.7 kilograms (30.3 lbs) with added weight coming from the cables. The hook must be closed to prevent accidental dislodging from its support rung.
Monitor Installation 7-3 Mounting the Monitor Handle to the Manhole Wall If the project will involve measuring flow over a long period of time, consider mounting the monitor permanently to the manhole wall. Using a monitor handle (p/n I40-0009), you can hang the monitor more securely and out of the way to allow use of the rungs. Mount the monitor handle to the manhole wall as follows: 1. Determine the appropriate location to mount the monitor handle to the manhole wall.
7-4 IETG FlowHawk Manual 5. Mount the bottom of the bracket onto the monitor mounting flange with two M8 x 30-mm stainless steel bolts, two M8 stainless steel lock washers, and two M8 stainless steel flat washers. Bolting the mounting bracket to the flange welded to the monitor 6. Carefully lower the monitor into the manhole, and place the keyhole of the mounting bracket over the anchor bolt.
Monitor Installation 7-5 Monitor installed in the manhole 8. Neatly coil and secure the excess sensor and communication cables in the manhole to simplify future monitor service activities. Secure the cables to plastic anchors or M6 x 55-mm anchor bolts using 5-mm x 300-mm cable ties. Note: Be careful to avoid damaging the sensor cables during installation activities. Even small pinholes in the cable can cause a sensor to malfunction or fail.
8-1 CHAPTER 8 Maintenance and Troubleshooting While the IETG FlowHawk™ flow monitor and sensors are designed for dependability and durability, all electronic devices are vulnerable to wear, malfunction, or failure, particularly in a harsh sewer environment. However, many system problems can be avoided altogether by performing routine maintenance and inspections.
8-2 IETG FlowHawk Manual Maintaining the System Components The FlowHawk flow monitor and sensors should receive routine onsite inspections and remote confidence checks to maintain the equipment in optimal working condition, minimize monitor downtime, and prevent possible data loss. IETG recommends performing these inspections following initial system installation, during site visits, and on a scheduled interval (i.e., quarterly or during battery pack replacement).
Maintenance and Troubleshooting Compressed air Flat head screwdriver and assorted wrenches Magnet (for troubleshooting wireless communications) 8-3 Inspecting the Monitor Perform the following inspections during site visits or from a remote location (when applicable): Inspect the monitor mounting bracket to verify that the bracket and bolts are free of heavy corrosion and the bolts are tightened and secure.
8-4 IETG FlowHawk Manual Confirming the Monitor Confirm the accuracy of the sensor subsystems in the monitor on a regular basis through Profile or Qstart. Confirmation involves comparing manually-measured depth of flow and velocity readings to the monitor's readings. This process also verifies sensor parameters. Refer to the Profile User's Guide #950015 (version B4 or higher) or the Profile or Qstart online help for detailed information on performing confirmation procedures.
Maintenance and Troubleshooting 8-5 EMUs do not support this diagnostic functionality. However, IETG does provide an LED window on the EMUX for monitoring activities occurring through the ports on the EMUX, such as communications and data transfer. Refer to Appendix D, Modbus/EMUX Configuration and Diagnostics, for more information.
8-6 IETG FlowHawk Manual Proper location to contact magnet on GSM Module Note: The GSM module will not initiate the diagnostic code sequence while codes representing monitor activity are displaying in the window. Therefore, always verify that the LED window is blank before attempting to activate the code sequence. In addition, make sure the LED window is in clear view before initiating the code sequence.
Maintenance and Troubleshooting 8-7 Codes active after removing magnetic from contact with GSM Module Upon activation, interpret the diagnostic codes in succession in the following way: Note: The LED window displays only one number/ character at a time.
8-8 IETG FlowHawk Manual Testing the Monitor Cryout Capability You can test the monitor’s ability to perform a cryout, representing a system event or alarm, to an IntelliServe® system (when applicable) by holding the magnet against the GSM module just to the left of the antenna jack (with LEDs properly oriented and antenna connection facing downward) for 5 seconds and then releasing the magnet from the module. The sequence Cryout indicates initiation of the cryout test message to IntelliServe.
Maintenance and Troubleshooting 8-9 The Print Preview dialog displays the current system information, including the monitor battery voltage, in printable format. Select the Print button to print the report contents, if desired. Monitor Status report with internal battery pack voltage Replacing the Monitor Battery Pack Note: The only service or maintenance activities IETG permits within the monitor chassis are battery pack and fuse replacement.
8-10 IETG FlowHawk Manual IETG currently offers two versions of the 12-volt battery pack for replacing the existing battery pack in the FlowHawk, when necessary. However, based on the date on which the monitor and/or battery pack was manufactured, the monitor may contain an earlier version of the 12-volt battery pack that is no longer available.
Maintenance and Troubleshooting 8-11 12-volt battery packs (left – potted; right – unpotted) Replace the internal battery in the FlowHawk monitor in the following way: 1. Collect the data from the monitor (remotely or on-site). This will reduce the risk of data loss once the battery is disconnected. 2. (applicable only when using a GSM Module) Remove the monitor from the manhole, and disconnect the communication cable (running from the GSM module) from the COMM port on the monitor. 3.
8-12 IETG FlowHawk Manual Viewing 12-volt battery pack in monitor canister from top 7. Place the top next to the canister, and then disconnect the battery cable from the dome cable and set the top/power regulator dome assembly aside. Note: Keep the underside of the top, the regulator dome, and the top gasket free of dirt, mud, and other debris. Debris and dirt can compromise the seal of the monitor once it is reassembled.
Maintenance and Troubleshooting 8-13 Placing top next to monitor (left) and disconnecting battery pack from top (right) 8. (applies only to 12-volt potted battery packs) Remove the foam spacer disc seated on top of the battery. 9. Pull out the battery pack from the canister using the white handle attached to the top of the pack. 10.
8-14 IETG FlowHawk Manual Carefully slide the thick red band securing the PCB on the side of the battery pack off of the PCB. Carefully disconnect the PCB from the battery pack at the white plastic connector. Disconnecting the PCB from the battery pack Set the PCB temporarily aside in a clean, dry location. Do not discard! This PCB will be used with the replacement battery pack. 11. Connect the PCB to the replacement battery pack and then secure the PCB to the side of the pack with the red band.
Maintenance and Troubleshooting 8-15 14. Coil the excess cabling around the inner wall of the canister, and carefully lower the top/dome assembly back onto the canister. Keeping the proper orientation between the canister and the top is critical to maintaining the watertight and airtight seal on the monitor. Once the top has been torqued down after manufacture, the sealing gasket develops a memory profile of the canister lip.
