3600 Flow Monitor Operation and Maintenance Manual May 1998 530002A2 An introductory guide to the ADS 3600 intrinsically safe flow monitor ADS Corporation 4940 Research Drive Huntsville, AL 35805 USA (256) 430-3366
Copyright 1998 ADS Corporation ADS and QuadraScan are registered trademarks of ADS Corporation. All other brand and product names are trademarks or registered trademarks of their respective holders. FieldScan is a trademark of ADS Corporation. All other brand and product names are trademarks or registered trademarks of their respective holders. The IBM Personal Computer is a trademark of International Business Machines Corporation.
i Contents Chapter 1 Introduction 1-1 The ADS Flow Monitoring System .................................................................... 1-3 Flow Monitoring with the QS3600 ............................................................... 1-3 Intrinsic Safety.................................................................................................... 1-5 Unique Features ............................................................................................
ii ADS 3600 Flow Monitor O&M Manual Confirmation ....................................................................................................... 3-8 Chapter 4 Ring, Sensor, and Special Installations 4-1 Preparing for Installation .................................................................................... 4-3 Required Supplies ......................................................................................... 4-4 Ring Assembly........................................................
Contents iii Lightning Protection Module Installation................................................... 5-25 Monitor Activation ........................................................................................... 5-27 Data Collection and Confirmation .................................................................... 5-28 Chapter 6 Monitor Maintenance 6-1 Remote Confidence Checks................................................................................ 6-2 Monitor .......................
1-1 CHAPTER 1 Introduction The ADS QuadraScan 3600 (QS3600) flow monitor is a compact, microprocessorbased flow monitor that meets the requirements of intrinsic safety (IS) certification. (For more information on the QS3600 IS certification, see “Intrinsic Safety” on page 1-5.) The QS3600 flow monitor is installed in a sewer manhole and is connected by telephone lines and a modem to a central computer. Installed on the central computer, ADS QuadraScan software configures and activates the monitor.
1-2 ADS 3600 Flow Monitor O&M Manual Warnings, Certifications, FCC Compliance, and Conformity................ 1-8 Intrinsically Safe (IS) Certification................................................... 1-8 FCC Compliance............................................................................... 1-8 Additional Notice of Canadian Emissions Requirements................. 1-9 Declaration of Conformity..............................................................
Introduction 1-3 The ADS Flow Monitoring System The ADS flow monitoring system is a comprehensive and sophisticated system that uses powerful scientific and engineering concepts to measure and monitor open channel flows.
1-4 ADS 3600 Flow Monitor O&M Manual Typical 3600 Flow Monitor Installation Typically, the monitor is attached to the inside wall of a manhole using bolts. Depth and velocity flow sensors are installed in the sewer pipe to gather flow data. The sensors are mounted on a stainless steel ring, usually placed upstream in the sewer pipe. Cables connect the monitor in the manhole to the sensors in the sewer pipe.
Introduction 1-5 Intrinsic Safety Intrinsic safety (IS) is a special certification awarded to equipment when its design and manufacture meet the high standards of IS regulations . The main goal of IS regulations is to prevent the electronic equipment from causing explosions in potentially explosive environments. These environments are categorized as Class I, Division 1, Groups C and D in the USA and as Zone 0 in Europe; the QS3600 flow monitor is certified for use in these environments.
1-6 ADS 3600 Flow Monitor O&M Manual monitor cables and the phone lines connect within this interface box because IS standards require that telephone lines not be routed directly into a manhole since it is a potentially explosive environment. An additional precaution can be taken by using an ADS lightning protection module that is located above the phone line interface box on the pedestal or telephone pole and which stops high voltages before they reach the interface box.
Introduction 1-7 Maintenance Restrictions As mentioned earlier, all ADS QS3600 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. ADS must restrict certain maintenance tasks to ADS IS certified technicians. ADS allows you to perform only those maintenance tasks which do not require opening the monitor housing. All other maintenance must be performed by ADS IScertified technicians.
1-8 ADS 3600 Flow Monitor O&M Manual Warnings, Certifications, FCC Compliance, and Conformity Changes or Modifications Changes or modifications to the QS3600 flow monitor not expressly approved by the party responsible for compliance will void the IS certification. Personnel performing installation of the QS3600 flow monitor should carefully follow the guidelines contained in this manual when installing and maintaining the monitor.
Introduction 1-9 connection to the telephone network or premises wiring using compatible modular jacks/plugs and cabling that comply with FCC Part 68 rules. The telephone company may make changes in its facilities, equipment, operations, or procedures that could affect the operation of this equipment. If this occurs, the telephone company will provide advance notice so you can make the modifications necessary to maintain uninterrupted service.
1-10 ADS 3600 Flow Monitor O&M Manual Le present appareil numerique n'emet pas de bruits radioelectriques depassant les limites applicables aux appareils numeriques (de la class A) prescrites dans le Reglement sur le brouillage radioelectrique edicte par le ministere des Communications du Canada. Declaration of Conformity For European (EC member country) applications, a Declaration of Conformity is required to be kept on file at the facility responsible for repair and maintenance of this equipment.
2-1 CHAPTER 2 Hardware The QS3600 flow monitor is housed inside a cylindrical aluminum canister that is 62 cm (24 in.) long and 17 cm (6.6 in.) in diameter. The canister lid contains ultrasonic, pressure, velocity sensor, and communication cable connections as well as rain gauge and sampler communication cable connections. With the lid in place, the canister is airtight and waterproof. Warning: Only ADS Service Technicians are authorized to perform component level service on the QS3600.
2-2 ADS 3600 Flow Monitor O&M Manual Note: The depth board and velocity boards are also called the input/output (I/O) boards. Opening the lid of the monitor and removing the lid assembly reveals the one-piece chassis. The processor board is mounted to the chassis on the bottom of one side. Two Doppler velocity boards are mounted on top of the processor board. The depth board is mounted to the other side of the chassis' frame.
Hardware 2-3 Major Components of the QS3600 Monitor The major components of the QS3600 flow monitor include the processor board, the sensor interface boards, the battery pack, and the flow sensors. Refer to Appendix A for additional information regarding these components. Processor Board The processor board contains the central processing unit (CPU). It is mounted on the bottom of the chassis card frame plate which is installed on the lid assembly chassis.
