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Orca Manual PDF
Orca Manual PDF
INTRODUCTION CONTENTS
Application References 84
PATENT PENDING
Sonar Level System MANUAL
Rev 1.5, AUG 2010
Sonar Level System MANUAL
Rev 1.5, AUG 2010
SPECIFICATIONS
Sonar Level System MANUAL
Rev 1.5, AUG 2010
TYPICAL APPLICATIONS
Area Functions
Water Treatment Plant
Primary Sedimentation Tank Floc level / sludge blanket level
Sludge Thickener Tank Sludge bed level / clarity suspended solids / floc level
Calcium Hydroxide Reactor Sand/pellet bed level
Sodium Hydroxide Reactor Sand/pellet bed level
Sewage Treatment Plant
Primary Sedimentation Tank Sludge blanket level
Secondary / Final Clarifier RAS blanket level / rag/pinfloc layer / clarity sus-
pended solids
Sludge Thickener Tank Sludge bed level / clarity suspended solids
“DAF” Tank Sludge bed level / floating sludge level
Sequential Batch Reactor (SBR) Settling bed level / RAS blanket level
Industrial (food, paper etc.)
Primary Sedimentation Tank Sludge blanket level
Secondary Clarifier Tank RAS blanket level / clarity suspended solids / rag/pin-
floc layer
Thickener Tank Sludge bed level / clarity suspended solids / floc level
“DAF” Tank Sludge bed level / floating sludge level
Sequential Batch Reactor (SBR) Settling blanket level / RAS bed level
Carbon Column Carbon bed level
Mining/Mineral processing
Clarifier Tank Blanket level / clarity suspended solids / stratified floc
layers
Thickener Tank Sludge bed level / clarity suspended solids / stratified
floc layers
CCD’s Tank Sludge bed level / clarity suspended solids / stratified
floc layers
Settling Ponds Sludge bed level
Sonar Level System MANUAL
Rev 1.5, AUG 2010
Sonar Level System MANUAL
Rev 1.5, AUG 2010
INSTALLATION GUIDE
SUBMERSION:
MININUM 50MM
MAXIMUM 50%
OF TRANSDUCER
Sonar Level System MANUAL
Rev 1.5, AUG 2010
Sonar Level System MANUAL
Rev 1.5, AUG 2010
- Thickener (Gravity)
Controlling bed level, clarity of water
Part no: OSIRT302S4XC6 (3 crystal array 150 kHz)
Part numbers:
1. Primary Sedimentation Tank - Surface Scum Collectors
OSIRT002S4XC6+OSIRDYX+OSIRME-L2+OSIRSC-E
Gravity Thickener
2. Secondary Clarifier - Moving Bridge
OSIRT002S4XC6+OSIRDYX+OSIRME-L2+OSIRSC-A
Primary Clarifier
3. Secondary Clarifier - Fixed Bridge
OSIRT002S4XC6+OSIRDYX+OSIRME-L2+OSIRSC-E
4. Thickener
OSIRT302S4XC6+OSIRDYX+OSIRME-L2+OSIRSC-A
Sonar Level System MANUAL
Rev 1.5, AUG 2010
10
Sonar Level System MANUAL
Rev 1.5, AUG 2010
important where multiple ore types are processed Clarifiers: Controlling bed level and lighter floc
through the plant because of different settling interface
rates and characteristics. However the observers Part no: OSIRT303S4XC6 (3 crystal array
or clearometers floc batch systems fail from time 300kHz)
to time and the tailings thickener can change very
quickly to not settling out the suspended solids. Tailings dam: Controlling bed level
The clarity output from the sonar transmitter can Part no: OSIRT002S4XC6 (single crystal 150
kHz)
alarm this condition to the operator in the control
room. The clarity output can also be used in the
CCD’s: Controlling heavy bed level and clarity
control loop for the floc dosing system as a back
(suspended solids)
up. The use of the sonar BED level transmitter
Part no: OSIRT302S4XC6 (3 crystal array
will allow the tailings thickener to be run automat-
150kHz)
ically in conjunction with the underflow density
transmitter and torque amps from the scraper.
Paste thickeners: Controlling heavy bed level and
clarity (suspended solids)
This will reduce costs in:
Part no: OSIRT302S4XC6 (3 crystal array
1. Floc dosing
150kHz)
2. Return water pumping costs from the tailings
dam
Lamella thickeners: Controlling lighter interface
3. Reduce tailings volume to the tailings dam
from entering plates
4. Increase the quality and volume of water
Part no: OSIRT303S4XC6 (3 crystal array
returned to the concentrator
300kHz)
Cleaning Mechanism:
Hi-Rate thickeners: Controlling heavy bed level
Each sonar transmitter is provided with a scum
and clarity (suspended solids)
cleaning mechanism to suit the mechanical
Part no: OSIRT302S4XC6 (3 crystal array
layout of the thickener and allows the sonar
150kHz)
transmitter to work without operators needing to
clean the sensor.