8-16 IETG FlowHawk Manual 15. (applicable only when using a GSM Module) Reconnect the communication cable from the GSM Module to the COMM port on the monitor. Note: Do not reconnect the communication cable to the monitor while the monitor is taking a reading. This could damage the monitor. 16. Establish communication with the monitor remotely or on site using the IS PC Communication cable (p/n 8000-0054) to verify communication and check the new battery voltage.
Maintenance and Troubleshooting 8-17 Communication cable from GSM Module connected to COMM port on monitor with stretch tape properly applied Inspecting, Cleaning, and Handling the Sensors Perform the following sensor inspections during regular site visits: Verify that the installation ring or bands are secure and clear of debris. Clean the face of the Surface Combo Sensor/Ultrasonic Depth Sensor gently with a soft brush, and wipe the sensor with a clean, moist cloth.
8-18 IETG FlowHawk Manual Scrub the faces of the Peak Combo Sensor/Slimline Peak Combo Sensor with a soft bristle brush. Confirm that all sensor cables are neatly arranged, securely fastened, and free of debris, cuts, kinks, and breaks that may affect performance. Replace any sensor that has a damaged cable. When handling, storing, or packing the Surface Combo Sensor, avoid contacting the metal cable connector with the crystals on the sensor.
Maintenance and Troubleshooting 4. 8-19 Attach a new dryer tube to the pressure depth sensor by inserting the brass barbed fitting into the open end of the plastic tubing running from the sensor connector. Make sure the tubing seats firmly against the fitting to prevent air or moisture transfer. Inserting the brass barbed fitting into the tube 5. Secure the new dryer tube to the monitor. 6. Remove the black end-cap from the dryer tube before reinstalling the monitor in the manhole.
8-20 IETG FlowHawk Manual Replace the desiccant in the following way: 1. Clip the cable ties securing the dryer tube to the monitor, when applicable. 2. Use a 16-mm (or 5/8-in) nut driver to remove the inset nut at the free end of the dryer tube (end of the tube opposite the brass barbed fitting).
Maintenance and Troubleshooting 8-21 Note: Some desiccant may be reused following a special process designed to remove the moisture from the beads. Please consult the desiccant manufacturer for instructions on performing this procedure, when applicable. Replacing the SIM Card and Desiccant in the GSM Module Battery-powered FlowHawk monitors handle communications through a GSM Module (p/n 8000-0052). This module contains a replaceable desiccant pack and SIM card.
8-22 IETG FlowHawk Manual 3. Remove the electrical tape sealing the seam between the cover and top of the GSM module enclosure. 4. Loosen the four plastic Phillips head screws from the clear top of the module, and then remove the top. 5. (applicable only when replacing the desiccant) Replace the desiccant in the following way: Remove the existing desiccant pack from the module and discard. Inspect the inside of the module for any moisture.
Maintenance and Troubleshooting 8-23 Sliding back the clip to unlock the carrier Swing up the hinged clip to the carrier and remove the SIM card from the slot. Opening hinged clip and removing SIM card Record the number of the new SIM card (i.e., the IP address) on the site report. You will need this address to update the LIF in the Profile or Qstart software.
8-24 IETG FlowHawk Manual address is printed directly on the SIM card or on a label affixed to the card. Gently insert the new card into the slot on the SIM card carrier in the GSM module. Orient the card so that the beveled corner of the card will align with the beveled corner of the carrier. Close the clip to the carrier, and slide the clip forward to lock the SIM card into place. 7. Check the gasket and all edges of the module enclosure seal to make sure they are free of any debris. 8.
Maintenance and Troubleshooting 8-25 Replacing EMU Components IETG allows you to replace the following components in EMUs supporting communications for externally-powered FlowHawks, when necessary: GSM/GPRS Modem SIM Card Note: Do not open the Communication Interface/Barrier Box inside the EMU under any circumstances. In addition, do not attempt to perform any component-level repair.
8-26 IETG FlowHawk Manual Disconnecting the antenna cable from the EMU modem 5. Carefully slide the modem all the way out of the bracket in which it is secured. It is secured only by friction. A power and communication cable are connected to the back of the modem, so slide it out slowly to avoid accidentally pulling the cables out of the modem prematurely.
Maintenance and Troubleshooting 8-27 Sliding the modem out of the bracket in the EMU 6. Disconnect the ribbon (communication) cable and the black (power) cable from the back of the modem.
8-28 IETG FlowHawk Manual Disconnecting the ribbon and black cables from the back of the modem 7. Connect the ribbon and black power cables to the corresponding ports in the back of the new modem. 8. Carefully slide the modem back into the metal bracket in the EMU, avoiding pinching the cables between the modem and the back panel of the EMU. 9. Insert a new SIM card or the SIM card from the original modem into the slot on the new modem.
Maintenance and Troubleshooting 8-29 Replacing the SIM Card in the EMU Modem Replace the SIM card in the modem housed within the EMU in the following way: 1. Disconnect the external power running to the EMU. 2. Open the enclosure in which the EMU is installed. 3. Loosen the four plastic screws on the cover of the EMU, remove the cover, and then carefully set the cover aside to avoid damage and prevent dirt from contacting the cover gasket. 4.
8-30 IETG FlowHawk Manual Inserting the SIM card into the EMU modem 9. Slide the lock to the left to secure the SIM card. 10. Restore external power to the EMU. 11. Contact a data analyst to enter the IP address for the new SIM card in Profile or Qstart, and have the analyst attempt to connect to the monitor remotely to verify communication. 12. Replace and secure the cover to the EMU, and close the enclosure in which it is installed.
Maintenance and Troubleshooting 8-31 5. Slide the new SIM card into the clip until it is seated securely in place. 6. Restore external power to the EMUX. 7. Contact a data analyst to enter the IP address for the new SIM card in Profile, and have the analyst attempt to connect to the monitor remotely to verify communication. 8. Replace the cover onto the EMUX, and replace and tighten the screws.
8-32 IETG FlowHawk Manual The following section includes detailed instructions on replacing fuses (when applicable) in FlowHawk monitors. Replacing Fuses in the Monitor Regulator boards (manufactured as of 2012) in FlowHawk monitors have three fuses (p/n 508071, 508072, and 508073) that may be replaced independently upon failure.
Maintenance and Troubleshooting 8-33 3. Remove the four bolts securing the monitor top to the canister using a 13-mm nut driver. 4. Wipe away any debris or moisture that could enter the chassis once the unit is opened. 5. Remove the top (with the attached power regulator dome) by pulling straight up from the canister. 6. Place the top next to the canister upside down (with the dome facing upward), and then disconnect the battery cable from the dome cable.