2-4 ADS 3600 Flow Monitor O&M Manual Side View of Flow Monitor Chassis and Assembly The board allocates portions of memory to firmware (permanently stored software), data storage, and program manipulation and calculations. A light-emitting diode (LED) is located on the processor board and indicates the monitor's communication status. When the processor board is involved in external communications, the LED is ON.
Hardware 2-5 The processor board performs many functions; it z powers up each input board and provides each board with the parameters required to carry out the appropriate operations, z periodically scans the sensor interface boards and the optional rain gauge input to retrieve and store data readings, z outputs a discrete signal to a sampler, z transmits the stored data to the central computer for processing by QuadraScan software after data is collected, and z maintains the date and time.
2-6 ADS 3600 Flow Monitor O&M Manual IS Modem and Telephone Interface Box If the QS3600 flow monitor uses an IS modem instead of an EMU, it is located within the QS3600 monitor housing and complies with IS regulations. This modem communicates with the central computer via a telephone interface box, located on the telephone pole or on a nearby pedestal. (The IS modem does not require a separate battery for power; it uses the monitor’s battery pack.
Hardware 2-7 External Modem Unit An alternative way to communicate via a telephone line is to use an external modem unit (EMU), which houses the modem outside of the monitor. Two types of EMUs exist: one with an internal battery power source and one which uses an external power source. The EMU may be buried in a sidewalk or pavement box at the end of a trench dug away from the manhole, or the EMU may be bolted to a nearby wall.
2-8 ADS 3600 Flow Monitor O&M Manual External Power Source Some model 3600 flow monitors may require a continuous power source, for example real time flow monitors used in SCADA applications. The external modem unit (EMU) supplied for SCADA applications has a provision for continuous power from an external power source. This can be accomplished in two ways: alternating current (AC) or direct current (DC).
Hardware 2-9 when connecting the SCADA EMU to an AC power source using the ADS power cable with the three-prong wall plug transformer, make sure the power source is earth grounded. Note: Customers using their own power cables must pin the SCADA EMU connector according to the diagram displayed on the inside cover of the SCADA EMU to ensure proper earth grounding. In the event of power loss, the NiCad battery, located in the EMU, can provide operating power for the 3600 flow monitor.
2-10 ADS 3600 Flow Monitor O&M Manual configuration. Therefore, if utilizing a battery as the external dc voltage source, the length of the unit operation is dependent on several factors, such as the battery amphour rating, the battery charge state, the monitor configuration, and the monitor sample interval. These factors cannot be predicted by ADS.
3-1 CHAPTER 3 Flow Measurement This chapter describes the QS3600’s integral role in the ADS flow measurement process, including information on l monitor operation, l flow sensor operation, l data scrubbing (filtering erroneous data out of the data collected), l communications between the monitor and a computer, and l confirmation of the monitor’s accuracy. To learn about: See page: Monitor Operation ...............................................................................
3-2 ADS 3600 Flow Monitor O&M Manual Monitor Operation A central computer communicates with the QS3600 using a telephone line and modem. QuadraScan software must be installed on the computer, and site configuration information must be defined before the QS3600 flow monitor can be activated (see Chapter 5, “Monitor Installation and Activation,” and the QuadraScan User’s Guide for more information on using QuadraScan software on the computer).
Flow Measurement 3-3 Note: Refer to the QuadraScan User's Guide (version 5.01 or higher) for additional information and instructions on the interaction between the monitor and QuadraScan. The QS3600 can be used in real time applications in which the flow monitor will interface with the remote terminal unit (RTU). For more information on using the QS3600 in real time applications, refer to Using ADS Flow Monitors for Real Time Applications, document number 530006**, or contact your regional ADS office.
3-4 ADS 3600 Flow Monitor O&M Manual Flow Sensor Measurement Techniques The ultrasonic depth sensor, the pressure depth sensor, and the Doppler velocity sensor gather raw flow data. The ultrasonic and pressure depth sensors use independent measurement techniques to collect information about the depth of flow. The Doppler velocity sensor gathers flow velocity data. Upstream Installation The sensors are mounted on a ring that is installed in the sewer pipe upstream from a manhole.
Flow Measurement 3-5 recorded by one of two temperature sensors mounted inside the ultrasonic depth sensor. Enhanced firmware (permanently stored software) for the ultrasonic level sensor has been added to the 3600 monitor to increase its capabilities.
3-6 ADS 3600 Flow Monitor O&M Manual calculates the depth of flow. The pressure depth system also compensates for temperature, which is measured by a temperature sensor located inside the pressure sensor. Doppler Velocity Sensor The Doppler velocity sensor, called the velocity mouse, is placed at the bottom of the pipe next to the pressure depth sensor. It emits a wide, omnidirectional sound wave at a specific frequency upward into the flow.
Flow Measurement 3-7 Ultrasonic Depth Data Scrubbing There are a number of difficulties inherent to accurately measuring data in a sewer system, particularly at sewer manholes. Some of the common problems interfering with flow measurement are noise in the sewer, turbulent (non-laminar) flow, and flow that is not level or has foam on the surface. To minimize the effects of these disturbances, bad data points can be eliminated (data scrubbing) at two different times.
3-8 ADS 3600 Flow Monitor O&M Manual Transmitting Data to the Computer The monitor stores readings from the sensors at specified time intervals. These readings are stored until the monitor's memory is full; when the monitor’s memory is full, new readings begin to overwrite previous ones. (Monitor storage capacity is discussed in Appendix A.) If the central computer is remotely collecting the data, a telephone line and a modem are used.
4-1 CHAPTER 4 Ring, Sensor, and Special Installations This chapter contains instructions for installing the adjustable stainless steel ring and the sensors. These installation procedures require training and should not be attempted by inexperienced personnel. Because of the hazardous conditions that can exist in sewers and other places where the monitor is installed, a team of two or more people should be involved in the installation.
4-2 ADS 3600 Flow Monitor O&M Manual Special Installations ............................................................................ 4-20 Required Supplies......................................................................... 4-21 Standard Ultrasonic Mount........................................................... 4-22 Adjustable Ultrasonic Mount ........................................................ 4-27 Surcharge Mount..........................................................................
Ring, Sensor, and Special Installations 4-3 Preparing for Installation The QS3600 flow monitor is delivered fully assembled and tested. The installation process includes l assembling the ring, l mounting the sensors, l connecting sensor cables to the monitor, l installing the ring in the sewer pipe, and l installing the monitor in the manhole. Note: Refer to Chapter 5 for information on installing the monitor and software, as well as on activating and confirming the monitor.
