ADS Model 4000 Installation, Operation, and Maintenance Manual December 2004 530017A0 4940 Research Drive Huntsville, Alabama 35805 (256) 430-3366
ii ADS Model 4000 Manual 2004 ADS Corporation. All rights reserved. ADS, ADS Environmental Services, and Accusonic are registered trademarks of ADS Corporation. FieldScan is a trademark of ADS Corporation. ADS Model 4000 is a trademark of ADS Corporation. All other brand and product names are trademarks or registered trademarks of their respective holders. Notice of Proprietary Information The information contained herein represents the latest information available at the time of publication.
Table of Contents iii Table of Contents Chapter 1 Introduction 1-1 Warnings and FCC Compliance..................................... 1-4 FCC Part 68 Compliance ........................................ 1-4 Product Warranty ........................................................... 1-6 New Product Warranty ........................................... 1-6 Out-of-Warranty Product Repairs........................... 1-7 Troubleshooting Fee ............................................... 1-7 Shipping ..........
iv ADS Model 4000 Manual Chapter 4 Communication and Activation 4-1 Providing Telephone Service ......................................... 4-2 Running the Telephone Cable Between the Monitor and Service Locations ............................................. 4-2 Mounting the Lightning Protection Module ........... 4-5 Preparing the Telephone Cable ............................... 4-5 Wiring the Telephone Cable to the Monitor ........... 4-7 Wiring the Telephone Cable to the Lightning Protection Module....
Table of Contents Appendix B Switch and Jumper Settings v B-1 ID Switch Settings ..................................................B-2 Options Switch Settings..........................................B-3 Jumper Settings.......................................................
1-1 CHAPTER 1 Introduction The ADS Model 4000 long-term flow monitor measures open channel flow in sanitary sewers, storm sewers, pump stations, 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 Billing Monitoring sewage handling facilities (wastewater treatment plants and pump station
1-2 ADS Model 4000 Manual The Doppler velocity sensor gathers peak flow velocity data. These sensors display exceptional durability and accuracy, even under harsh and turbulent flow monitoring conditions. The monitor receives the raw data from the sensors based on a defined time interval and then processes the data, which may involve calculating the flow rate. This data, stored in the monitor memory, is available to the user for collection, further processing, analysis, and reporting.
Introduction 1-3 conversion kit also is available to convert existing battery-powered units to external power. This manual offers detailed instructions on installing the 4000 flow monitor and sensors, providing communication with monitor (remote or on-site), and performing routine maintenance and troubleshooting on the system.
1-4 ADS Model 4000 Manual Warnings and FCC Compliance Manhole and sewer system work involves confined space entry and is inherently dangerous. Therefore, installers and technicians should comply with all federal, state, and municipal 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.
Introduction 1-5 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 necessary modifications to maintain uninterrupted service. In the unlikely event that this equipment harms the telephone network, the telephone company will notify you that temporarily discontinuing telephone service may be required.
1-6 ADS Model 4000 Manual Product Warranty This section includes the warranty for the ADS Model 4000. New Product Warranty All new products manufactured by ADS Environmental Services will be free from defects in material and workmanship for one year following the date of shipment from ADS. During this warranty period, upon satisfactory proof of a defect, the product may be returned for repair or replacement, at the option of ADS.
Introduction 1-7 Out-of-Warranty Product Repairs After the new product warranty expires, a product may be returned, at the owner’s prepaid expense, to ADS 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 ADS.
2-1 CHAPTER 2 System Overview The ADS Model 4000 flow monitor and sensors are primarily designed for monitoring flow in sanitary and storm sewers. The monitor mounts to the manhole rim or wall slightly below the manhole cover; the sensors typically attach to a ring installed in the sewer pipe a short distance upstream from the manhole invert.
2-2 ADS Model 4000 Manual The monitor transmits and receives electronic signals to and from the sensors to measure the flow depth and velocity based on a time defined interval. It then gathers and processes this information, which may involve calculating the flow rate. The monitor can transfer the recorded flow data to the user's PC for determining flow rate, performing flow analysis, and reporting.
System Overview 2-3 ADS Model 4000 Flow Monitor The ADS Model 4000 flow monitor is a waterproof, airtight, cylindrical, marine-grade aluminum canister housing a chassis securing multiple printed circuit boards and a portable power source.
2-4 ADS Model 4000 Manual Side view of 4000 flow monitor chassis assembly ADS Model 4000 WR (Wireless-Ready) The ADS Model 4000 WR flow monitor is designed to communicate through an external, wireless communication device. Wireless communication occurs through a connection between the monitor and a CDPD device called the ADS Model 3800. Note: Since the 4000 WR does not communicate using telemetry, it contains neither a modem board nor a lightning protection board.
System Overview 2-5 Maintaining the monitor time and date Performing power management Providing each board with the parameters required to carry out the associated operations Outputting a discrete signal to a sampler Transmitting the stored and current data to the user's PC The board allocates portions of memory to firmware (permanently stored software), data storage, and program manipulation and calculation.
2-6 ADS Model 4000 Manual Connectors Connectors located on top of the monitor receive the following cabling and components: Ultrasonic depth sensor Doppler velocity sensor Pressure depth sensor Telemetry or serial (DMI or wireless) communication Rain gauge/sampler/external power Battery Pack The 12-volt battery pack, mounted to the bottom of the chassis, provides the power for operating the monitor and maintaining the monitor memory through the power supply on the processor board.