8-34 IETG FlowHawk Manual Nut securing dome Removing nut securing regulator dome to monitor top 8. Carefully lift off the dome from the top. Notice the three fuses seated on the regulator board on the inside of the dome. Underside of monitor top (left) and inside of regulator dome (right) 9. Remove the bad fuse(s) from the regulator board by gently, but firmly, pulling and lifting it straight up from the board.
Maintenance and Troubleshooting 8-35 Close up of regulator board showing the three color-coded fuses Blue fuse removed from the regulator board 10. Carefully insert the new, replacement fuse(s) into the corresponding holes in the dome without bending the fuse filaments. Verify that the color strip on the fuse matches the color on the regulator board adjacent to the holes. Make sure the fuse(s) is seated firmly and securely.
8-36 IETG FlowHawk Manual 11. Realign and reseat the dome against the monitor top, and replace and tighten the nut securing the dome to the top. 12. Reconnect the battery cable to the cable exiting from the hole in the top/dome assembly. 13. Coil the excess cabling around the inner wall of the canister, and carefully lower the top/dome assembly back onto the canister. Keeping the proper orientation between the canister and the top is critical to maintaining the watertight and airtight seal on the monitor.
Maintenance and Troubleshooting A CH NN E L A CH 2 NN E L 8-37 1 0518 II 1 G Ex ia IIB T4 Ga Sira 09ATEX2027X MODEL: 8000 - FHK/FST ST ONLY TE M AX . 8 2 kP Use only battery pack 106152 a FLOWHAWK TM IETG CO M M W W W. I E T G .C O . U K Returning the monitor top to the proper orientation with the canister 14. Establish communication with the monitor remotely or on site using the IS PC Communication Cable (p/n 8000-0054) to verify communication.
8-38 IETG FlowHawk Manual Troubleshooting The FlowHawk flow monitor contains several different components that perform many different functions. Since a malfunctioning component increases the risk of losing data, isolating the problem component is essential to performing troubleshooting activities efficiently. Minimizing monitor downtime is critical.
Maintenance and Troubleshooting 8-39 Some problems that occur will not require a site visit, such as incorrect equipment identification numbers or other system parameters the user can re-enter on the local PC. However, some problems will require a site visit. When this is necessary, inform the data analyst any time a field crew is en route to a monitor site to troubleshoot problems so that the analyst can attempt to collect the monitor data before they arrive.
8-40 IETG FlowHawk Manual Problem Time on the monitor clock is incorrect. Possible Causes Monitor clock may be a faulty. Possible Solutions Verify the time on the PC clock and correct if necessary. Monitor time zone difference for the PC clock may not have been set correctly when the monitor was activated. Reactivate the monitor to enable the clock. Verify the time zone setting of the monitor. Correct and reactivate if necessary. Collect the data from the monitor and replace monitor if defective.
Maintenance and Troubleshooting Problem Gap exists within the collected data. Possible Causes Monitor time may be incorrect. Possible Solutions Check monitor time, and reset clock if necessary. Monitor firmware file may be corrupt. Attempt to collect data within the gap. Contact your regional IETG representative. Problem Data is missing at the beginning or end of the date range following data collection. Possible Causes Monitor activation may have failed. Monitor time may be incorrect.
8-42 IETG FlowHawk Manual Problem Monitor independently discontinues logging data. Possible Causes Battery pack may be dead or below minimum voltage requirement (7.5 volts - internal), or external power source may be down. 3.3-volt fuse on regulator may have blown. Monitor memory may have been corrupted during firmware upgrade, causing the monitor to record data only during monitor communications. Possible Solutions Replace battery pack. Replace the 3.
Maintenance and Troubleshooting 8-43 Communication Problems The following tables contain general troubleshooting techniques for communications. Problem Monitor does not answer via wireless communication. Possible Causes Signal strength to the modem may be insufficient. Battery pack may be dead or below minimum voltage requirement (7.5 volts - internal), or external power source may be down. Wireless network failure. Monitor may have lost communication with network and cannot re-establish communication.
8-44 IETG FlowHawk Manual Possible Solutions Check the diagnostic codes on the GSM module (using magnet) while it is connected to the monitor to verify the IP address is available. If it does not display, disconnect the module from the monitor for at least 1 minute and then reattach the module. Once the LED is no longer illuminating, reactivate the diagnostic codes to verify whether the IP address is now available. Relocate the antenna (consider a pedestal mount) Replace the antenna.
Maintenance and Troubleshooting 8-45 Problem Modem connects but monitor does not respond. Possible Causes Connection Type configuration has reverted to Serial. Possible Solutions Verify that the communication type is set to GPRS. 3.3-volt fuse on regulator may have blown. Inspect the communication cable connection between the modem and monitor to determine if the cable is disconnected or has been damaged. Connect directly with the monitor using the 8000-0054 cable. Verify the monitor responds.
8-46 IETG FlowHawk Manual Problem Monitor cannot communicate over a serial connection. Possible Causes Serial connection to monitor or field computer may be loose. Direct Connect Cable may be damaged. Serial port on the computer may not be generating adequate power for the Direct Connect Cable to facilitate communication with the monitor. 3.3-volt fuse on regulator may have blown. Possible Solutions Verify cable connections to monitor and field computer are secure.
Maintenance and Troubleshooting 8-47 Ultrasonic Depth Subsystem The following tables contain general troubleshooting techniques for problems with the ultrasonic depth subsystem corresponding to the Surface Combo Sensor and the Ultrasonic Depth Sensor. Note: Contact your IETG representative for further diagnosis prior to replacing a sensor. Problem Range from ultrasonic depth subsystem is slightly inconsistent with manually measured range. Possible Causes Physical offset may be incorrect.
8-48 IETG FlowHawk Manual Problem Range from ultrasonic depth subsystem is significantly greater than manually measured range. Possible Causes Physical offset may be incorrect. Pipe height may be incorrect. Electronic offset may be incorrect. Sensor may not be level. Foam or other substance may be absorbing the pulse. Sensor may be faulty. Possible Solutions Verify the physical offset. Verify the pipe height. Verify electronic offset and adjust if necessary.
Maintenance and Troubleshooting 8-49 Problem Range from the ultrasonic depth subsystem is too short (but not zero). Possible Causes Pipe height may be incorrect. Electronic offset may be incorrect. CS3 depth sensor may be dirty. CS3 depth sensor may be faulty. Possible Solutions Verify the pipe height. Verify electronic offset and adjust if necessary. Clean the sensor. Replace the sensor. Contact your regional IETG representative.
8-50 IETG FlowHawk Manual Problem Depth data indicates a surcharged pipe, but the pipe is free flowing. Possible Causes Physical offset may be incorrect. Electronic offset may be incorrect. Pipe height may be incorrect. Sensor may be dirty. Sensor may be faulty. Possible Solutions Verify the physical offset. Verify the pipe height. Verify electronic offset and adjust if necessary. Clean the sensor. Contact your regional IETG representative. Replace the sensor. Replace the monitor if defective.