4-4 ADS 3600 Flow Monitor O&M Manual Required Supplies Obtain the following supplies before installing the ring, sensors, and monitor. You may not need all of the materials each time you install a monitor, but the materials should be available to prevent any costly delays. Supplies can be ordered from the ADS corporate office in Huntsville, Alabama. When ordering, specify QS3600 flow monitor ring-mounted installation hardware.
Ring, Sensor, and Special Installations 4-5 Ring Assembly The flow sensors are mounted on a stainless steel ring which is installed in the sewer pipe. There are several different ring sizes. Each ring is adjustable within about three inches to fit different pipes. Rings are designed for the secure installation of ultrasonic, velocity, and pressure sensors. Note: The last topic in this chapter, “Special Installations,” deals with installing equipment in non-standard pipes.
4-6 ADS 3600 Flow Monitor O&M Manual Ring Stabilizer With Spreader Mechanism Screw Inserted 2. On the open end of the ring (the end without a welded metal band), slide the ring stabilizer and spreader mechanism screw so that the ring stabilizer flanges are on the outside of the ring and the spreader mechanism screw is on the inside of the ring. Sliding Ring Stabilizer onto Ring 3. Slide the ring stabilizer all the way around the ring until it is about 10 cm or 4 in.
Ring, Sensor, and Special Installations 4-7 4. Position the ring so that the holes along the edge of the ring (the downstream side) are facing you. 5. With the back of the ultrasonic mount facing you (the end with the small metal peg pushed through the main plate), slide the mount onto the end of the ring’s right side (the end without the welded metal band). Adding the Sliding Ultrasonic Sensor Mount 6. Move the ultrasonic sensor mount to the left side of the ring. 7.
4-8 ADS 3600 Flow Monitor O&M Manual 9. Insert the spreader mechanism screw through the hole at the end of the right side so that the end of the right side of the ring fits snugly against the ring stabilizer. Ring Stabilizer Fully Connected (Side View) Connecting the Spreader Mechanism Once the ring has been assembled, the spreader mechanism must be attached. The spreader mechanism is delivered assembled and only needs to be attached to the ring.
Ring, Sensor, and Special Installations 4-9 4. Place a washer then the downstream, left side spreader bar onto the spreader mechanism screw on the left side of the ring by passing the screw through the hole (as illustrated in the following figure). Orienting and Attaching the Spreader Mechanism 5. Place the upstream, left side spreader bar onto the same screw. 6. Lightly turn the hex nut onto the screw, ensuring that it passes through the holes in the end of the spreader bar.
4-10 ADS 3600 Flow Monitor O&M Manual 8. Align the spreader mechanism screw so that the head is visible through one of the ring size adjustment holes. Aligning Screw Head and Adjustment Hole 9. Insert a Phillips head screw driver through the hole into the screw head while holding the hex nut with the 1/2 in. (13 mm) nut driver to tighten the screw. Tightening the Spreader Mechanism Screw and Hex Nut 10. Return the spreader mechanism back to the 6:00 position by turning the ring.
Ring, Sensor, and Special Installations 4-11 11. Insert the second spreader mechanism screw through the desired ring size adjustment hole. 12. Slip the large washer onto the screw. Inserting Washers onto the Spreader Mechanism Screw 13. Through the holes in the end of the spreader bars, turn and tighten the second hex nut on the screw. Complete and Attach Spreader Mechanism (Inside Ring View) Quality Control There are two checks you can make to ensure the quality of the ring assembly.
4-12 ADS 3600 Flow Monitor O&M Manual Properly Installed Spreader Mechanism l The spreader mechanism will be loose on the hex nuts, but will tighten when the ring is tightened inside a pipe. l Look at the previous figure. Notice that the spreader mechanism fits snugly against the inside of the ring. This is what the ring should look like when it’s properly assembled. Note: When assembling the ring, check on the site report to see if silt is present.
Ring, Sensor, and Special Installations 4-13 Mounting the Sensors The following topics guide you through the steps necessary to mount the ultrasonic, velocity, and pressure sensors. The following figure illustrates their positions on the ring. 0° Ultrasonic Depth 0° Ultrasonic Depth Crank Crank Depth Velocity Pressure Velocity 180° + ?° 180° Without Silt With Silt Sensor Positions Note: When mounting the sensors, check on the site report to see if silt is present.
4-14 ADS 3600 Flow Monitor O&M Manual l Position the spreader assembly handle facing you. On the right-hand side of the ring, begin to secure the velocity cable along the trailing edge of the ring in a clockwise direction. Attach the sensor cables to the ring with cable ties that are 4 in. (10 cm) long and 0.08 in.(2 mm) wide. Pull the ties until they are taut. Continue this process until you reach the ultrasonic sensor. Cut off the excess portion of the cable ties.
Ring, Sensor, and Special Installations l 4-15 Position the spreader assembly handle facing you. On the right-hand side of the ring, begin to secure the velocity and pressure cables along the trailing edge of the ring in a clockwise direction. Attach the cable to the ring with cable ties that are 4 in. (10 cm) long and 0.08 in. (2 mm) wide. Pull the ties until they are taut. Continue this process until you reach the ultrasonic sensor. Cut off the excess portion of the cable ties.
4-16 ADS 3600 Flow Monitor O&M Manual Connecting Inputs and Outputs After the ring is prepared and the sensors have been attached, connect the cables to the appropriate ports on the monitor lid. Ports on the lid are marked with symbols to identify which sensor cables should be connected to which ports. Each sensor is unique and will not fit into another sensor’s port. The procedure for connecting cable connections to the lid ports follows.
Ring, Sensor, and Special Installations 4-17 Installing the Ring Caution: Ring installation requires entering a dangerous environment. Be extremely careful and follow all government and ADS safety procedures. l Designate one person to enter the manhole and install the ring. First, have the installer enter the manhole and position himself or herself to receive the ring. The installer should examine the sewer pipe to ensure that nothing is obstructing the flow or will inhibit installation.
4-18 ADS 3600 Flow Monitor O&M Manual l Place the ring assembly into the upstream pipe as far as necessary to ensure a good environment for flow measurement. The exact position of the ring varies from site to site, depending on pipe size and hydraulic conditions. q The ring should not be near the pipe mouth draw-down. q Install the ring flat (flush) against the inside wall of the pipe; otherwise it will obstruct flow and catch debris.