System Overview 2-7 Sensors The 4000 flow monitor uses the sensors to gather raw flow data. The ultrasonic and pressure depth sensors use independent measurement techniques to collect information concerning the depth of the flow. The Doppler velocity sensor gathers peak flow velocity data. A sewer system's hydraulics are much more stable and uniform in the incoming pipe than in the manhole invert or outgoing pipe.
2-8 ADS Model 4000 Manual Ultrasonic depth sensor sending signals to flow surface to determine range Quadredundancy Each ultrasonic depth sensor contains four ultrasonic transducers. Taking readings with four transducer pairs gives 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 2-9 The monitor discards the clearly erroneous readings (i.e., readings well outside the range of the majority of the readings). The monitor records the percentage of all acceptable readings used to arrive at the average value. Secondary scrubbing also can occur during data collection from the monitor to the analyst's PC using the Profile software. Refer to the Profile User's Guide (950015**) for more information.
2-10 ADS Model 4000 Manual The second process involves applying the standards set by the algorithm in the first sensor firing to process the return echoes and determine the range actually used to record the depth of flow in the pipe. The monitor takes 32 analog readings for each of the 12 transducer pairs (384 total firings). The analog signals produce a greater resolution and accuracy.
System Overview 2-11 upward into the flow. The sound wave bounces off particles in the flow and returns to the sensor. The velocity sensor measures the change in the sound wave's frequency from transmission to reception. This change is used to determine the velocity of the flow based on the Doppler effect. The Doppler effect describes the shift in frequency of a sound wave emitted by a moving object in relation to a stationary point.
3-1 CHAPTER 3 Monitor and Sensor Installation The ADS Model 4000 flow monitor and sensors are primarily designed for monitoring flow in sanitary and storm sewers. The monitor mounts to the manhole rim or wall slightly below the manhole cover. 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 ADS Model 4000 Manual Typical 4000 flow monitor and sensor installation This chapter contains general instructions for properly installing the monitor and sensors in sanitary, storm, and combined sewer lines and manholes. Note: Manhole and sewer system work involves confined space entry and is inherently dangerous. Therefore, installers and technicians must comply with all federal, state, and municipal regulations concerning confined space entry.
Monitor and Sensor Installation 3-3 Installing the Sensors in the Pipe There are two types of sensor installations: Standard Installations Special Installations Standard Installations involve installing a stainless steel ring to mount the sensors in round pipes up to 48 inches (122 cm) in diameter. Special Installations involve installing stainless steel bands to mount the sensors in round pipes over 48 inches (122 cm) in diameter or irregular-shaped pipes of any size.
3-4 ADS Model 4000 Manual Gathering Parts and Supplies Obtain the following supplies before installing the ring and sensors to prevent any costly delays. When ordering, specify the 4000 flow monitor ring-mounted installation hardware. Note: The values and units that appear in italics are direct conversions; therefore, these mechanical sizes may not actually exist. ADS has included the conversions only to enhance readability.
Monitor and Sensor Installation 3-5 Assembling the Ring The flow sensors mount to a stainless steel ring that is installed in the pipe. Several different ring sizes exist, and each ring is adjustable within about 3 inches to fit pipes of different diameters. Assemble the ring in the following way: Note: These instructions generally apply to overlapping rings. However, the 8-, 10-, and 12-inch rings do not have an overlapping section.
3-6 ADS Model 4000 Manual Sliding the ring stabilizer onto the ring 3. Slide the ring stabilizer all the way around the ring until it is about 4 inches (10 cm) from the welded metal band at the other end of the ring. Moving the ring stabilizer into position 4. Position the ring with the downstream edge (edge with the holes) facing you.
Monitor and Sensor Installation 5. 3-7 Slide the ultrasonic sensor mount onto the open end of the ring with the back of the ultrasonic mount (side with the slots) facing the outside of the ring. The side with the backstop should face the inside of the ring. Sliding the ultrasonic sensor mount onto the ring 6. Move the ultrasonic sensor mount around the ring. Note: Steps 7 and 8 apply only to overlapping rings. Proceed directly to step 9 for non-overlapping rings. 7.
3-8 ADS Model 4000 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.
Monitor and Sensor Installation 3-9 10. Place the ring on a flat surface with the spreader mechanism screw facing up. 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.
3-10 ADS Model 4000 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.
Monitor and Sensor Installation 3-11 18. Tighten the screw through the hole using a Phillips-head screwdriver while holding the hex nut with a ½-inch (13 mm) nut driver. Tightening the spreader mechanism screw and hex nut 19.
3-12 ADS Model 4000 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.
Monitor and Sensor Installation 3-13 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 should look.
3-14 ADS Model 4000 Manual Pressure Depth Sensor Bottom of the ring slightly to the left of the Doppler velocity sensor (when present) Proper positioning of sensors on the ring 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.
Monitor and Sensor Installation 3-15 Mounting the ultrasonic depth sensor to the mounting plate on the ring 2. Verify that the ultrasonic depth sensor mounts to the ring at the crown of the pipe. Mounting the Doppler Velocity Sensor Mount the Doppler velocity sensor to the ring in the following way: 1.
3-16 ADS Model 4000 Manual 2. Secure the sensor cable to the ring. Refer to Securing the Cables to the Ring (or Band) on page 3-42 for instructions on properly securing the cable. Note: If the installation includes a pressure depth sensor, wait to secure the sensor cables until both sensors are installed on the ring. Mounting the Pressure Depth Sensor Mount the pressure depth sensor to the ring in the following way: 1. Orient the ring so that the ultrasonic depth sensor is directly on top.