Maintenance and Troubleshooting 8-51 Problem Individual ultrasonic depth readings (SDEPTH_3) from the Surface Combo Sensor are consistently equivalent to the value obtained from the following equation: Pipe Height – Physical Offset + 9.99. Possible Causes Sensor may be faulty. Possible Solutions Replace the Surface Combo Sensor. 5-volt fuse on regulator may have blown. Replace the 5-volt blue fuse on the regulator or return the monitor to IETG for regulator replacement.
8-52 IETG FlowHawk Manual Upward Depth Subsystem The following tables contain general troubleshooting techniques for the upward depth subsystem corresponding to the Peak Combo Sensor and Slimline Peak Combo Sensor. Note: Contact your regional IETG representative for further diagnosis prior to replacing a sensor. Problem UpDepth data periodically reads 16 mm (0.63 in). Possible Causes Minimum flows are occurring within sensor deadband (extending 25 mm (1.
Maintenance and Troubleshooting Problem UpDepth data seems erratic over a full depth range. Possible Causes Sensor transmit/receive surfaces may be dirty. 8-53 Sensor may be rotated greater than 15 degrees from center. Sensor may be faulty. Processor board may be faulty. Possible Solutions Clean the sensor transmit/receive surfaces. Check the sensor connections. Ensure the sensor is installed as closely as possible to the 6:00 position in the pipe, silt allowing.
8-54 IETG FlowHawk Manual Problem Individual UpDepth_1 values consistently read -9.99. Possible Causes Sensor may be faulty. Possible Solutions Replace the Peak/Slimline Peak Combo Sensor. 5-volt fuse on the regulator may have blown. Replace the 5-volt blue fuse (when replaceable) on the regulator or return the monitor to IETG for regulator replacement. Caution: Do not connect a questionable sensor to another monitor before verifying the integrity of the sensor.
Maintenance and Troubleshooting 8-55 Peak Velocity Subsystem The following tables contain general troubleshooting techniques for the velocity subsystem corresponding to the Peak Combo Sensor, Surface Combo Sensor (Surcharge Velocity Sensor only), and Slimline Peak Combo Sensor. Since the Surface Combo Sensor is mounted at the top of the pipe, potential issues involving a sensor that is out of the flow do not apply to the Surface Combo Sensor.
8-56 IETG FlowHawk Manual Problem Velocity data does not fluctuate much (but is not 0). Possible Causes Sensor may be dirty. Minimum flows may be occurring within the sensor deadband (extending 25 mm (1.0 in) up from the bottom of the Peak Combo Sensor or Slimline Peak Combo Sensor). Velocity function may be broken. Possible Solutions Clean the sensor’s transmit/receive surfaces. Verify that minimum flows are occurring outside the sensor deadband. Check the sensor connections.
Maintenance and Troubleshooting Problem Velocity data seems erratic or exhibits poor quality. Possible Causes Sensor transmit/receive surfaces may be dirty. 8-57 Sensor may be close to extending out of the flow. Designated value for the maximum velocity parameter may be too high, creating too broad of a range. Sensor may be faulty. Processor board may be faulty. Possible Solutions Clean the sensor transmit/receive surfaces.
8-58 IETG FlowHawk Manual Problem Individual PEAKVEL_1 or PEAKVEL_3 values consistently read -9.99. Possible Causes Sensor may be faulty. Possible Solutions Replace the Peak, Slimline Peak, or Surface Combo Sensor. 5-volt fuse on regulator may have blown. Replace the 5-volt blue fuse (when replaceable) on the regulator or return the monitor to IETG for regulator replacement. Caution: Do not connect a questionable sensor to another monitor before verifying the integrity of the sensor.
Maintenance and Troubleshooting 8-59 Problem Individual SURFACEVEL_3 values consistently read 9.99. Possible Causes Sensor may be faulty. Possible Solutions Replace the Surface Combo Sensor. 5-volt fuse on regulator may have blown. Replace the 5-volt blue fuse (when replaceable) on the regulator or return the monitor to IETG for regulator replacement. Caution: Do not connect a questionable sensor to another monitor before verifying the integrity of the sensor.
8-60 IETG FlowHawk Manual Pressure Depth Subsystem The following tables contain general troubleshooting techniques for the pressure depth subsystem corresponding to the Peak Combo Sensor, Surface Combo Sensor, and Ultrasonic Depth Sensor with the pressure depth option. Note: Contact your regional IETG representative for further diagnosis before replacing a sensor. Problem Pressure depth readings are erratic. Possible Causes Pressure vent tube may be pinched or blocked with water.
Maintenance and Troubleshooting 8-61 Problem Individual PDEPTH_1 values consistently read 0 under wet pipe conditions. Possible Causes Sensor may be faulty. Possible Solutions Replace the Peak Combo Sensor. 5-volt fuse on regulator may have blown. Replace the 5-volt blue fuse (when replaceable) on the regulator or return the monitor to IETG for regulator replacement. Caution: Do not connect a questionable sensor to another monitor before verifying the integrity of the sensor.
A-1 APPENDIX A Specifications This appendix contains specifications for the IETG FlowHawk flow monitor and associated subassemblies, sensors, cables, and wireless communication hardware. FlowHawk Flow Monitor (8000-FHK-60C) Enclosure Cylindrical, 6.39-millimeter (0.
A-2 IETG FlowHawk Manual Battery Life 15 months at 15-minute sample rate and weekly communications Actual battery life will vary depending on operating temperature, number of active devices operated, and frequency of communications. Connectors U.S.
Specifications A-3 • The log rate determines the number of readings taken per day. At a 15-minute sample rate, the monitor will record 96 readings a day for a single entity. At a 2-minute sample rate, the monitor will record 720 readings a day for a single entity. • One entity reading consumes 8 bytes of monitor memory. • The following table lists the standard number of entities recorded for each sensor device. The date/time stamp for a reading is equal to one reading.
A-4 IETG FlowHawk Manual Intrinsically-Safe Sensors Peak Combo Sensor (8K-CS4-xx-35/1H) This sensor supports upward ultrasonic depth, peak velocity, and pressure depth. Enclosure Dimensions Cable ABS plastic shell, epoxy-filled Enclosure: 172 millimeters (6.76 in) long x 31 millimeters (1.23 in) wide x 21 millimeters (0.83 in) high Standard size: 10.7 meters (35 ft) or 30.5 meters (100 ft) long x 7.6 millimeters (0.30 in) nominal OD, polyurethane jacket Extension cables available up to 91.