Ring, Sensor, and Special Installations 4-19 spaced every 46 to 61 cm (18 to 24 in.) from the bottom of the manhole to the top. Final Sensor Cable Preparation l Neatly bind together all sensor cables leading away from the ring. Use cable ties that are 20 cm (8 in.) long and 0.4 mm (0.14 in.) wide. Space the cable ties 20 to 30 cm (8 to 12 in.) apart along sensor cables located within 1.5 m (5 ft) of the ring.
4-20 ADS 3600 Flow Monitor O&M Manual Special Installations This topic deals with installing equipment in non-standard environments. For example, pipes which are not round and pipes greater than 48 in. (a standard stainless steel ring cannot be used) require a special installation. If the site requires a special installation, usually the requirements are site-specific.
Ring, Sensor, and Special Installations 4-21 Required Supplies Obtain the following supplies before conducting a special installation. You may not need all of the materials each time you need to do a special installation, but the materials should be available to prevent any costly delays. Supplies can be ordered from the ADS corporate office in Huntsville, Alabama. When ordering, specify QS3600 flow monitor special installation hardware.
4-22 ADS 3600 Flow Monitor O&M Manual Standard Ultrasonic Mount The standard ultrasonic mount is the original sensor mounting method, and it is still the most popular mounting method in use. You will need the following parts when assembling one standard ultrasonic mount: l one metal ultrasonic plate, l one quick release bracket (machine screws included), l four 6-32 × 1 in. (25 mm) round head machine screws, l eight 6-32 washers, and l four 6-32 × 5/16 in. (8 mm) nuts.
Ring, Sensor, and Special Installations 4-23 Screws Attach Top Part of Quick Release to Ultrasonic Plate Screws Attach Base Plate of Quick Release to Ultrasonic Plate Top Part of Quick Release Ultrasonic Plate Base Plate of Quick Release 01-12.pcx Ultrasonic Plate Installation l Determine location where the ultrasonic sensor is to be installed. (Refer to location report.) l Locate the apex of the pipe.
4-24 ADS 3600 Flow Monitor O&M Manual l Mount the anchor bolt. l Place a 7/16 in. (11 mm) nut on the bolt and twist until it stops (hand tight only). This nut is referred to as the adjustment nut. l Replace the plate over the anchor bolt and install a washer and a second 7/16 in. (11 mm) securing nut just enough to hold the plate on the stud. l Orient the attached ultrasonic plate in the desired position and press against the crown (soffit) of pipe.
Ring, Sensor, and Special Installations 4-25 01-17.pcx Leveling the Plate l To ensure that the plate remains level, hold the adjustment nuts firmly in place with the aid of a 7/16 in. (11 mm) wrench. Firmly tighten the 7/16 in. (11 mm) securing nuts against the bottom side of the plate. l Attach the ultrasonic sensor to the installed ultrasonic plate via the quick disconnect mount. Verify the installed ultrasonic sensor is level. 01-02.
4-26 ADS 3600 Flow Monitor O&M Manual 01-24.pcx The Finished Installation of the Plate and Sensor Verify that the Ultrasonic Sensor is Level.
Ring, Sensor, and Special Installations 4-27 01-07.pcx End View Showing the Sensor and the Mounting Plate Halves of the Quick Release Mount Adjustable Ultrasonic Mount The adjustable ultrasonic mount was derived from the adjustable ring concept–a piece of stainless steel with a sliding ultrasonic plate. It is a new design and will improve the time efficiency of the ultrasonic installation. You will need the following parts when assembling one standard ultrasonic mount: l one 30 cm (12 in.
4-28 ADS 3600 Flow Monitor O&M Manual Sliding Ultrasonic Plate Mounting Band 01-01.pcx Ultrasonic Plate and Mounting Band Installation 01-01.pcx The Adjustable Ultrasonic Depth Sensor Mount l Locate the apex of the pipe. l Position and hold the sliding ultrasonic plate in center apex of the pipe and scribe a mark on both sides where the ultrasonic plate is to be located.
Ring, Sensor, and Special Installations 4-29 l Center the 30 cm (12 in.) band, allowing about 100 mm (4 in.) of overhang on each side from scribed location. l Press one end of the curved band until it conforms with the pipe configuration and spot drill to mark the bolt location. l Remove the curved band and drill the anchor bolt hole. l Mount the anchor bolt. l Locate the pre-drilled hole on the curved band and attach the band to the anchor bolt with a washer and a 7/16 in.
4-30 ADS 3600 Flow Monitor O&M Manual 01-02.pcx Sliding the Ultrasonic Sensor in Place l Double check the ultrasonic sensor to confirm that it is still level. Surcharge Mount The surcharge mount is a V-shaped bracket with an ultrasonic plate attachment. Its use is limited to installations on manhole walls and not in the sewer pipe itself.
a aaaaa Ring, Sensor, and Special Installations 4-31 aaaa a a S/C mount installed correctly good return signal Pooling in the invert Velocity sensor 93038 Because the Bracket Mounts onto the Manhole Wall, Be Aware that Rungs and Brick Outcroppings May Affect the Ultrasonic Sensor Readings.
4-32 ADS 3600 Flow Monitor O&M Manual You will need the following parts when assembling a surcharge mount: l an aluminum surcharge mount, l four 6-32 × 1 in. (25 mm) round-head machine screws, l eight 6-32 washers, and l four 6-32 × 5/16 in. (8 mm) nuts. You will need the following tools when assembling a surcharge mount: l a medium slotted screw driver and l a 5/16 in. (8 mm) nut driver. Pre-Installation Assembly l Position the top of ultrasonic sensor to the base of the surcharge plate.
Ring, Sensor, and Special Installations 4-33 Anchor Bolt Angled Metal Bracket S/C Mount sensor 93040 Surcharge Mount Installation l Locate the height at which the ultrasonic portion of the bracket needs to be installed (determined by location report). l Press the bracket firmly against the manhole wall. l Locate the three pre-drilled holes at the top of the bracket. l Spot mark the middle hole with a drill. l Remove the bracket. l Drill and mount the anchor bolt.