Monitor and Sensor Installation 3-17 cable ties Dryer Tube Properly securing the dryer tube to the monitor 4. Secure the sensor cable to the ring. Refer to Securing the Cables to the Ring (or Band) on page 3-42 for instructions on properly securing the cable. Installing the Ring in the Manhole The ring must fit securely in the pipe with the sensors properly positioned to ensure the most accurate monitoring results. Install the ring in the pipe in the following way: 1.
3-18 ADS Model 4000 Manual Installing the ring at least 12 inches upstream from the manhole invert Keep the following in mind: Make sure the ultrasonic depth sensor is at the top (crown) of the pipe, the Doppler velocity sensor is at the bottom of the pipe above any silt present and below the flow surface (during minimum flows), and the pressure depth sensor is near the bottom.
Monitor and Sensor Installation 3-19 If necessary, temporarily clear away silt to install the ring. Make sure the ring is flat (flush) against the inside wall of the pipe to avoid obstructing the flow or catching debris. 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.
3-20 ADS Model 4000 Manual Tap the sensor mount to the right or left with a rubber mallet until it is level. Warning: Tapping the sensor mount with the sensor attached could damage the sensor. Always remove the sensor before tapping the mount with a mallet. Remount the sensor onto the mount, and recheck the level. 6. Fully tighten the ring until it fits securely and completely flush against the pipe wall. Warning: Avoid overtightening the ring. This could bend the crank assembly. 7.
Monitor and Sensor Installation 3-21 Performing a special installation involves the following process: Gathering the equipment and supplies Mounting the ultrasonic depth sensor Mounting the Doppler velocity sensor Mounting the pressure depth sensor Before beginning the installation, conduct a thorough investigation of hydraulic and other site conditions. The hydraulics of a site directly affect the monitor's ability to accurately measure flow depth and velocity.
3-22 ADS Model 4000 Manual Quantity Description ADS Part Number 1 4000 flow monitor ADS Model 4000 15 11-inch cable tie (28-cm) I05-0003 25 4-inch cable tie (10-cm) I05-0001 15 8-inch cable tie (20-cm) I05-0002 10 anchor cable tie I05-0004 15 ¼- × 2 ¼-inch anchor bolt (with 7/16-inch nut and washer) I01-0002 3 3/83/16-inch × 1-inch nut I15-0002 6 3/83/16-inch washer I55-0001 3 3/83/16-inch × 1-inch bolt I01-0001 1 3/8- × 2-inch (8- × 50-mm) stud I01-0009 2 4-40 × 5/16-i
Monitor and Sensor Installation 3-23 Mounting the Ultrasonic Depth Sensor Two special installation methods are available for mounting the ultrasonic depth sensor: Standard Ultrasonic Mount This mount, the most common mounting method in use today, is used for mounting the ultrasonic depth sensor in the pipe during special installations.
3-24 ADS Model 4000 Manual Securing one end of the ultrasonic depth sensor mounting band 6. Slide the adjustable ultrasonic plate onto the band with the backstop edge closest to the invert and the two band slots facing up. Sliding the ultrasonic depth sensor mounting plate onto the band 7. Align the sliding ultrasonic plate with the scribe marks, and conform the other end of the curved band with the pipe. 8. Spot drill to mark an anchor bolt location, and mount another anchor bolt to the pipe. 9.
Monitor and Sensor Installation 3-25 Securing the other end of the band Note: If the plate has too much play, attach another anchor bolt approximately 1 inch (25 mm) from the plate. 10. Slide the ultrasonic 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. See illustration on page 2-19. 11.
3-26 ADS Model 4000 Manual Surcharge Mount Use the following method to mount the ultrasonic depth sensor at a site that may experience surcharge conditions: 1. Place the top of the ultrasonic depth sensor against the base of the surcharge plate, aligning the holes of the plate with the holes on top of the sensor. 2. Insert a 6-32 × 1-inch (25-mm) round-head machine screw with a 6-32 washer through the ultrasonic plate and sensor, and secure with a 6-32 washer and 5/16-inch (8-mm) nut. 3.
Monitor and Sensor Installation 3-27 6. Identify the three pre-drilled holes at the top of the bracket, and spot drill the manhole wall through the middle hole with a drill. 7. Remove the bracket, and drill and mount an anchor bolt. 8. Secure the top of the bracket to the manhole wall with a washer and 7/16-inch (11-mm) nut. 9. Push up on the bottom portion of the bracket until the ultrasonic depth sensor portion of the bracket is level. 10.
3-28 ADS Model 4000 Manual installer to secure the band to both sides of the pipe wall and to position the Doppler velocity sensor at the bottom center of the pipe. These options are not possible using the ½-band mount. Therefore, the ¾-band mount is the preferable method for mounting the sensors.
Monitor and Sensor Installation 2. 3-29 Determine which end of the band will be the long end (end extending almost completely up one side of the pipe). For cable routing purposes, ADS recommends reserving the left side of the pipe (upstream from the manhole) for the long end of the band. Note: Position the edge of the band with the cable tie holes (edge with small holes) facing downstream. 3.
3-30 ADS Model 4000 Manual 6. Secure the sensor cables along the downstream edge of the long end of the band according to the instructions in Securing the Cables to the Ring (or Band) on page 3-43. 7. Position the band in the pipe so that the sensors will remain below the flow surface (even during minimum flows) and above the silt level. 8. Make sure two pre-drilled holes are visible above the flow surface on the short end of the band.
Monitor and Sensor Installation 3-31 Sensors mounted using a ¾-band mount in the pipe with and without silt 15. 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 Cables in the Pipe and Manhole on page 3-43. ½-Band Mount Perform the following procedure to mount the Doppler velocity sensor and pressure depth sensor (when applicable) in a pipe using the ½-band mount: 1.