Specifications A-5 Peak Doppler Velocity Range -9.1 to 9.1 meters per second ( -30 to 30 ft/sec) Deadband Extending 25 millimeters (1.0 in) up from the bottom of the sensor Frequency 250 kHz Resolution 0.003 meters per second (0.01 ft/sec) Accuracy 0.06 m/sec (+/- 0.2 ft/sec) or 4% of actual peak velocity (whichever is greater) in flow velocities from -1.52 to 6.10 m/sec (-5 to 20 ft/sec) Pressure Depth Pressure Range 0.0 – 0.34 Bar (0.0 to 5.0 PSI): up to 3.5 meters (11.5 ft) 0.0 – 1.
A-6 IETG FlowHawk Manual CS3-V2-XX-30) are available in the previous version of the FlowHawk Installation, Operation, and Maintenance Manual (QR 775012 A3). Enclosure ABS plastic shell, epoxy-filled Dimensions Cable 269 millimeters (10.61 in) long x 52 millimeters (2.03 in) wide x 62 millimeters (2.45 in) high Standard size: 9.14 meters (30.0 ft) long x 11 millimeters (0.
Specifications A-7 Surface Velocity Accuracy +/- 0.08 meters per second (0.25 ft/sec) or 5% of the actual reading (whichever is greater) in flow velocities from 0.30 to 4.57 m/s (1.00 to 15.00 ft/sec) Note: Flow conditions may cause the designated accuracy to vary and hinder or prevent the effective use of surface velocity technology. Deadband 76 mm (3 in) from the bottom of the rear, descended portion of the sensor Minimum Velocity 0.
A-8 IETG FlowHawk Manual Surcharge Pressure Depth Pressure Range 0.0 - 0.34 Bar (0.0 to 5.0 PSI): up to 3.5 meters (11.5 ft) 0.0 - 1.03 Bar (0.0 to 15.0 PSI): up to 10.5 meters (34.5 ft) Pressure Accuracy Pressure Resolution 0 - 0.34 Bar (0.1 - 5.0 PSI): +/- 36 mm (1.4 in) 0 - 1.03 Bar (0.1 - 15.0 PSI): +/- 104 mm (4.1 in) 0.25 millimeters (0.01 in) Ultrasonic Depth Sensor (p/n 8K-CS3-V0-xx-30) This sensor supports downward ultrasonic depth and optional pressure depth.
Specifications A-9 Downward Ultrasonic Depth Accuracy 3.2 millimeters (0.125 in) Deadband 12.7 millimeters (0.5 in) or 5% of maximum range, whichever is greater Frequency 40 kHz Range 12.7 millimeters (0.5 in), or 5% of maximum range (whichever is greater) to 3.05 meters (10.0 ft) Resolution 0.25 millimeters (0.01 in) Drift 0.0 millimeters (0 in) Pressure Depth (optional) Pressure Range 0.0 – 0.34 Bar (0.0 to 5.0 PSI): up to 3.5 meters (11.5 ft) 0.0 – 1.03 Bar (0.0 to 15.0 PSI): up to 10.
A-10 IETG FlowHawk Manual Slimline Peak Combo Sensor (p/n 8K-CS4-35) This sensor supports upward ultrasonic depth and peak velocity. Enclosure ABS plastic shell, epoxy-filled Dimensions Enclosure: 136 millimeters (5.36 in) long x 32 millimeters (1.25 in) wide x 21 millimeters (0.81 in) high Cable Standard size: 10.7 meters (35 ft) long x 7.9 millimeters (0.31 in) nominal OD, polyurethane jacket Extension cables available up to 91.
Specifications A-11 Peak Doppler Velocity Range -9.1 to 9.1meters per second ( -30 to 30 ft/sec) Deadband Extending 25 millimeters (1.0 in) up from the bottom of the sensor Frequency 250 kHz Resolution 0.003 meters per second (0.01 ft/sec) Accuracy 0.06 m/sec (+/- 0.2 ft/sec) or 4% of actual peak velocity (whichever is greater) in flow velocities from -1.52 to 6.
A-12 IETG FlowHawk Manual Wireless GSM Module (p/n 8000-0052) The wireless GSM module supports the battery-powered FlowHawk. Modem Size GSM/GPRS cellular modem supporting GPRS TCP/IP (Transmission Control Protocol/Internet Protocol) Cable: 7.6 millimeters (0.3 in) nominal OD Length: 1.82 meters (6 ft) Enclosure: 130 x 79 x 36 millimeters (5.1 x 3.1 x 1.
Specifications A-13 External Modem Unit (p/n 3800-0148) The EMU (external modem unit) supports the externally-powered FlowHawk monitor. Enclosure Dimensions Weight Operating Temperature External Power Wireless Modem Connections Communication Cable Rectangular UL-Recognized NEMA 4X/6P composite enclosure with stainless steel hardware 457 millimeters (18 in) high x 152 millimeters (6 in) wide x 191 millimeters (7.5 in) deep 5.
A-14 IETG FlowHawk Manual External Modem Unit/Multiplexer (p/n 106226E) The IETG external modem unit/multiplexer (EMUX) supports the externally-powered FlowHawk monitor and SCADA or process control systems. Enclosure Dimensions Weight Operating Temperature External Power Wireless Modem Connections Communication Cable Rectangular NEMA 1 plastic enclosure with stainless steel hardware 159 mm (6.26 in) high x 155 mm (6.08 in) wide x 64 mm (2.5 in) 0.68 kilograms (1.
Specifications Antenna Communication Protocols Addressing A-15 Supports Smarteq™ mini-wing/slim (SMA/TNC) or customer-supplied antenna with the following specifications: • 50 ohms • VSWR<1:1.5 • maximum gain of 3 dBi • Male SMA connector TCP/IP for wireless communication Modbus for data transfer Fixed address via AT&T custom APN Power Supply (p/n 5000-0727) The power supply supports external-powered FlowHawk monitors.
B-1 APPENDIX B Part Numbers This appendix contains a parts list of the most commonly ordered and used parts supporting the IETG FlowHawk™ flow monitoring system. Monitors 8000-FHK-60C FLOWHAWK MONITOR (INCLUDES 12-VOLT IS BATTERY PACK) 8000-FHK-EP-60C FLOWHAWK MONITOR, EXTERNAL POWER (EXCLUDES 12-VOLT IS BATTERY PACK) Sensors and Sensor Cables 8K-CS4-05-35 SENSOR, CS4, UPWARD DEPTH, PEAK VELOCITY, PRESSURE SENSOR 0 – 0.34 Bar (0 – 5 PSI), 10.