Part numbers:
1. Tailings thickeners c/- surface scum boom
Some successful examples commonly found
OSIRT302S4XC6+OSIRDYX+OSIRME-
within the Mining industry:
L3+OSIRSC-E
Coal Preparation Plants
2. Tailings thickeners no surface scum boom
Tailings thickener: Controlling heavy bed level
OSIRT302S4XC6+OSIRDYX+OSIRME-
and clarity (suspended solids)
L3+OSIRSC-A
Part no: OSIRT302S4XC6 (3 crystal array
150kHz)
3. Concentrate thickeners
OSIRT702S4XC6+OSIRDYX+OSIRME-
Mining Concentrators
L3+OSIRSC-A
Tailings thickeners: Controlling heavy bed and
clarity (suspended solids)
4. Concentrate thickener c/- surface scum boom
Part no: OSIRT302S4XC6 (3 crystal array
OSIRT702S4XC6+OSIRDYX+OSIRME-
150kHz)
L3+OSIRSC-E
Concentrate thickeners: Controlling heavy bed
level and clarity (suspended solids)
Part no: OSIRT702S4XC6 (7 crystal array
150kHz)
11
power level.
thickener, CCD’s
thickeners, CCD’s
clarifiers, tailings dam
Hawk’s ORCA Sonar Sensors
12
Mounting Bracket and
Clearometer Electro Actuator Cleaner
FEEDWELL
RED Trend shows changes in
CLARIFIED ZONE
clarity over an 8hr period (output2)
ORCA Sonar Transmitter provides 2 outputs Large spikes show major variations
‘Bed Level’ Position (output 1) and in inflow media to the thickener.
CHOOSING A SONAR TRANSDUCER - MINING
‘Clarity’ (output 2)
FREE SETTLING ZONE TME ‘Clarity’ output is a 4-20mA output
proportional to the percentage of suspended
HINDERED ZONE solids between the sonar sensor and the
‘Bed Level’ interface. This output could be
used in a PID Control of automatic floc
COMPACTED ZONE dosing.
Rev 1.5, AUG 2010
MANUAL
Sonar Level System MANUAL
Rev 1.5, AUG 2010
13
Sonar Level System MANUAL
Rev 1.5, AUG 2010
14
Sonar Level System MANUAL
Rev 1.5, AUG 2010
DIMENSIONS
100.75mm (3.9) 127.50mm (5”) 111.50mm (4.3”) 111.50 m (4.3”) R 5mm (0.2”)
59.25mm (2.3”) 41.50mm
19.25
28.75 19.25
(0.7”)
2x 8.50 20 (0.7”) 29.25 (1.6”)
(1.1”) (1.1”) (0.7”)
111.50mm (4.3”)
111.50mm (4.3”)
62mm (2.4”)
150mm (5.9”)
5mm
5mm
(0.2”)
(0.2”)
51mm (2.0”) 51mm (0.2”)
5mm (0.2”) 5mm (0.2”)
19.25 (0.7”)
R 4.25
60mm (2.3”)
211.50mm (8.3”) (0.1”)
4.00
(0.1”)
570mm (22.4”)
OSIRT Transducer
135 mm (5.3”)
75mm (2.9”)
570mm (22.4”)
831mm (32.7”)
o
42.5
330mm (12.9”)
= Decant Range
X
75mm (2.9”)
15
Sonar Level System MANUAL
Rev 1.5, AUG 2010
DIMENSIONS
762.5mm (30”)
570mm (22.4”)
762.5mm (30”)
570mm (22.4”)
X
X
o
42.5
16
Sonar Level System MANUAL
Rev 1.5, AUG 2010
DIMENSIONS
10.5mm (0.4”)
106mm (4.2”) 192mm (7.6”)
192mm (7.6”)
76.5 (3”) 145mm (5.7”)
38mm (1.5”)
106mm (4.2”)
160mm (6.3”)
142mm (5.6”)
160mm (6.3”)
83mm (3.3”)
10mm (0.4”)
61mm (2.4”) 8mm (0.3”)
166mm (6.5”) 151mm (5.9”)
166mm (6.5”)
17
Sonar Level System MANUAL
Rev 1.5, AUG 2010
18
Sonar Level System MANUAL
Rev 1.5, AUG 2010
Water Level
Ultrasonic
Transducer
Mounting
Bracket
Moving
Target
Cleaning
Actuator
Sonar
Transducer
19
Sonar Level System MANUAL
Rev 1.5, AUG 2010
Sliding Pipe
Sonar Transmitter
Pipe Guide
Mounting Bracket
Pipe Guide
Electro-Actuator
Sonar Cleaning
Float with
Sonar Sensor
20
Sonar Level System MANUAL
Rev 1.5, AUG 2010
9
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21
Sonar Level System MANUAL
Rev 1.5, AUG 2010
IMPORTANT
Leave an extra 2 turns of cable where the transducer connects to the actuator to
minimise stress and wear on the cable
22
Sonar Level System MANUAL
Rev 1.5, AUG 2010
9
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23
Sonar Level System MANUAL
Rev 1.5, AUG 2010
24
Sonar Level System MANUAL
Rev 1.5, AUG 2010
This automated scraper system is used for applica- cleaning sequence water sprays can be included
tions where suspended solids need to be mechani- with this option.