3-32 ADS Model 4000 Manual 4. When applicable, mount the pressure depth sensor to the band in the following way: Mount the pressure depth sensor 2 inches to the left of the Doppler velocity sensor. Make sure the sensor will be underneath the flow once installed. Secure the pressure depth sensor to the band using two 3mm × 8-mm countersink screws. If the sensor does not have screw inserts, use two medium-sized cable ties to secure the sensor to the ring.
Monitor and Sensor Installation 3-33 10. Conform the portion of the band above the flow surface to the pipe wall, and install an anchor bolt, nut, and washer every 12 to 24 inches (30 to 61 cm) up to the top of the band. Completed ½-band mount in pipe 11. 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 Cables in the Pipe and Manhole on page 3-43.
3-34 ADS Model 4000 Manual Installing the Monitor in the Manhole After installing the sensors and establishing telephone service, install the monitor in the manhole. The monitor mounts inside the manhole by an aluminum mounting bracket attached to the monitor and bolted to the manhole wall or rim. The following procedures for monitor installation apply to most sites.
Monitor and Sensor Installation 3-35 Select a location that will allow you to remove the monitor easily during service visits using the mounting bracket (extension handle). Select a location that provides only a minimal potential for the monitor to experience surcharge conditions. Select a location that will prevent the manhole lid from potentially damaging the monitor during removal or when rotating in the opening. 2.
3-36 ADS Model 4000 Manual 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. Note: ADS strongly recommends attaching a security line to the monitor before lowering it into the manhole to prevent the monitor from accidentally dropping down the manhole during installation. 7. Tighten and secure the bolt against the mounting bracket.
Monitor and Sensor Installation 8. 3-37 Neatly coil and secure the excess sensor and telephone cables in the manhole to simplify future monitor service activities. Secure the cables to plastic anchors or anchor bolts using 14inch (35-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.
3-38 ADS Model 4000 Manual Drilling the hole in the manhole rim 4. Use a 3/8-inch (9-mm) x 16 threads-per-inch tap to cut threads in the hole. Twist the tap clockwise ¾ turn, and then back out ½ turn before continuing deeper. Using the tap to thread the hole 5.
Monitor and Sensor Installation 3-39 screwing it back into the hole. Lubricate the hole between threading. 6. Place two 9/16-inch (14-mm) nuts (with a washer in between) onto one end of the 3/8- × 2-inch (8- × 50-mm) stud. Placing two nuts and a washer onto the stud 7. Using two wrenches, turn the inner nut counter-clockwise and the outer nut clockwise simultaneously to bind the two nuts together on the stud.
3-40 ADS Model 4000 Manual Binding the nuts together with the washer in between 8. Install the stud into the tapped hole using the outer nut to engage the wrench. Continue turning the nut clockwise until the stud is seated at least ¾ inch (19 mm) deep in the hole. Installing the stud into the hole in the manhole rim 9. Separate the nuts, and turn the inner nut until it is flush against the rim.
Monitor and Sensor Installation 3-41 10. Slide the washer against the inner nut, and turn the outer nut toward the edge of the stud. Positioning the nuts on the stud to receive the mounting bracket 11. Mount the bottom of the mounting bracket onto the monitor flange with two 3/8- x 2-inch (8- × 50-mm) bolts and nuts. It may be necessary to drill new holes in the flange. 12. Carefully lower the monitor into the manhole, and place the keyhole in the bracket over the outer nut on the stud.
3-42 ADS Model 4000 Manual Securing the Sensor Cables The following sections address securing the sensor cables to the ring (or band), pipe, and manhole. Securing the Cables to the Ring (or Band) Securing the Doppler velocity sensor and pressure depth sensor cables to the ring (or band, when applicable) 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.
Monitor and Sensor Installation 3-43 2. Continue securing the cables until reaching the ultrasonic depth sensor or the top of the pipe. 3. Pull the ties until they are taut, and cut off the excess portion of the cable ties. Warning: Do not overtighten the cable ties or kink the sensor cables! The pressure depth cable sheathes two components: the electrical cables that operate the sensor and an air tube that ventilates the sensor.
3-44 ADS Model 4000 Manual Drive the plastic anchor into the pipe with a hammer until flush and secure. Run the cable tie through the loop in the plastic anchor and around the cables. Tighten the cable tie around the cables, and cut off the excess cable tie material. Warning: Overtightening the cable ties may damage the sensor cables. 2. Secure the cables with a cable tie and plastic anchor every 18 to 24 inches (46 to 61 cm) along the pipe crown (when necessary) from the ring to the manhole. 3.
Monitor and Sensor Installation 3-45 Connecting the Sensors to the Monitor After attaching the sensors to the ring, connect the sensor cables to the appropriate ports on the top of the monitor. The ports are labeled to identify the appropriate connection for each sensor. Connect the sensor cables to the monitor ports in the following way: 1. Place the monitor in an upright position to view the monitor connector ports. FOR TEST ONLY Cable connector ports 2.
3-46 ADS Model 4000 Manual 5. Connect each sensor cable to the appropriate port. Tighten each connector in a clockwise direction until it clicks, and verify that it is seated correctly. While the Doppler velocity sensor and pressure depth sensor have identical pin configurations, they are not interchangeable when connecting to the monitor. Therefore, be careful to connect the sensors to their assigned ports on the monitor. The monitor will not operate properly if these sensors are interchanged. 6.