B-2 IETG FlowHawk Manual 8K-CS5-V2-05-30 SENSOR, CS5, US DEPTH, SURFACE VEL, PRESSURE SENSOR 0 – 0.34 Bar (0 – 5 PSI), 9.14meter (30-ft) CABLE 8K-CS5-V2-15-30 (available late 2012) SENSOR, CS5, US DEPTH, SURFACE VEL, PRESSURE SENSOR 0 – 1.03 Bar (0 – 15 PSI), 9.14meter (30-ft) CABLE 8K-CS4-35 SENSOR, CS4, UPWARD DEPTH, PEAK VELOCITY, 10.6-meter (35-ft) CABLE 8000-0023–xxx (xxx represents cable length in feet) SENSOR EXTENSION CABLE, FOR SENSORS without PRESSURE; STANDARD LENGTHS: 7.6m (25 ft), 15.
Part Numbers B-3 106227B-xx (xx represents the cable length in feet) CABLE, COMM, FST TO EMU; STANDARD LENGTHS: 3.0m (10 ft), 25.9m (85 ft), 30.5m (100 ft), 41.1m (135 ft) – other cable lengths up to 91.4m (300 ft) are also available by request 8000-0054-01 CABLE, ASSY, FST TO TELOG 8000-0044-25 CABLE, EXT, COMM/GSM, 7.
B-4 IETG FlowHawk Manual I25-0086 RING, SS, 343-400mm (13.5-15.75 in) I25-0087 RING, SS, 368-425mm ( 14.4-16.75 in) I25-0088 RING, SS, 425-476mm (16.75-18.75 in) I25-0089 RING, SS, 470-527mm (18.5-20.75 in) I25-0090 RING, SS, 521-578mm (20.5-22.75 in) I25-0091 RING, SS, 572-730mm (22.5-28.75 in) I25-0092 RING, SS, 724-933mm (38.5-36.75 in) I25-0093 RING, SS, 927-1238mm (36.5-48.75 in) I25-0094 RING, SS, 1238-1543mm (48.75-60.
Part Numbers 2 B-5 This item is part of the mounting hardware included with the monitor for the flange handle (p/n I40-0009). Note: In all applications, only IETG IS-Certified Service Technicians are authorized to perform FlowHawk board and/or component-level repair.
C-1 APPENDIX C Monitor Activity Codes This appendix contains a list of the monitor activity codes that display automatically on the GSM module LED window while the monitor is running. This list also includes descriptions of the monitor activities corresponding to the code: Note: The LED window is available only on the GSM Module supporting battery-powered IETG FlowHawk™ monitors. Externally-powered FlowHawk monitors communicate through the modem in the EMU or EMUX.
C-2 IETG FlowHawk Manual Code Monitor Activity A Processing alarms J No active events H Hanging up t Reading temperature b Reading the (upward) ultrasonic depth sensor or the ultrasonic depth sensor in the Surface Combo Sensor A Reading all the sensor pairs from the (upward) ultrasonic depth sensor (standalone or integrated sensor in the Surface Combo Sensor) P Reading pressure depth (from the Peak Combo Sensor or Surface Combo Sensor) u Reading updepth (from the Peak Combo Sensor) A Ca
Monitor Activity Codes Code Monitor Activity C Deep sleep (monitor going to sleep) A Calling cycle modem power from sleep b Running BASIC task C-3
D-1 APPENDIX D Modbus/EMUX Configuration and Diagnostics This appendix contains essential configuration, diagnostic, and reference information and instructions regarding communication and data exchange involving the FlowHawk™, EMUX, and RTU.
D-2 IETG FlowHawk Manual Setting up PC-to-EMU Communication Performing on board configuration and diagnostics and programming the Modbus data registers requires a physical connection between the EMUX and a PC loaded with a terminal emulator application setup with the appropriate communication parameters. Connecting the PC to the EMUX Communication between the PC and EMUX requires the following hardware and software: • PC or laptop computer with an RS-232 serial port.
Modbus/EMUX Configuration and Diagnostics • Stop Bits 1 • Handshaking None D-3 Running the Onboard Diagnostics The EMUX requires limited configuration and diagnostics to ensure successful operation and communication among the user, RTU, EMUX, and the monitor. Perform these tasks by accessing the onboard diagnostics menus available on the EMUX through the terminal emulator (e.g., HyperTerminal).
D-4 IETG FlowHawk Manual • The system will exit the current menu or submenu following 30 seconds of inactivity. To return to the initial location before the timeout occurred, enter three consecutive bangs (!!!) to return to the main menu from the READY state or hit the appropriate number key to return to a particular submenu from the main menu. • Exit any submenu by entering a lower case “x”. The following sections provide instructions on how to complete the parameters or diagnostics in each submenu.
Modbus/EMUX Configuration and Diagnostics • D-5 Power Mode Enter 6 to toggle between the two available power modes. The initial in parentheses (C or S) indicates the current mode. Sleep Choosing this mode powers down the EMUX following 60 seconds of inactivity. When powered down, the LED will not be illuminated. The unit will awaken when a request or activity occurs at one of the ports.
D-6 IETG FlowHawk Manual monitor is not detected, a Failed to detect monitor message will display. Update Firmware via XMODEM Selecting this submenu enables you to update the EMUX firmware through the terminal emulator or another serial connection that supports XMODEM. Note: Currently, EMUX firmware updates cannot be performed through wireless communication. Therefore, perform all firmware updates using a serial connection.
Modbus/EMUX Configuration and Diagnostics D-7 • Cryout address This represents the address of the server that will receive the monitor events. • Date and Time This represents the current date and time on the EMUX clock. System Tests Selecting this submenu allows you to perform the following system tests: • Restart Emux Enter a 1 to restart the EMUX. Restarting involves initializing all of the runtime variables and reloading the firmware.
D-8 IETG FlowHawk Manual Note: The entities available are based on the sensors used and the data logged. In addition, all values are floating point, unless otherwise defined. Register Addresses for Entity Data The following table contains the entities currently available for output and the associated register addresses. The register addresses for the quality values corresponding to the current data display in parentheses.
Modbus/EMUX Configuration and Diagnostics Description Profile Entity Flow rate based on QContinuity FLOW1 Second Flow rate based on QContinuity FLOW2 Peak Velocity from the monitor RAWVEL Monitor Battery Voltage (daily) BTYVOLT Flow Rate Threshold from monitor QTHRESHOLD Average Flow Rate from monitor QMLI_AVG Average Flow Depth from monitor DMLI_AVG Depth Threshold from monitor DTHRESHOLD Pressure Sensor Calibration Value PRESSK Unidepth UNIDEPTH Standard Units of Measure Litres per
D-10 IETG FlowHawk Manual Description Standard Units of Measure Scan (Wakeup) Rate n/a Registers 40132-40133 40134-40135 Reserved Depth Conversion Coefficient Millimeters 40136-40137 Velocity Conversion Coefficient Meters Per Second 40138-40139 Volume Conversion Litres per Second 40140-40141 Temperature Conversion Type Celcius 40142-40143 EMUX LED Window This section defines the characters, symbols, or activities that may display on the LED window on the front of the EMUX.