4-34 ADS 3600 Flow Monitor O&M Manual l Spot mark with a drill in the middle hole. l Rotate the bracket 90°. l Drill and mount the anchor bolt. l Secure the bottom of the bracket with a washer and 7/16 in. (11 mm) anchor bolt. l Verify that the ultrasonic portion of the bracket is level.
aa Ring, Sensor, and Special Installations 4-35 a Crown Front View Typical Pipe D. Point E. Anchor Bolt (1 of 4) C. A. B. 3/4 Ring Flow Line Invert Velocity Sensor ADS-3004 "C" or 3/4 Ring Velocity Special Pre-Installation Assembly l Position the metal band so that the small holes drilled along the edge of the ring are facing towards you. This is the downstream side of the band.
4-36 ADS 3600 Flow Monitor O&M Manual l Place the velocity sensor on the band surface that will face inside (or towards the flow). The velocity cable should exit toward the edge of the band where the small pre-drilled holes (which run the length of the band) are located. l Line up the holes in the band with the screw holes on the bottom of the velocity sensor. l Attach the velocity sensor to the ring using the two 3 mm × 8 mm countersink screws.
Ring, Sensor, and Special Installations 4-37 l Flow Depth If the pipe is large and flow levels deep during minimum flows the velocity band may not reach the other side of the pipe. (Securing two bands together may give the necessary length, but the installation will become more difficult.) l Silt If there is excessive silt present in a large pipe, it will hamper the installation of the band. Removing massive silt amounts in a large deep line is usually impractical. Crown Front View Typical Pipe D.
4-38 ADS 3600 Flow Monitor O&M Manual l Continue to apply pressure to the band and locate the pre-drilled hole closest to the water surface on the long end of the band. l Drill and mount the anchor bolt to the pipe surface. l Maneuver band in position; it should be a very tight fit, and you may have a problem lining up the pre-drilled hole with the anchor bolt. l Secure the band to the anchor bolt with the 7/16 in. (11 mm) washer nut combination.
aa Ring, Sensor, and Special Installations 4-39 l This mounting method uses a special flat strip of rigid aluminum instead of the standard band. It is stronger and is less likely to become damaged during high flow conditions. l It is imperative that the ring (below the water's surface) be secured with an anchor bolt and placed within 25 to 75 mm (1 to 3 in.) of the velocity sensor. This will prevent the velocity sensor from becoming clogged should debris accumulate between the pipe and the metal band.
4-40 ADS 3600 Flow Monitor O&M Manual l Step on the band to determine if any play is present. Note: If the band is not completely flush, locate the pre-drilled hole closest to the sensor. This is rather difficult as you will have to use the touch and feel method. Once located, use a compressor drill or a 60 cm (24 in.) extended bit and drill another anchor bolt hole under the flow surface. Secure the anchor bolt to the pipe and attach the band with a 7/16 in. (11 mm) nut and corresponding washer.
Ring, Sensor, and Special Installations has been anchored (bolted) to the wall. This will help to prevent sensor damage during flow increases.
5-1 CHAPTER 5 Monitor Installation and Activation Once the adjustable ring and the sensors have been installed into the sewer pipe, you must install and activate the monitor. If you are not installing a monitor with an IS modem, you must also install the external modem unit (EMU). As with the ring and sensors, installing the monitor requires training and should not be attempted by inexperienced personnel.
5-2 ADS 3600 Flow Monitor O&M Manual Installing the EMU The following information serves as a guideline for installing an EMU. Carefully follow these guidelines so that the installation conforms to all NEC (national electrical code) guidelines for installations into Class 1, Division 1, Groups C and D hazardous areas.
Monitor Installation and Activation 5-3 Pavement Box Location Locate the pavement box in a well-drained, level, grassy area which is slightly higher than the surrounding area. The box should not be subjected to standing water during and after rain events. Although the cover will withstand most loads, the boxes are not designed for constant abuse by traffic. The pavement box should only be installed in a road after all other options are exhausted.
5-4 ADS 3600 Flow Monitor O&M Manual equipment can cause. This is a very reasonable request and should never be ignored. z Verify the minimum depth of the trenches as required by local codes. Local authorities will verify the local code requirements for trenching depths. The authorities will need to know that our trenches are being dug for cabling that carries maximum voltages of 9 Vdc for a communication cable and normal phone voltages for telephone service.
Monitor Installation and Activation 5-5 Pavement Box Pavement Box Installation Prior to installation, obtain 25 kg (50 lb.) of pea gravel and one brick for each corner of the box. The bricks provide direct ground support for the EMU to prevent it from sinking into the gravel. z Dig the trench approximately 20 cm (8 in.) deeper than the depth of the box. z Add 15 to 20 cm (6 to 8 in.) of pea gravel or crushed rock to the bottom of the trench. The gravel provides drainage for the EMU.
5-6 ADS 3600 Flow Monitor O&M Manual z a pick-ax for stubborn digging, z a regular digging shovel, z a level for leveling the top of the pavement box, z a chalk line to layout trenches, z a hacksaw to cut the conduit, z a socket set for the monitor and top of the pavement box, z a 50 ft (15 m) of 1/8 in.
Monitor Installation and Activation The following supplies are required for installing the pavement box. Quantity Unit Description 1 Each Quazite PG1730BB12 Box with Mouseholes 1 Each Quazite PG1730CA00 Non-Locking Cover 1 Each Quazite UH0357AA Long Cover Hook (for cover removal) 1 Each 13 mm (0.5 in.) Rigid Galvanized Conduit Nipple--a minimum of 15 cm (6 in.) longer than the manhole wall thickness 1 Each Type EY-1, 13 mm (0.5 in.
5-8 ADS 3600 Flow Monitor O&M Manual External Modem Unit (EMU) Installation Installed Pavement Box and EMU Use the following procedure when installing the EMU. z Place one brick or cinder block below each corner of the EMU to keep it off the bottom of the pavement box. Raise the EMU as high as possible, but verify that it does not prevent closing the lid on the pavement box.
Monitor Installation and Activation 5-9 through conduit since it is not direct burial cable. To install this cable, refer to Installing the Communication Cable Using Conduit on page 5-10. However, when installing the communication cable between the DAA and the QS3601 monitor, ADS does not require running the cable through conduit because the cable used in this application is direct burial cable.