4-1 CHAPTER 4 Communication and Activation After installing the sensors in the pipe and connecting the sensors to the monitor, it is necessary to establish communication with the monitor (through telemetry or the direct modem interface) and activate the monitor. This chapter contains instructions on establishing telephone service at the monitor location for communicating with the monitor from a remote location and using the direct modem interface (DMI) cable to communicate with the monitor at on site.
4-2 ADS Model 4000 Manual Providing Telephone Service Providing telephone service to the monitor involves the following steps: Running the telephone cable between the monitor and service locations Mounting the lightning protection module Preparing the telephone cable Wiring the telephone cable to the monitor Wiring the telephone cable to the lightning protection module Wiring the lightning protection module to the network interface box Warning: To avoid possible shock, make all connections to the monitor
Communication and Activation 4-3 In addition, notify the local underground utilities locating service concerning the desired pedestal location and cable route. Typically, notification must occur 2 to 3 days before excavation activities are scheduled to begin. After finalizing the pedestal location and cable route, run the telephone cable between the monitor location and the designated pedestal location in the following way: 1.
4-4 ADS Model 4000 Manual Extend the conduit approximately 12 inches vertically out of the trench (from the ground surface) at the designated pedestal location. Running conduit from the telephone service location to the manhole 4. Use urethane foam to seal the space between the conduit and the corbel to prevent infiltration into the manhole. 5. Use urethane foam or a weatherhead to form a seal between the telephone cable and conduit at each end of the conduit.
Communication and Activation 4-5 Mounting the Lightning Protection Module The next step in establishing telephone service is mounting the lightning protection module to the service pedestal. Mount the module in the following way: 1. Remove the front cover from the pedestal. 2. Use the screws included with the lightning protection module to mount the module on the pedestal at least 12 inches (30 cm) above the ground surface and next to or 6 to 8 inches (15 to 20 cm) below the network interface box.
4-6 ADS Model 4000 Manual 1. Carefully strip about 3 inches of the external insulation from each end of the telephone cable. Stripping the external insulation from the telephone cable 2. Remove the internal braiding, and separate the four insulated wires. Separating the insulated wires 3. Cut off both the black and white wires down to the level of the external insulation. These wires will not be used in this application.
Communication and Activation 4-7 Stripping ½ inch (13 mm) of insulation from each wire 5. At the pedestal end of the cable, fold over both exposed wires (doubling the thickness). Insert each wire into an uninsulated #10 ring terminal lug (22-18 gauge), and crimp the wires to the lugs. Wiring the Telephone Cable to the Monitor After preparing the telephone cable, wire the telephone cable to the monitor in the following way: 1. Seat the mating telephone connector onto the communications port (COMM.
4-8 ADS Model 4000 Manual 2. Insert the telephone cable through the plastic potting collar past the loose wires. Inserting the telephone cable through the plastic potting 3. Apply solder to the end of each wire by heating the wire with a soldering iron and contacting the wire with the solder. This will cause the solder to flow onto the heated wire. Applying solder to the wire ends 4.
Communication and Activation 4-9 contacting the socket with the solder. This will cause the solder to flow into the socket. Filling the wire sockets in the connector with solder 5.
4-10 ADS Model 4000 Manual 6. Wrap the exposed wire ends with small pieces of plastic or tape to prevent a possible short from occurring if they contact during the potting process. 7. Slide the plastic potting collar over the soldered wires, and secure the collar onto the threaded portion of the metal connector.
Communication and Activation 4-11 10. Use 3MTM Linerless Rubber Splicing Tape to secure the cable to prevent it from moving during the curing process. Wrap the tape around the entire connector/cable assembly and about 1 inch (25 mm) up the telephone cable beyond the assembly. Note: Support the telephone cable during the curing process by running a cable tie between the telephone cable and the monitor flange. Curing typically requires about 25 minutes.
4-12 ADS Model 4000 Manual Lightning protection module wiring diagram Note: Remember, the wire colors referenced in this manual are based on the telephone cable ADS recommends for these applications. However, the wires inside some telephone cables may vary in color and number. Therefore, when the actual wire colors and number differ from those designated in this manual, connect the available wiring in reference to ground, ring, and tip. 4.
Communication and Activation 4-13 10. Clamp the exposed wire to the ground rod protruding from the ground inside the pedestal or to the telephone company's existing ground wire (when properly connected to the ground rod). Wiring the Lightning Protection Module to the Network Interface Box The final step in establishing telephone service is wiring the lightning protection module to the telephone company’s network interface box. Accomplish this task in the following way: 1.
4-14 ADS Model 4000 Manual Wiring diagram of telephone company network interface box Note: Since the colors inside some boxes vary, this manual does not reference colored posts for connection. The installer should connect the wires to the posts in reference to ring and tip. 7. Use urethane foam to seal the space between the telephone cable coming from the manhole and the conduit. This prevents sewer gases from traveling through the conduit from the manhole into the pedestal.
Communication and Activation Complete wiring diagram 4-15
4-16 ADS Model 4000 Manual Using the Direct Modem (DMI) Cable Communicating with the monitor on site requires the direct modem interface (DMI) cable and a field computer running the FieldScan software. Equipped with an inline modem, the DMI cable provides direct communication between the user and the monitor without the need of telemetry.
Communication and Activation 4-17 Activating and Confirming the Monitor After installing the monitor, activate and confirm the monitor to initiate the data collection process. Activation involves using the FieldScan software to download the BASIC code, configuration information, and other parameters to the monitor. The monitor requires these files and information to properly measure the flow. Activating the monitor also tests communication between the user's computer and the monitor.