cally removed from the transducer face during each Part Number: OSIRSC-ZS
Scraper
UHMW
Scraper Movement
y x
Scraper Actuator
Cleaner Actuator
Sonar Scum
Mounting Bracket
Sonar Transducer
Scraper
UHMW
25
Sonar Level System MANUAL
Rev 1.5, AUG 2010
WIRING DIAGRAM
SHLD
COM
COM
COM
GRN
BRN
BLU
BLK
YEL
NO
NO
NO
NC
NC
NC
TOP
ANALOG2 ANALOG1 TRANSDUCER COMMS DC-IN AC-IN
BOTTOM
- Is - -
A
WHT
RED
BLK
BLU
Test
B
N
L1
TRANSDUCER
26
Sonar Level System MANUAL
Rev 1.5, AUG 2010
WIRING DIAGRAM
Actuator
SONAR 234 REMOTE TRANSMITTER
RELAY 1 RELAY 2 RELAY 3 ACTUATOR
SHLD
COM
COM
COM
GRN
BRN
BLU
BLK
YEL
NO
NO
NO
NC
NC
NC
TOP
ANALOG2 ANALOG1 TRANSDUCER COMMS DC-IN AC-IN
BOTTOM
- Is - -
A
WHT
RED
BLK
BLU
Test
B
N
L1
Junction
Box
TRANSDUCER
27
Sonar Level System MANUAL
Rev 1.5, AUG 2010
WIRING DIAGRAM
Analog Output 1
{ L1
AC Supply
90 - 260Vac Supply
N
User DC Supply Terminal
+
Connection
–
–
+
4-20mA
PLC
+
NOTE1*: RL Max = 750Ω DCS RL Max 750Ω Use Is
if user DC Supply 24V IND 4-20mA shielded
– cable
PLC +
NOTE1* RL Max 750Ω
DCS Use Is
IND 4-20mA shielded
– cable
{ L1
AC Supply
90 - 260Vac
Supply N
NOTE2*: Use
Terminal
Isolated current + shielded Connection
output can be made
PLC
cable –
4-20mA
28
Sonar Level System MANUAL
Rev 1.5, AUG 2010
WIRING DIAGRAM
Analog Output 1
DC Supply
User + +DC
DC Supply – GND Terminal
+ Connection
NOTE2* –
PLC
4-20mA
DCS RL Max 400Ω +
IND
4-20mA Is
– Use shielded cable
DC Supply
User + +DC
DC Supply – GND
Terminal
+ Connection
PLC –
4-20mA
NOTE1*
DCS RL Max 750Ω + ANALOG 2
IND
4-20mA Use
– shielded cable
User + +DC
DC Supply – GND
Terminal
+ Connection
PLC –
4-20mA
NOTE1*
DCS RL Max 750Ω Use + ANALOG 2
IND shielded
4-20mA
– cable
29
Sonar Level System MANUAL
Rev 1.5, AUG 2010
WIRING DIAGRAM
Analog Output 2
DC Supply
User + +DC
DC Supply – GND
NOTE: Terminal
Internal SMART + Connection
card configured
for 3, 4 wire. PLC –
4-20mA
NOTE:
DCS RL Max 400Ω + ANALOG 2
IND
RL Max = 750Ω 4-20mA Use
if user DC Supply 24V – shielded cable
DC Supply
User + +DC
DC Supply – GND
NOTE: Terminal
Internal SMART + Connection
card configured
for 3, 4 wire. PLC –
4-20mA
NOTE:
DCS RL Max 400Ω Use + ANALOG 2
IND shielded
RL Max = 750Ω 4-20mA
if user DC Supply 24V – cable
30
Sonar Level System MANUAL
Rev 1.5, AUG 2010
DEVICENET
DEVICENET
MASTER
EXT
TERM
5. V+
4. CAN_H
3. SHEILD
2. CAN_L
1. V-
31
Sonar Level System MANUAL
Rev 1.5, AUG 2010
DEVICENET
Output Data
Profibus/Devicenet now transmit 18 bytes/9 words, description of the words is as follows (For firm-
ware version 5.54 and above)
32
Sonar Level System MANUAL
Rev 1.5, AUG 2010
PROFIBUS
PROFIBUS
MASTER
EXT
TERM
5. B IN
4. A IN
3. SHEILD
2. B OUT
1. A OUT
33
Sonar Level System MANUAL
Rev 1.5, AUG 2010
Output Data
Profibus/Devicenet now transmit 18 bytes/9 words, description of the words is as follows (For firm-
ware version 5.54 and above)
34
Sonar Level System MANUAL
Rev 1.5, AUG 2010
ENTERING DATA
All software adjustments are achieved via the four PUSH BUTTONS on the front panel.