5-10 ADS 3600 Flow Monitor O&M Manual Following the directions on the hydraulic cement can, mix enough of the cement to apply around the conduit–both from inside and outside the manhole. Wearing rubber gloves and using a trowel, force the cement into the hole surrounding the conduit, then trowel a bead around the conduit. The cement should harden in about one hour. Note: Wire the communication cable to the communication device before mating the communication cable connector to the flow monitor.
Monitor Installation and Activation 5-11 amounts of tape (do not use cable ties). Pull the cable through the conduit to the pavement box. z Allow extra length on the communication cable so that the monitor can be removed easily from the manhole for service. Installing the Communication Cable Directly in the Ground Install the direct burial communication cable in the following way: z After the cement hardens, remove the protective tape and screw a plastic bushing onto the rigid conduit.
5-12 ADS 3600 Flow Monitor O&M Manual Inside View of the EMU Communication and Telephone Cable Wiring A communication cable must join the EMU and the monitor. First you must verify that the EMU cable connector is not connected to the monitor because cables easily short and blow a fuse in the monitor when they are pulled through conduit.
Monitor Installation and Activation Number Description 1 Yellow 2 Blue (22 gauge wire) 3 Black (glossy color and 22 gauge wire) 4 White 5 Red (22 gauge wire) 6 Green (22 gauge wire) 7 Brown 8 Orange 9 Red (18 gauge wire) 10 Blue (18 gauge wire) 11 Black (glossy color and 18 gauge wire) 12 Green (18 gauge wire) Drain Black (flat color, heat-shrunk cover and 22 gauge wire) Yello w Connects Cable to Monitor 2 Black (22 gauge) 3 W hite 4 Green (22 gauge) Brow n Communication
5-14 ADS 3600 Flow Monitor O&M Manual z Because EMU telephone cable connections vary from country to country, connect the phone cable to the connectors on the EMU communication box according to the following color scheme. Country Telephone Cable Wires Germany Connect the black and yellow cable wires. Britain Connect the red and green cable wires. United States Connect the red and green cable wires. Australia Connect the red and green cable wires.
Monitor Installation and Activation 5-15 1 DSR 6 E RD D A C B TD DTR Direct Connect Port at the EMU DB-9F at RTU 9 5 GND Typical Wiring Configuration Pins Function Pin A to Pin 5 Signal ground. Pin B to Pin 2 RD - Receive Data is the signal by which serial data is transmitted from the 3600 flow monitor and received by the RTU. Pin C to Pin 3 TD - Transmit Data is the signal by which serial data is transmitted from the RTU and received by the 3600 flow monitor.
5-16 ADS 3600 Flow Monitor O&M Manual more information on the ID switch. The options switch (SW3) indicates the specific configuration of the monitor ( modem/serial, baud rate, etc.). The options switch is normally set correctly by manufacturing; see the following figures and table for more information on the options switch. Note: For both SW2 and SW3, closed means on, and open means off.
Monitor Installation and Activation 106100 P roce ssor B oard T hese sw itch es are th e only red a nd wh ite switches on the b oar d.
5-18 ADS 3600 Flow Monitor O&M Manual 1 2 3 4 5 Power Time-out Spare 106/103 6 7 Connection Type Open Monitor will go to sleep.
Monitor Installation and Activation Configuration Jumper Position J1 or J2 1-2 or 1-2 Memory Configuration 1024K (512K×8 in U6 and U7) ADC Reference Configuration MAX154 ADC (in U1) J4 Not Installed AD7824 ADC (in U1) J4 Installed Normal Operation J5 1-2 Storage J5 2-3 Battery Backup Configuration 5-19 When you store a monitor, you must disable the backup battery; use the above information to disable and enable a backup battery. The shaded cells are for general information only.
5-20 ADS 3600 Flow Monitor O&M Manual Three-position Jumper Header Backup Battery w ithout Jum per Operating Battery in Storage 3 3 3 2 2 2 1 1 1 J5 J5 J5 To disable the backup battery, locate Jumper 5 (a three position jumper header). Move the jumper to cover positions 2 and 3. The battery is now disabled. When the jumper is covering positions 1 and 2, the backup battery is operating. Multiplexor Priority Setting The serial multiplexor electronics are located inside the EMU.
Monitor Installation and Activation 5-21 106317A PCBJ1 In addition, most applications in a SCADA system require modem port priority. This allows the QuadraScan software to perform data collections and activations when necessary. Coordinating QuadraScan activities with SCADA system operation minimizes real-time data loss and ensures that these activities occur at a non-critical time. To ensure the modem port has priority, place the jumper on the two pins closest to the label “modem”.
5-22 ADS 3600 Flow Monitor O&M Manual Monitor Installation This section contains procedures which apply to most sites. However, because manholes differ, certain sites might require slight variations in these procedures. Before installing the monitor at the site, verify that the monitor is configured correctly for the applications being supported. Verify that the monitor battery is operating correctly. (For more information on battery maintenance, see Chapter 6, “Monitor Maintenance.
Monitor Installation and Activation 5-23 Determine if one or two mounting holes can be drilled into the existing structure. Mark the location of the mounting hole(s). z Drill the mounting hole(s) into the manhole rim 25 mm deep (1 in.) using an 8 mm (3/8 in.) bit. z Place a tap in each hole with an 8 mm (3/8 in.) tap. z Screw an 3/8 × 2 in. (8 × 50 mm) stud into the tapped hole. z Mount the bottom of the flange onto the monitor with two 3/8 × 2 in. (8 × 50 mm) bolts and nuts.
5-24 ADS 3600 Flow Monitor O&M Manual Note: When you order the cable, you must order the length required for that site. The maximum length is 300 ft.
Monitor Installation and Activation 5-25 Lightning Protection Module Installation The lightning protection module is a gray rectangular box that is attached to a PVC pipe or to the telephone pole with 3/4 in. self-tapping screws. A cable connects the lightning protection module to the telephone company network interface box. A ground wire connects the module to the telephone company’s ground rod or wiring. Note: This module is available as optional protection and is not included with the 3600 product.
5-26 ADS 3600 Flow Monitor O&M Manual z Secure the outside cover of the lightning protection module by inserting a cable tie through the slot at the top of the box. Ensure that the network interface box is closed and tightened. z If the lightning protection module cable needs to be buried, refer to “Underground Services and Lines Location” on page 5-3 and to “Pavement Box and Cable Trench” on page 5-4.