5-1 CHAPTER 5 Maintenance and Troubleshooting While the ADS Model 4000 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.
5-2 ADS Model 4000 Manual Maintaining the System Components The 4000 flow monitor and sensors should receive routine on-site inspections and remote confidence checks to maintain the equipment in optimal working condition, minimize monitor downtime, and prevent possible data loss. ADS recommends performing these inspections following initial system installation, during site visits, and on a scheduled interval (i.e., quarterly or during battery replacement).
Maintenance and Troubleshooting 5-3 Confirming the Monitor Confirm the accuracy of the sensor subsystems in the monitor on a regular basis. Confirmation involves comparing manuallymeasured depth of flow and velocity readings to the monitor's readings. This process also verifies sensor calibrations. Refer to the FieldScan User's Guide (#950021**) for detailed information on confirmation procedures.
5-4 ADS Model 4000 Manual 2. Loosen bolts and remove the monitor lid with chassis from the aluminum canister. 3. Remove the cables ties securing the battery pack, and unscrew the rubber stops holding the battery pack in place. 4. Disconnect the orange connector (attached to the cable running from the battery pack) from the processor board (P6). 5. Remove the battery pack from the chassis. 6. Place the new battery pack into the chassis, and replace the rubber stops.
Maintenance and Troubleshooting 5-5 Checking 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 ultrasonic sensor gently with a soft brush saturated with rubbing alcohol, and wipe the sensor with a clean, moist cloth. Verify that the face of the ultrasonic depth sensor is horizontally level with the flow. Reposition, if necessary, according to the procedures in Chapter 3.
5-6 ADS Model 4000 Manual Checking Communication Devices Inspect the following communication devices during site visits: Lightning Protection Module Check the lightning protection module for lightning strikes, damaged or poor connections, or corrosion. Replace a burned out module, and repair any bad or corroded connections in the wiring. Network Interface Box If any problems exist with the network interface box, check the connectors to ensure that the cable entries are tight and waterproof.
Maintenance and Troubleshooting 5-7 Troubleshooting The 4000 flow monitoring system contains several different components that perform many different functions. Since a malfunctioning component increases the risk of losing data, isolating the part containing the problem quickly is essential to performing troubleshooting activities efficiently. Minimizing monitor downtime is critical.
5-8 ADS Model 4000 Manual 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, many 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.
Maintenance and Troubleshooting Problem Monitor does not answer a telephone call. Possible Causes Telephone connection at monitor may be damaged, loose, or leaking. 5-9 Telephone cable may be noisy, damaged, or dead. Lightning protection module may be damaged. Battery pack may be dead or below minimum voltage requirement (8.0 volts). Monitor may be defective. Lightning protection board in monitor may be defective. Modem in monitor may be defective. Modem in office or field computer may be defective.
5-10 ADS Model 4000 Manual Problem Busy signal occurs when calling the monitor. Possible Causes Someone else may be communicating with monitor. Telephone cable may be damaged. Lightning protection module may be damaged. Telephone cable may have shorted. Lightning protection board in monitor may be damaged. Modem in monitor may be damaged. Possible Solutions Wait a few minutes, and attempt to communicate with monitor again. Connect at the site using the DMI cable, and try to communicate with monitor.
Maintenance and Troubleshooting 5-11 Problem Monitor establishes a connection, but does not respond to any message. Possible Causes User may have entered incorrect identification information. Cabling may be loose. Lightning protection board in monitor may be damaged. Modem in monitor may be faulty. Possible Solutions Verify the identification information (monitor serial number, telephone number, etc.) and correct if necessary. Listen for noise at the site using a field phone.
5-12 ADS Model 4000 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. PC clock may read incorrect time. Reactivate the monitor to enable the clock. Collect the data from the monitor and replace monitor. Problem You receive a Device Time Out message in FieldScan. Possible Cause Depth or velocity board may be faulty.
Maintenance and Troubleshooting 5-13 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. Monitor’s basic code or variable file may be corrupt. Possible Solutions Verify whether the monitor has been activated, and activate if necessary. Check monitor time, and reset clock if necessary. Run diagnostics in FieldScan to verify whether a basic code problem may exist.
5-14 ADS Model 4000 Manual Problem Range from ultrasonic depth subsystem is slightly inconsistent with manually measured range. Possible Causes Electronic or physical offset(s) may be incorrect. Possible Solutions Verify the electronic and physical offsets, and adjust offsets if necessary. Pipe height may be incorrect. Verify the pipe height. Adjust the electronic offset(s). Problem Range from ultrasonic depth subsystem is significantly greater than manually measured range.
Maintenance and Troubleshooting 5-15 Problem Range from the ultrasonic depth subsystem is too short (but not zero). Possible Causes Electronic or physical offset(s) may be incorrect. Pipe height may be incorrect. Ultrasonic depth sensor may be dirty. Pulse Command and Spare 2 Delay parameters may not be adjusted properly. Ultrasonic depth sensor may be faulty. Possible Solutions Verify the electronic and physical offsets. Verify the pipe height. Clean the ultrasonic depth sensor.
5-16 ADS Model 4000 Manual Problem Raw ultrasonic depth data shows depths greater than the pipe diameter. Possible Causes Electronic or physical offsets may be incorrect. Pipe height may be incorrect. Pipe may be surcharged. Ultrasonic depth sensor may be dirty. Ultrasonic depth sensor may be faulty. Possible Solutions Verify the physical and electronic offsets. Verify the pipe height. Clean the ultrasonic depth sensor. Contact a trained ADS technician. Replace the ultrasonic depth sensor.
