Hawk ORCA User manual

ORCA
Sonar System
Sludge and Settling Level Interface Monitoring
User Manual
Sultan Sonar Manual Rev 1.0
A Higher Level of Performance
www.hawkmeasure.com
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Table of Contents
ORCA Sonar System
2
Contents
Overview 3
Principle of Operation 3
Function 3
Benefits 3
Features 3
System Components 4
Auto Scum Cleaner 4
OSIRT Transducer 4
OSIR Amplifier 4
Dimensions 5
OSIR Remote Amplifier 5
OSIRMELx* - Mounting Pole 5
OSIRSCE - Impact Plate 5
OSIRSCE Impact Plate 6
OSIRT302S4 Transducer 6
OSIRSCA Actuator 6
OSIRT302SH Transducer 6
OSIRSCD Floating Sonar 6
Mounting Bracket 7
Assembly 8
Mounting Bracket / Pole assembly 8
Mounting Bracket / Pole assembly 9
Dimensions & Mounting Connection 10
Impact Plate Mounting Connection 10
Mounting & Hardware Assembly 11
Impact Plate Assembly 11
*A: Important Cabling Steps to Follow 11
Installation Guide 12
Installation Guide 12
Round Tanks – Centre Feedwell 12
Rectangular Tanks – End Feed 12
Ball float 12
Impact Plates 12
Wiring 13
Wiring - Remote Transmitter 13
Wiring Extension 13
Actuator Cable Specication 14
Probus PA - Foundation Fieldbus (PA/FF) 15
DeviceNet 16
Probus DP 17
Setup Procedure 18
Powering The Unit 18
Quickset 19
Typical High & Low Level 19
App Type 20
Interface Table 20
Bed Depth 20
App Type2 21
Interface Table 21
Clarity 21
Output Adjustment 22
Comms Type 23
Comms Type (Menu) 23
Modbus 23
HART 23
Cleaning Menu 24
Cleaning 24
Actuator 24
Setup Procedure 25
Advanced 25
(1) Gain4 default settings 25
(2) Gain-Over-Distance bias 25
Relay Actions 26
Operating Diagnostics 27
Operating State 27
Application Calibration 28
How to set up the unit -
Bed Level + Hindered / settling layer measurement 28
Bed Depth 28
How to set up the unit - Bed Level + Clarity 29
Bed Depth 29
How to set up the unit - Hindered Layer + Clarity 30
Troubleshooting 31
Unit is measuring incorrect Bed or Space 31
PLC indication does not match measurement 31
Some menu options are missing 31
Error Codes 32
Unit Specs & Health Checks 33
ORCA Electric Actuator Troubleshooting 34
Part Numbering 35
Remote Electronics 35
Remote Sonar Transducer 36
Automatic Scum Cleaner 37
Accessories 37
Specications 38
Warranty and Liability 39

ORCA Sonar System
Overview
3
Benets
• Improved efficiency and control of the thickener process
• Fully automated plant systems with reliable interface level monitoring
• Advanced warning of process upset or hydraulic in-balance
• Reduced maintenance with automatic cleaning mechanism warranty (no blades to replace)
• Reduced site operational costs significantly with improved process & extraction control
• Improved health and safety on site (no manual dips required).
Principle of Operation
The ORCA Sonar Series transducer emits a high powered low frequency sonar pulse, which is reflected
from the interface density selected. The reflected signal is processed using specially developed software
algorithms that eliminate unwanted densities and stratified layers, allowing measurement of Bed or RAS
levels. It can be calibrated to measure lighter densities such as the hindered / free settling layer & floc or one
of the outputs could be used for a “Clarity” output, similar to a basic turbidity transmitter measuring solids in
suspension. The unit can include two outputs to measure two different interfaces simultaneously.
Function
The ORCA Series Sonar, sludge blanket and interface controller, consists of a microprocessor based
transmitter, with easy menu driven programming via keypad, PC or 3G modem. The ORCA controller works
together with appropriate sonar transducer and transducer cleaning mechanism.
Features
• Dual independent analogue outputs to track two
different interfaces, or clarity simultaneously, with
the one sonar sensor
• Easy to use pre-set calibrations to track specic
density interfaces, eg: oc / uff layer, Bed
• Industrial scum cleaning mechanisms that do not
require maintenance
• Control room graphics of tanks and interfaces via
GosHawk II
• Wide range of communications: Modbus, HART,
Foundation Fieldbus, DeviceNet, Probus DP and
Probus PA
• 3G remote support capability for calibration,
commissioning or technical back-up
• 3 programmable relays.