E-1 APPENDIX E System Configuration and Setup to Support the Telog Ru-33 Using a battery-powered FlowHawk™ to support the Telog® Ru-33 Recording Telemetry Unit (RTU) requires some limited configuration and setup. These procedures involve designating the appropriate identification information to enable recognition and data exchange between the IETG and Telog units and running the using a communications cable to connect the monitor to the RTU. Note: The Telog Ru-33 must have firmware version 3.
E-2 IETG FlowHawk Manual Configuring the Monitor to Support the Ru-33 Configuring the FlowHawk to support the Telog Ru-33 requires setting three parameters in Profile when establishing a new location. • Scan frequency This represents the interval at which the monitor takes readings. These readings are available for retrieval directly from the monitor, but are overwritten with new data at each new interval.
System Configuration and Setup for Telog Ru-33 E-3 Triton-Telog Comm Cable Antenna connector 5-pin connector A CH NN E L A CH 2 NN E L 1 0518 II 1 G Ex ia IIB T4 Ga Sira 09ATEX2027X 9-hole port MODEL: 8000 - FHK/FST ST ONLY TE Use only battery pack 106152 Telog Ru-33 M AX . 12 PS I FLOWHAWK TM IETG CO M M W W W.A D S E N V.
In-1 Index 1 1/2-band mount, 3-41 12-volt IS battery pack, 2-3, 2-11 checking voltage, 8-8 reading voltage, 8-5 replacement, 8-10 3 3/4-band mount, 3-39 A activating the monitor, 6-63, 6-84 logs, 6-84 activation logs, 6-98 activity codes, 8-5 adding a second monitoring point, 6-10 alarms testing monitor cryouts, 8-8 antenna, 1-4 installation, 4-8 ATEX compliance, 1-12 hazardous area, 1-12 standards, 1-2 special conditions for use, 1-5 auto collection, 6-8 B band securing the sensor cables, 3-43 battery
In-2 IETG FlowHawk Manual certifications, 1-9 ATEX, 1-12 EC Type Examination Certificate, 1-16 IECEx, 1-20 modem, 1-12 SIRA, 1-16 special conditions for use, 1-5 channels, 2-10, 6-22, 6-35, 6-52 checking the sensors, 8-17 cleaning the sensors, 8-17 coefficient A, 6-40 coefficient B, 6-40 collecting data from a monitor, 6-86 COMM port, 2-10 communication, 1-4, 4-1 antenna, 1-4 installation, 4-8 direct, 2-3 EMU, 1-4, 4-26 communication cable installation, 4-20, 4-22 installation, 4-20, 4-36 modem replacemen
Index In-3 creating a monitor installation table, 6-11 creating a monitor location, 6-5 creating a second monitoring point, 6-10 editing devices Data Delivery, 6-55 Flow, 6-57 MLI, 6-57 Modem Setup, 6-53 Peak Combo Sensor, 6-22 Slimline Peak Combo Sensor, 6-22 Smart (Ultrasonic) Depth Sensor, 6-49 Surface Combo Sensor, 6-34 Ultrasonic (Smart) Depth Sensor, 6-49 EMUX, D-1 Modbus, 6-9, E-2 Modbus/local port, D-4 overview, 1-25 selecting and editing devices, 6-17 Telog Ru-33, 6-9, E-2 configuring the EMUX, D-
In-4 IETG FlowHawk Manual Peak Combo Sensor editing pressure parameters, 6-24 editing temperature parameters, 6-31 editing ultrasonic parameters, 6-22 editing velocity parameters, 6-26 selection, 6-17 Slimline Peak Combo Sensor editing temperature parameters, 6-31 editing ultrasonic parameters, 6-22 editing velocity parameters, 6-26 Surface Combo Sensor editing pressure parameters, 6-47 editing smart depth (ultrasonic) parameters, 6-35 editing temperature parameters, 6-49 Ultrasonic (Smart) Depth Sensor e
Index In-5 replacing the SIM card, 8-29 specifications, A-13, A-14 wiring power supply, 5-4 EMU modem replacement, 8-25 EMUX, 1-4, 2-12 activity codes, D-10 antenna installation, 4-47 communication cable installation, 4-40 configuration and diagnostics, D-1 connecting the SCADA RTU, 4-49 data registers, D-7 external power, 2-3, 2-12, 4-49 firmware update, D-6 installation, 4-40, 4-45 tools and supplies, 4-41 wiring the communication cable, 4-43 installing external DC power, 5-2 installing the SIM card, 4-4
In-6 IETG FlowHawk Manual replacing the SIM card, 8-21 specifications, A-12 testing monitor cryouts, 8-8 viewing diagnostic codes from the monitor, 8-5 GSM Module installation, 4-19 GSM/GPRS communication, 2-5, 4-3 modem information, 1-12 H handling the sensors, 8-18 hazardous conditions, 1-2 hydraulics, 2-14, 3-4 hydrograph depth and velocity data, 6-90 I IECEx certificates, 1-20 certification, 1-20 compliance, 1-20 hazardous area compliance, 1-20 standards special conditions for use, 1-5 IETG Ltd, 1-2
Index In-7 mounting Surface Combo Sensor to the ring assembly, 3-29 mounting to the ring, 3-21 mounting Ultrasonic Depth Sensor to the ring assembly, 3-29 ring assembly, 3-11 standard mount, 3-45 surcharge mount, 3-50 SIM card EMU, 4-31 EMUX, 4-41 GSM module, 4-13 site investigation, 3-4 Slimline Peak Combo Sensor 1/2-band mount, 3-41 3/4-band mount, 3-39 special, 3-5, 3-33 1/2-band mount, 3-41 3/4-band mount, 3-39 mounting the Peak Combo Sensor, 3-38 mounting the Slimline Peak Combo Sensor, 3-38 parts and
In-8 IETG FlowHawk Manual M magnet, 8-5 maintenance checking the sensors, 8-17 parts and supplies, 8-2 restrictions, 1-7 sensor inspection, 8-17 system components, 8-2 manhole conditions, 3-5 corbel, 4-24 depth, 3-6 mounting the monitor manhole wall, 7-3 rung, 7-2 securing sensor cables, 3-53 manhole depth, 6-8 manual collection, 6-8 maximum velocity, 6-29, 6-40, 6-45 memory, 2-1 MLI editing device, 6-57 Modbus, 2-3, 2-6, 2-7, 6-67 configuration, 6-9, D-1, E-2 connecting the RTU to the EMUX, 4-49 defining