Monitor Installation and Activation 5-27 Monitor Activation After the monitor is installed, QuadraScan software must be installed on the central computer, and the monitor must be activated. Once activated, the monitor can begin collecting flow data. Software Installation Before the QS3600 flow monitor can be activated, QuadraScan software must be installed on the central computer. More than one computer can act as the monitor’s central computer at different times.
5-28 ADS 3600 Flow Monitor O&M Manual z After the software is downloaded and the configuration information is entered, test for proper monitor operation by following the confirmation procedures outlined in the next section, “Data Collection and Confirmation,” and in the QuadraScan User's Guide. Data Collection and Confirmation QuadraScan software retrieves data over telephone lines or onsite from a monitor and places it into a collection device.
6-1 CHAPTER 6 Monitor Maintenance The QS3600 flow monitor and flow sensors should be routinely checked in order to maintain them in optimal working condition and to prevent problems that might cause the loss of data. The procedures outlined in this chapter include: l remote confidence checks that can be performed at the central office by the data analyst and l local confidence checks that are made at the monitor site.
6-2 ADS 3600 Flow Monitor O&M Manual Remote Confidence Checks Review the QuadraScan hardware logs to verify the normal status of the monitor clock, local monitor communications, the monitor BASIC code, the battery status, and the monitor temperatures. Replace the battery when the battery status indicates low (an approved technician must replace the battery in QS3600 flow monitors). Note: Local confidence checks are made onsite during a visit to the monitor location.
Monitor Maintenance 6-3 As discussed in Chapter 1, “Maintenance Restrictions,” IS monitors must be maintained by an ADS IS certified technician. If an ADS IS certified technician is not available locally to replace the battery, the IS monitors must be sent to ADS for battery replacement. In order to preserve its IS certification, a 3600 housing cannot be opened by anyone other than an ADS Service Technician. Opening the monitor housing will immediately void its IS status.
6-4 ADS 3600 Flow Monitor O&M Manual Note: If the EMU uses an external ac power source, power is continuously received, and the NiCad batteries are continuously recharging. For real time applications, an externally powered EMU is used. The modem must be set up using the following parameters if you replace this modem with a non-ADS modem or if your ADS modem is not functioning correctly. These parameters force the modem to be an auto-answer modem.
Monitor Maintenance 6-5 Maintaining the EMU Batteries If the monitor using internal batteries reports that the EMU batteries are low, you can replace them (any field crew member can perform this procedure). l Purchase six alkaline D-cell batteries from a local store. l At the monitoring site, open the pavement box, and remove the lid from the EMU. l Replace the old batteries with the new ones following the polarity chart in the battery holder.
7-1 CHAPTER 7 Troubleshooting This chapter provides general guidelines for correcting monitor problems and contains hints that will help you troubleshoot problems with monitor parts and subsystems. Warning: As discussed in Chapter 1, “Maintenance Restrictions,” monitors used in IS applications must be sent to ADS for maintenance that requires opening the monitor’s housing. Only ADS Service Technicians may perform component-level maintenance on monitors.
7-2 ADS 3600 Flow Monitor O&M Manual Guidelines Remember that when a monitor has to be shut down, all flow measurement and optional functions are also shut down. It is important that you keep monitor downtime to a minimum. This section explains methods of handling monitor problems which will help you minimize downtime.
Troubleshooting 7-3 Troubleshooting The following tables contain troubleshooting hints for managing problems with specific components and subsystems of the QS3600 flow monitor. General Monitor Problems The following tables contain common troubleshooting techniques for the 3600 flow monitor. Problem The monitor does not answer a telephone call. Possible Cause The EMU modem or monitor battery is low. The modem switch settings are incorrect. The modem, communication board, or processor board is faulty.
7-4 ADS 3600 Flow Monitor O&M Manual Problem Possible Cause Destination ID error message is received when calling the monitor. An incorrect monitor ID may have been entered in the central computer. The modem may be faulty. Solution Verify the monitor ID at the central computer and correct it if necessary. If the error message remains, contact your regional ADS office and arrange for an ADS IS certified technician to verify the ID switch settings.
Troubleshooting Problem Possible Cause Solution 7-5 Statements do not print on the event notification station printer when the event status changes. Power to the printer may be off. The printer may be off-line or out of paper. The messages may not be configured properly in BASIC code. The modem may not be functioning properly. Turn the printer on, load the paper, and set it to on-line. Call the modem with a regular telephone to ensure that it answers and is ready to receive.
7-6 ADS 3600 Flow Monitor O&M Manual Ultrasonic Depth Subsystem Use the following tips to help resolve problems with the ultrasonic depth subsystem. Warning: Prior to replacing a sensor, contact an ADS trained technician for further diagnosis. Problem Possible Cause Solution The range from the ultrasonic depth subsystem is close but not exact. The electronic or physical offset may be incorrect. The pipe diameter could be incorrect. Verify the physical offset and change it if necessary.
Troubleshooting Problem Possible Cause Solution 7-7 The raw depth of flow data has a value greater than the pipe diameter. The pipe is surcharged; the sensor is dirty; or the sensor is faulty. Verify that the pipe diameter, physical offset, and electronic offset are correct in QuadraScan’s location information file. Clean the ultrasonic depth sensor. If the problem is still unresolved, contact an ADS trained technician for further information about replacing the ultrasonic sensor.
7-8 ADS 3600 Flow Monitor O&M Manual Doppler Velocity Subsystem Use the following tips to help resolve problems with the Doppler velocity subsystem. Warning: Prior to replacing a sensor, contact an ADS trained technician for further diagnosis. Problem Possible Cause Solution A data value of 0 is read often. The Doppler velocity sensor may be dirty, weakened, or broken. The cabling between the velocity board and the velocity sensor may be bad. The velocity board may be faulty. Clean the velocity sensor.
Troubleshooting Problem Possible Cause Solution 7-9 The velocity data readings are abnormally high. Wires on the P2 connector may be loose. The velocity sensor may be covered with silt. The velocity sensor may be out of the flow. The flow may be reversed or slower than 0.15 m/s (0.5 ft/s). Check the site conditions and relocate the velocity sensor if necessary. If the problem is still unresolved, replace the monitor and send the old one to ADS for service.
7-10 ADS 3600 Flow Monitor O&M Manual Problem Possible Cause The pressure depth subsystem temperature and depth readings are erratic. The cabling to the pressure sensor or the pressure board may be faulty. The pressure sensor may be faulty. Solution Examine the pressure sensor and clean it if necessary. If the problem is still unresolved, contact an ADS trained technician for further information about replacing the pressure sensor.