In Run Mode
(A) Press and hold - interupts normal operations and al-
lows access to software menu headings.
In Calibrate Mode
(B) Momentary press - saves selected value.
Press and hold - scrolls through set-up menus and
parameters.
In Run Mode
(A) Displays operating diagnostics on display LCD.
In Calibrate Mode
(B) Increases display value.
(C) Scrolls through software parameters.
In Run Mode
(A) Displays operating diagnostics on display LCD.
In Calibrate Mode
(B) Decreases display value.
In Calibrate Mode
(A) Press when all calibrations are complete.
(B) Stores all parameters, returns the ORCA Sonar to
normal operating run mode.
35
Sonar Level System MANUAL
Rev 1.5, AUG 2010
GAIN
TX SETUP GAIN STEP
DIST STEP
THRESHOLD
BLANKING
EMPT DIST
TEMP TRIM
DIST TRIM
VELOCITY
E WIDTH 1
GAIN 2
THRESHOLD 2
E WIDTH 2
FLOCK
FILL DAMP
OUTPUT AD EMPTY DAMP
4mA ADJ
20mA ADJ
ANALOG
20mA ADJ 2
20mA ADJ 2
SIMULATE
COMMUNICATIONS TYPE - MODPUS
OMM TYPE
RLY MOD 1
RLY MOD 2
RLY MOD 3
CLEANING
36
Sonar Level System MANUAL
Rev 1.5, AUG 2010
APP Type 2
OFF
BED
RAS
FLOC
CLARITY
FAIL SAFE
20mA, 4mA, Lst Knw, 20.20mA, 3.80A, 3.50mA
FAIL TIME
3.0min - 0.0min
DISP MODE
Level
% Level
SPACE
I: SEN ADD
1 to 25
OFFSET
0.0cm
500.0cm
Continued next page
37
Sonar Level System MANUAL
Rev 1.5, AUG 2010
Lo Level
0% or 4ma position
0 - 60 metres
Hi Level
100% or 20ma position
0 - 60 metres
Fill Rate
0.1m to >20m per hour fill rate
Empty Rate
0.1m to >20m per hour pump out rate
38
Sonar Level System MANUAL
Rev 1.5, AUG 2010
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39
Sonar Level System MANUAL
Rev 1.5, AUG 2010
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40
Sonar Level System MANUAL
Rev 1.5, AUG 2010
Distance Trim:
Allows for fine calibration of the measuring distance.
Only when required. Factory calibrated.
Velocity:
Allows for a change in the speed of sound.
Factory calibrated consult your distributor or factory.
E Width 1:
Factory calibrated consult your distributor or factory.
Application 2 #
(only used with Dual Analogue Orca Transmitter)
Gain 2:
Sensitivity range of sonar transducer factory set for
applications.
Range: 0.0% to 95.0%
Threshold 2:
Factory set for selected applications the size of the signal
in volts, that the instrument will accept as validated.
Check with your distributor or factory before changing.
Range: 0.00v to 2.49v
E Width 2:
Factory calibrated.
Consult your distributor or factory.
FLOC MARG
4mA Adjust:
Trim 4mA Output
20mA Adjust:
Trim 20mA Output
Analog
4ma - 20ma
Invert Output
20ma - 4ma
Simulate:
Drive the output and display using up/down push buttons.
4mA Adjust 2
20mA Adj 2
Comm Type:
Modbus (factory default)
Options: Hart, Profibus.
Continued next page
42
Sonar Level System MANUAL
Rev 1.5, AUG 2010
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Sonar Level System MANUAL
Rev 1.5, AUG 2010
ENTERING DATA
SOFTWARE TREE
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44
Sonar Level System MANUAL
Rev 1.5, AUG 2010
ENTERING DATA
DIAGNOSTIC DISPLAYS
The diagnostic displays appear on the top line of the display, after pressing the
push button when the sonar transmitter is in the operations mode.
The diagnostics provide the user with valuable performance feedback on how the
sonar is performing, whilst in operation mode.
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