Maintenance and Troubleshooting Problem Ultrasonic depth readings are erratic. Possible Causes Noise may exist in the sewer pipe. 5-17 Ultrasonic depth sensor may be dirty. Flow may be choppy or foamy. Ultrasonic depth sensor may not be level. Pulse command and spare 2 delay parameters may be set too low for the pipe. Possible Solutions Check the flow conditions. Clean the ultrasonic depth sensor. Check the level of the ultrasonic depth sensor.
5-18 ADS Model 4000 Manual Problem Ultrasonic depth sensor reports two abnormal temperatures. Possible Causes Ultrasonic depth sensor connection to monitor may be loose. Both temperature sensors may be faulty. Ultrasonic depth sensor may be faulty. Possible Solutions Secure ultrasonic depth sensor connection to monitor (if necessary). Replace the ultrasonic depth sensor. Replace the depth board.
Maintenance and Troubleshooting Problem Monitor often provides a velocity reading of 0. Possible Causes Doppler velocity sensor may be dirty or broken. 5-19 Cabling between the velocity board and the velocity sensor may be bad. Velocity board may be faulty. Velocity parameters may require adjustment. Possible Solutions Clean the velocity sensor. Check the velocity parameters. Consider increasing the maximum carrier parameter. Inspect the velocity sensor cables for tightness.
5-20 ADS Model 4000 Manual Problem Velocity data seems erratic. Possible Causes Velocity sensor may be dirty. Velocity sensor may be faulty. Velocity board may be faulty. Possible Solutions Clean the velocity sensor. Check the sensor connections. Check the velocity parameters. Contact a trained ADS technician. Replace the velocity sensor. Replace the velocity board. Problem Velocity readings are abnormally high. Possible Causes Wires on the P2 connector may be loose.
Maintenance and Troubleshooting 5-21 Problem Temperature reading from the pressure depth sensor shows a value of -273° C (-459° F). Possible Causes Cable connecting the pressure sensor to the monitor may be loose or broken. Pressure sensor may be faulty. Depth board is not responding or may be faulty. Possible Solutions Secure pressure sensor connection to monitor (if necessary). Replace the pressure sensor. Replace the depth board. Problem Pressure depth readings are consistently incorrect.
5-22 ADS Model 4000 Manual Problem Pressure depth sensor temperature readings are incorrect, but depth data is accurate. Possible Causes Temperature sensor may be faulty. Possible Solutions Replace the sensor. Depth board may be faulty. Replace the depth board. Problem Pressure depth sensor temperature and depth readings are erratic. Possible Causes Pressure sensor may be faulty. Possible Solutions Examine the pressure sensor and clean if necessary. Depth board may be faulty.
A-1 APPENDIX A Specifications This appendix contains specifications for the ADS Model 4000 flow monitor; associated processor, modem, lightning protection, and sensor boards; sensors; and lightning protection module. ADS 4000/4000WR Flow Monitor The following section contains specifications for the 4000/ 4000 WR flow monitor, processor board, and modem board. All references to the modem, modem board, and lightning protection board or module apply only to the 4000.
A-2 ADS Model 4000 Manual Operating Temperature Power 0° to 60° C (32° to 140° F) Primary Power: 12-volt battery pack (approximate life-span of 365 days at 15-minute sample rate) Memory Backup: 3-volt lithium battery (maintains monitor memory during primary power loss or battery swap) Secondary Backup: Battery-backed RAM (maintains monitor memory during primary power and lithium battery failure) Connectors Inputs and Outputs U.S.
Specifications Temperature Measurement Clock Switches On-board (standard) and off-board (optional) temperature sensors Crystal-controlled, hardware clock/calendar (lithium battery backed) 8-position identification switch 8-position option switch for selecting operating parameters Modem Board Modem Communication 1200 baud Hayes-compatible, non-autoanswer 1200 baud analog Depth Subsystem The following includes specifications for the ultrasonic depth sensor, the pressure depth sensor, and the depth board
A-4 ADS Model 4000 Manual Drift Cable 0.0 inches Standard size: 35.0 feet (10.67 m) long x 0.50 inches (1.27 cm) diameter Pressure Depth Sensor Enclosure Dimensions Range Streamlined molded epoxy 5.0 inches (12.7 cm) long x 1.36 inches (3.45 cm) wide x 1.0 inch (2.54 cm) high 0.0 to 5.0 psi: up to 11.5 feet (3.5 m) 0.0 to 15.0 psi: up to 34.5 feet (10.5 m) 0.0 to 30.0 psi: up to 69.0 feet (21.0 m) Accuracy 0.2% of full scale for these ranges: 0.1-5.0 psi: 0.25-11.5 feet (0.08-3.5 m) 0.1-15.0 psi: 0.
Specifications A-5 Doppler Velocity Subsystem The following contains specifications for the Doppler velocity sensor and Doppler velocity board. Doppler Velocity Sensor Enclosure Dimensions Range Accuracy Molded PVC plastic 2.375 inches (6.03 cm) long x 1.125 inches (2.85 cm) wide x 0.5 inches (1.27 cm) high -5.0 to 20.0 feet per second (-1.5 to 6.1 m/s) 0 to 5.0 feet per second (-1.5 to 1.5 m/s): 0.8% full scale 5.0 to 10.0 feet per second (1.5 to 3.0 m/s): 1.2% full scale 10.0 to 15.