Troubleshooting 7-11 Recommended Spare Parts For a typical flow monitoring application, the system uptime is critical. If possible, do not disable a monitor in order to resolve a problem. ADS recommends maintaining a spares stock of at least 10% of monitors and sensors.
A-1 APPENDIX A Features and Specifications This topic contains information on the features and specifications of the QS3600 flow monitor and associated hardware components. Information is included on data storage; the processor board; the ultrasonic depth, Doppler velocity, and pressure depth subsystems; and communications. To learn about: See page: General Features and Specifications....................................................... A-2 Data Storage................................................
A-2 ADS 3600 Flow Monitor O&M Manual General Features and Specifications The following table contains information about general features and specifications of the QS3600. Functional Description The microprocessor-based flow monitor works with the central computer and ADS software and provides flow rate measurement and reporting functions. Optional functions include reading a rain gauge and sending signals to the optional sampler.
Features and Specifications Methodology A-3 Depth and Velocity Flow Measurement The monitor activates flow sensors to take readings to determine the depth and velocity of the flow The monitor scans and stores sensor readings at prescribed intervals (such as every 15 min).
A-4 ADS 3600 Flow Monitor O&M Manual Downloaded Software The downloaded BASIC program enables the QS3600 flow monitor to scan input devices and store readings on the processor board. A BASIC program is maintained in the battery-backed RAM to protect against program loss in event of a battery failure. The onboard BASIC interpreter provides sophisticated mathematical functions. The central computer downloads the BASIC program to the monitor via a modem and telephone line.
Features and Specifications Data Storage The following table illustrates the number of days that data can be stored in the QS3600 memory in different monitor configurations.
A-6 ADS 3600 Flow Monitor O&M Manual 106100 Processor Board The following table contains information about general features and specifications of the 106100 processor board. Processor Memory 80C31 CMOS Microprocessor The EPROM has 64K bytes (program storage). The RAM has 1024K bytes of battery-backed data storage. Programming Language Program Loading Communication BASIC The program is loaded via a modem over standard, voice-grade telephone lines or via a direct serial connection.
Features and Specifications A-7 Depth Subsystem The depth subsystem includes the ultrasonic depth sensor and the pressure depth sensor. This subsystem also includes the depth board. Ultrasonic Depth Sensor The following table contains information and specifications for the ultrasonic depth sensor. Measurement Technique Accuracy Frequency Quadredundancy Ultrasonic pulse echo ranging measures the elapsed time between the transmission of the ultrasonic signal to the flow surface and echo reception.
A-8 ADS 3600 Flow Monitor O&M Manual Pressure Depth Sensor The following table contains information and specifications for the pressure depth sensor. Measurement Technique Effective Range The pressure sensor gauge references the difference in atmospheric and water pressures in the sewer pipe to determine the depth of flow in the pipe. The sensor has a range up to 3.35 m (11 ft). Greater ranges are available through factory modifications. Resolution The resolution is within 1.0 mm (0.04 in.).
Features and Specifications A-9 Doppler Velocity Subsystem The following topic contains information about the Doppler velocity subsystem, including the Doppler velocity sensor and digital specifications for the Doppler velocity board. Doppler Velocity Sensor The following table contains information and specifications for the Doppler velocity sensor.
A-10 ADS 3600 Flow Monitor O&M Manual Communications The following topic contains information about the EMU, SCADA EMU, and DAA. EMU The following table contains information and specifications for the EMU.
Features and Specifications A-11 DAA The following table contains information and specifications for the SCADA EMU. Functional Description Housing Provides communication link between telephone network interface and 3601 monitor; contains non-intrinsically safe portion of the modem communication Gray PVC Dimensions 4.13 inches (10.5 cm) high x 3.25 inches (8.3 cm) wide x 1.88 inches (4.
In-1 Index A D Activation installation of monitor 5-27 overview 3-2 software 5-27 DAA communication cable 2-10 buried directly 5-11 installation 5-8 Data acquisition 1-4, 5-28 collection 3-8 confirmation 3-8 scrubbing 3-7 storage A-5 Data Access Arrangement See DAA Declaration of Conformity 1-10 Depth Board digital specifications A-8 Depth Subsystem specifications A-7 Doppler Velocity Board digital specifications A-9 Doppler Velocity Sensor mounting in pipe 4-13 operation 3-6 specifications A-9 trouble
In-2 ADS 3600 Flow Monitor O&M Manual wiring 5-12 description 2-7 direct connection communication local RTU 5-14 external power 1-6, 2-8 failure 6-5 installation 5-2, 5-8 communication cable 5-8 pavement box 5-3, 5-5 trenching 5-4 underground lines 5-3 internal power 1-6, 2-7 introduction 1-4 NiCad battery 2-9 SCADA System 2-8, 5-14 telephone cable wiring 5-12 EMU Batteries replacement 6-5 Explosive Gases manholes 1-5 QuadraScan 3600 IS Flow Monitor 1-5 External Modem Unit See EMU F FCC Compliance 1-8 inte
Index multiplexor priority 5-20 modem 5-21 L Leveling Ultrasonic Sensor 4-25 Lightning Protection Module checking 6-3 installation 5-25 warning 5-25 Local Confidence Checks 6-2 Local RTU direct connection communication 5-14 M Maintenance battery pack 6-2 EMU 6-3 real time applications 6-4 EMU batteries 6-5 flow sensors 6-4 lightning protection module 6-3 local confidence checks 6-2 monitor 6-2 overview 6-1 remote confidence checks 6-2 restrictions 1-7, 6-3 telephone interface box 6-3 troubleshooting 7-1 mon
In-4 ADS 3600 Flow Monitor O&M Manual sensor cables 4-19 silt 4-17 non-overlapping rings 4-12 spreader mechanism 4-8 S Safety warning 1-8 SCADA EMU description 2-8 direct connection communication local RTU 5-14 external AC power 2-8 external DC power 2-9 Serial Multiplexor Electronics 5-20 Silt 3/4 mount installation 4-37 Special Installation 4-20 supplies 4-21 ultrasonic sensor adjustable mount 4-27 standard mount 4-22 surcharge mount 4-30 velocity sensor 1/2 band mount 4-38 3/4 mount 4-34, 4-36 Specifica