Index In-9 out-of-warranty repairs, 1-28 overview, 2-4 ports, 2-10 power, 1-4 external, 5-1 processor board, 2-8 regulator replacement, 8-31 replacing the fuses, 8-32 remote communication, 4-3 replacing the battery pack, 8-10 replacing the fuses, 8-32 replacing the regulator, 8-31 returns, 1-28 running sensor diagnostics, 6-69 securing the dryer tube, 3-58 sensors, 1-3 shipping for warranty work, 1-28 specifications, A-1 telemetry, 1-4 Telog Ru-33, E-1 testing cryout capability, 8-8 torque for bolts, 8-16
In-10 IETG FlowHawk Manual Ultrasonic Depth Sensor, 2-17 downward ultrasonic depth, 2-18 pressure depth option, 2-19 P part numbers monitor, B-1 sensors, B-1 system components, B-1 parts GSM module installation, 4-6 maintenance, 8-2 replacement, B-1 special installation, 3-34 standard installation, 3-8 PC communication cable, 4-52 Peak Combo Sensor 1/2-band mount, 3-41 3/4-band mount, 3-39 connecting to the monitor, 3-56 diagnostics, 6-69 pressure, 6-74 temperature, 6-82 upward ultrasonic, 6-71 velocity,
Index In-11 power, 1-4 12-volt IS battery pack, 2-3, 2-11 battery pack, 1-4, 2-3 replacement, 8-10 checking battery pack voltage, 8-8 consumption, 5-3 diagnostic codes, 8-5 external, 2-12, 5-1 EMU, 2-3, 2-12 EMUX, 2-3, 2-12, 4-49 installation, 5-2 power supply, 5-4 power supply specifications, A-15 requirements, 5-3 internal 12-volt IS battery pack, 2-11 battery voltage, 8-5 checking battery pack voltage, 8-8 replacing the battery pack, 8-10 regulator replacement, 8-31 replacing fuses, 8-32 replacing the r
In-12 IETG FlowHawk Manual R regulator replacement, 8-31 replacing fuses, 8-32 regulator replacement, 8-31 repairs out of warranty, 1-28 replacement 12-volt IS battery pack, 8-10 desiccant in dryer tube, 8-19 dryer tube, 8-18 EMU modem, 8-25 SIM card in modem, 8-29 EMUX SIM card in modem, 8-30 fuses, 8-32 GSM module desiccant pack, 8-21 SIM card, 8-21 parts/part numbers, B-1 regulator, 8-31 returns international, 1-28 ring assembly, 3-11 installation, 3-25 mounting Peak Combo Sensor, 3-23 mounting Slimlin
Index In-13 mounting to the ring, 3-21 overview, 2-14 Peak Combo Sensor, 2-14 Slimline Peak Combo Sensor, 2-23 Surface Combo Sensor, 2-19 Ultrasonic Depth Sensor, 2-17 pressure depth option, 2-19 part numbers, B-1 Peak Combo Sensor editing devices, 6-22 mounting to the ring, 3-23 overview, 2-14 peak velocity, 2-16 pressure depth, 2-16 running pressure diagnostics, 6-74 running temperature diagnostics, 6-82 running upward ultrasonic diagnostics, 6-71 running velocity diagnostics, 6-76 specifications, A-4 tr
In-14 IETG FlowHawk Manual storing, 8-18 Surface Combo Sensor downward ultrasonic depth, 2-21 editing devices, 6-34 leveling, 3-30 mounting to the ring, 3-29 overview, 2-19 physical offset, 3-32 pressure depth, 2-22 running pressure diagnostics, 6-74 running smart depth diagnostics, 6-79 running surcharge velocity diagnostics, 6-76 running surface velocity diagnostics, 6-76 running temperature diagnostics, 6-82 specifications, A-5 surcharge peak velocity, 2-22 surface velocity, 2-21 troubleshooting downwa
Index In-15 overview, 2-23 peak velocity measurement, 2-23 upward ultrasonic depth measurement, 2-23 special installation, 3-38 specifications, A-10 troubleshooting peak velocity, 8-55 temperature, 8-61 upward ultrasonic depth, 8-52 smart depth editing sensor device parameters, 6-35, 6-49 sensor diagnostics, 6-79 special conditions for use, 1-5 special installation, 3-5 1/2-band mount, 3-41 Peak Combo Sensor, 3-41 Slimline Peak Combo Sensor, 3-41 3/4-band mount, 3-39 Peak Combo Sensor, 3-39 Slimline Peak C
In-16 IETG FlowHawk Manual surcharge pressure depth editing sensor device parameters, 6-47 sensor diagnostics, 6-74 troubleshooting, 8-60 Surface Combo Sensor connecting to the monitor, 3-56 diagnostics, 6-69 pressure, 6-74 smart depth, 6-79 surcharge velocity, 6-76 surface velocity, 6-76 temperature, 6-82 editing device pressure parameters, 6-47 smart depth (ultrasonic) parameters, 6-35 temperature parameters, 6-49 editing devices, 6-34 handling and storage, 8-18 inspection, 8-17 IS certification, 1-3 le
Index In-17 troubleshooting, 8-38 communication, 8-39, 8-43 fee, 1-28 monitor, 8-39 Peak Combo Sensor peak velocity, 8-55 pressure depth, 8-60 temperature, 8-61 upward ultrasonic depth, 8-52 peak velocity, 8-55 pressure depth, 8-60 Slimline Peak Combo Sensor peak velocity, 8-55 temperature, 8-61 upward ultrasonic depth, 8-52 Surcharge Combo Sensor surcharge peak velocity, 8-55 surcharge peak velocity, 8-55 surcharge pressure depth, 8-60 Surface Combo Sensor downward ultrasonic depth, 8-47 surcharge depth,
In-18 IETG FlowHawk Manual V velocity direction, 6-28, 6-39, 6-44 velocity measurement peak, 2-16, 2-23 surcharge peak, 2-22 surface, 2-21 velocity type, 6-57 voltage regulator board, 2-11 W wall mounting, 7-3 warnings, 1-9 warranty, 1-27 customer service, 1-29 international returns, 1-28 invalidation, 1-9 new product, 1-27 out-of-warranty repairs, 1-28 shipping, 1-28 troubleshooting fee, 1-28 wet well, 3-5 wireless antenna installation EMUX, 4-47 in-road, 4-8 wireless communication, 1-4, 2-5, 4-3 anten