System Components
ORCA Sonar System
4
Auto Scum Cleaner
OSIRSCA Pictured with Mounting Pole
OSIR Amplier
OSIRT Transducer

Dimensions
ORCA Sonar System
5
14 mm (0.6”)
74 mm (2.9”)
78 mm (3.1”)
107 mm (4.2”)
111.5 mm (4.4”)
4 mm (0.2”)
50 mm (2”)
131.5 mm (5.2”)
7.5 mm (0.3”)
192.5 mm (7.6”)
141.5 mm (5.6”)
190 mm (7.5”)
182.5 mm (7.2”)
147 mm (5.8”)
167.5 mm (6.6”)
147 mm (5.8”)
30.7 mm (1.2”)
158 mm (6.2”)
108 mm (4.3”)
190 mm (7.5”)
174 mm (6.9”)
192.5 mm (7.6”)
182.5 mm (7.2”)
30.0
20
.
2
33.029.029.033.0
1
6
.
2
OSIR Remote Amplier
OSIRSCE - Impact PlateOSIRMELx* - Mounting Pole
22.0
M25 x 1.5 Ext Thd
mates with Pole Adaptor
HAW_P_ST-SS-TC
27.0
M25 x 1.5 Ext Thd
mates with Cable
Gland Adaptor
HAW_P_ST-SS-EPEC
26.5
*X mm
588mm
605mm
300mm
588mm
605mm
300mm

Dimensions
ORCA Sonar System
6
α°
500mm (19.6”)
252mm (9.9”)
650mm (25.6”)
500mm (19.6”)
252mm (9.9”)
650mm (25.6”)
X
X
605mm (23.8”)
252mm (9.9”)
650mm (25.6”)
42.5
o
42.5
o
X
X = Decent Range
Distance from safety
rail or Bridge may vary
X
130mm (5.1”)
200mm (7.9”)
1" BSP Nipple
130mm (5.1”)
230mm (9.0”)
1" BSP Nipple
OSIRSCE Impact Plate OSIRSCA Actuator OSIRSCD Floating Sonar
OSIRT302S4 Transducer OSIRT302SH Transducer

Dimensions
ORCA Sonar System
7
252.0
5.0
240.0
Rail / Bridge
Mounting U bolts
440.0
330.0
111.5
20.0
25.0
79.5
365.8139.5
650.0
150.0
(A) Base Plate
(A) Base Plate
Mounting Bracket

Assembly
ORCA Sonar System
8
Mounting Bracket / Pole assembly
11
4
12
10
9
8
3
6
13
7
14
15
18
19
20
1
13
2
5
16
17
11
4
12
10
9
8
3
6
13
7
14
15
18
19
20
1
13
2
5
16
17
OSIRSCA pictured

Assembly
ORCA Sonar System
9
Item
No.
Part Number Description Qty
1OSIRxxx ORCA Transmitter 1
2SUNHOOD Stainless Steel Sunhood 1
3SA-SS-AAFB Stainless Steel Front Bracket 1
4SA-SS-AARB Stainless Steel Rear Bracket 1
5LAUS061196E Actuator Actuator (only with OSIRSCA/OSIRSCD) 1
6ST-SS-EPEC Pole to Cable Gland Adaptor with M16 cable gland 1
7ST-APC-26.8-INT SS Internal Pipe Clamp 1
8ST-APC-26.8-EXT SS External Pipe Clamp 1
9ST-SS-EP Mounting Pole 1
10 OSIRTxxxxxxxx Sonar Transducer 1
11 ZPP-M5X20MM M5x20 Phillips Pan Head 8
12 U-BOLT 50mm x 8DIA U-Bolt with nuts and washers 4
13 BOL-M10x15SS M10 x 15mm SS Bolt 4
14 BOL-M10x50SS M10 x 50mm SS Bolt with washer & nyloc nut 1
15 BOL-M10x40SS M10 x 40mm SS Bolt with washer & nyloc nut 2
16 ST-SS-TC Sonar Pole Adaptor 1
17 GLA-M16 M16 Cable gland IP68 with washer 1
18 Washer-M10 M10 washer for M10x40mm & M10x50mm SS Bolt 6
19 Nut-M10 M10 nut for M10x40mm & M10x50mm SS Bolt 5
20 Nut-M8 M8 nyloc nut for 50mm U-bolt 8
Mounting Bracket / Pole assembly
11
4
12
10
9
8
3
6
13
7
14
15
18
19
20
1
13
2
5
16
17

Dimensions & Mounting Connection
ORCA Sonar System
10
Impact Plate Mounting Connection
The top of the Impact Plate has 3 x 7mm bolt holes
which can be secured to an angle iron or equivalent
bracket. There is also a M25 (1.5”) threaded
connection for a mounting pole connection. The
Impact Plate is designed to swing parallel with the
counter weights. The surface sweeper must come
in contact with the legs of the Impact Plate which
swings the bracket lifting the transducer out of the
liquid. When the sweeper has cleared, it will drop
back in and use the counter weights to re-center. The
force of the movement will clear the sensor face of
any build up
Impact Plate Connection Point
Angle iron or equivalent
Swing
Bolt
90mm (3.54”)
50mm (1.97”)
7.00
(0.79”)
×3
M25 x 1.5 INT
THD THRU
ISOVIEW FOR
REFERENCE ONLY