A-6 ADS Model 4000 Manual Lightning Protection The following table contains the specifications for the lightning protection module and board. Lightning Protection Module Housing: Gray PVC (Service Location) Polyswitch: 600-volt 150-milliamps over-current protector Dimensions: 4.13 inches (10.5 cm) high x 3.25 inches (8.3 cm) wide x 1.88 inches (4.
B-1 APPENDIX B Switch and Jumper Settings This appendix contains instructions for changing the ID switch, options switch, and jumper settings. ADS Model 4000 and 4000 WR monitors are preset by the manufacturer with the correct settings; therefore, ADS discourages opening new monitors. However, technicians must adjust these settings on a new board when a board swap occurs or on an existing board when storing the monitor. The following sections provide instructions for changing these settings.
B-2 ADS Model 4000 Manual ID Switch Settings The ID switch, designated as SW2 on the processor board, identifies the monitor serial number. This number must be correct to ensure successful communication operations with the monitor. The switch consists of 8 settings representing the last 2 digits of the 5-digit monitor serial number. The first 4 numbers (settings) represent the last (fifth) digit of the serial number; the last 4 numbers (settings) represent the fourth digit.
Switch and Jumper Settings B-3 Options Switch Settings The options switch, identified by SW3 on the processor board, indicates the specific configuration of the monitor, including parameters such as the method of communication (modem/serial) and baud rate. For the 4000 monitor, switch 4 is the only switch that should be in the closed position on the options switch. All other switches should remain in the open position.
C-1 APPENDIX C External Power This appendix contains instructions for converting the ADS Model 4000 from receiving power via the internal battery pack to receiving power via an external DC power source. This conversion requires a special kit available by special order through Accusonic Technologies (part # 3506-0023). The monitor requires a DC power source with a voltage between 9 and 14 volts at 1 amp of continuous current for proper operation. Install the conversion kit in the following way: 1.
C-2 ADS Model 4000 Manual 7. Install the replacement I/O cable (part # 103197B) for external power into the empty I/O hole. Insert the connector up into the hole through the bottom of the monitor lid, making sure the Oring seats properly against the chassis. Hold the connector in place with one hand to keep the O-ring in place while tightening the connector nut. 8. Connect the new I/O cable to the processor board in the following way: Connect the shortest wire to the processor board at P4 (upper-right).
Switch and Jumper Settings 9. C-3 Securely connect the mating connector (without cable) to the I/O connector on top of the monitor. 10. Strip ½ inch (13 mm) of insulation from the positive and negative wires coming from the external power source. Note: Make sure the external power source is off while stripping, soldering, and connecting the wires. 11.
In-1 Index 1 1/2-band mount, 3-31 3 3/4-band mount, 3-28 4 4000WR, 2-4 A activation, 4-17 B battery backup jumper settings, B-3 battery pack, 2-6 minimum voltage requirements, 5-3 replacement, 5-3 boards, 2-3 depth, 2-5 processor, 2-4 troubleshooting, 5-8 velocity, 2-5 C cables DMI connecting to the monitor and field computer, 4-16 sensor securing in the pipe/manhole, 3-44 securing to the ring/band, 3-43 telephone laying cable between monitor and service locations, 4-2 preparing for connection to li
In-2 ADS Model 4000 Manual depth boards, 2-5 desiccant replacement, 5-5 DMI cable running between monitor and field computer, 4-16 Doppler velocity sensor description and operation, 2-11 installation, 3-15 mounting sensor to the ring, 3-15 special installation, 3-28 1/2-band mount, 3-31 3/4-band mount, 3-28 specifications, A-5 troubleshooting, 5-18 drive-by, 2-4 dryer tube, 3-16 E external DC power capability, 2-6 conversion, C-1 requirements, 2-6 F FCC compliance, 1-4 G ground rod installation, 4-4 I
Index monitor activation, 4-17 boards, 2-3 CDPD, 2-4 communication wireless, 2-4 connecting sensors, 3-46 connectors, 2-6 converting to external power, C-1 description, 2-3 drive-by, 2-4 ID switch settings, B-2 inspection, 5-2 installation, 3-34 mounting to the manhole rim, 3-37 mounting to the manhole wall, 3-34 jumper settings, B-3 maintenance, 5-2 memory backup, 2-5 opening enclosure, 5-3 options switch settings, B-3 power battery pack, 2-6 external source, 2-6 processor board, 2-4 replacing 12-volt batt
In-4 ADS Model 4000 Manual sensors, 2-7 confirmation, 4-17, 5-3 connecting sensors to the monitor, 3-46 Doppler velocity sensor, 2-11 troubleshooting, 5-18 inspection, 5-5 installation, 3-3 Doppler velocity sensor, 3-15, 3-28 pressure depth sensor, 3-16, 328 ring assembly, 3-5 special, 3-20 standard, 3-3 ultrasonic depth sensor, 3-14, 323, 3-26 mounting to the ring, 3-13 pressure depth, 2-10 pressure depth sensor troubleshooting, 5-20 scrubbing, 5-5 securing cables in the pipe/manhole, 3-44 securing cable
Index wiring telephone cable to monitor, 4-7 troubleshooting, 5-7 boards, 5-8 depth board, 5-13, 5-20 Doppler velocity sensor, 5-18 monitor, 5-8 pressure depth sensor, 5-20 ultrasonic depth sensor, 5-13 velocity boards, 5-18 U ultrasonic depth sensor data scrubbing, 2-8 description and operation, 2-7 installation, 3-14 leveling, 3-19 mounting sensor to the band, 3-23 mounting sensor to the ring, 3-14 quadredundancy, 2-8 smart depth, 2-9 special installation standard mount, 3-23 surcharge mount, 3-26 speci