ADS Environmental Services QR 775012 A4 User Manual

IETG Intrinsically-Safe
FlowHawk
Installation, Operation, and
Maintenance Manual
Cross Green Industrial Estate
IETG Ltd.
Cross Green Way
Leeds LS9 0SE England
+44 (0)8450 179 333
www.ietg.co.uk
ii IETG FlowHawk Manual
2012 ADS
LLC. All rights reserved.
ADS , Profile, IntelliServe, FlowHawk , and Qstart are either trademarks or registered trademarks of ADS LLC.
Enfora is a trademark of Enfora, Incorporated. Microsoft and Windows are registered trademarks of Microsoft
Corporation.
Scotchkote is a trademark of 3M. Teflon is a registered trademark of E.I. du Pont de Nemours and
Company.
Telog is a registered trademark of Telog Instruments.
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. ADS LLC reserves the right to make any changes or modifications to the content of this document, without notice, to reflect the latest changes to the equipment. No part of this document may be reproduced in any form without the written consent of ADS LLC.
Table of Contents iii
Table of Contents
Chapter 1 Introduction……… ................... 1-1
Intrinsic Safety ............................................................... 1-2
FlowHawk System Certification .............................. 1-2
Installation and IS Considerations ........................... 1-5
Special Conditions for Safe Use .............................. 1-5
Maintenance Restrictions ............................................... 1-7
Warnings, Certifications, GSM/GPRS Compliance,
and Conformity ................................................ 1-9
Changes or Modifications ....................................... 1-9
Control Drawing .................................................... 1-10
European ATEX Hazardous Area Compliance ..... 1-12
IECEx (International Electrotechnical
Commission Explosive) Hazardous Area
Compliance .................................................... 1-20
Declaration of Conformity .................................... 1-23
Installation and Configuration ...................................... 1-25
Product Warranty ......................................................... 1-27
New Product Warranty .......................................... 1-27
Out-of-Warranty Product Repairs ......................... 1-28
Trouble s hooting Fee ............................................. 1-28
Shipping ................................................................ 1-28
European Service Centre ....................................... 1-29
Chapter 2 System Overview ..................... 2-1
FlowHawk Flow Monitor ............................................... 2-4
Communications ...................................................... 2-4
Processor Board ...................................................... 2-8
Connector Ports ....................................................... 2-9
Power .................................................................... 2-11
Sensors ......................................................................... 2-14
Peak Combo Sensor .............................................. 2-14
Ultrasonic Depth Sensor ....................................... 2-17
Surface Combo Sensor .......................................... 2-19
Slimline Peak Combo Sensor ................................ 2-23
iv IETG FlowHawk Manual
Chapter 3 Sensor Installation and
Connection………………… ................... 3-1
Investigating Site Characteristics ................................... 3-4
Flow Hydraulics ...................................................... 3-4
Pipe and Manhole Characteristics ........................... 3-5
Installing the Sensors in the Pipe .................................... 3-7
Standard Installation................................................ 3-7
Special Installations .............................................. 3-33
Securing the Sensor Cables in the Pipe and Manhole .. 3-53
Connecting the Sens ors to the Monitor ........................ 3-56
Securing the Dryer Tube to the Monitor ............... 3-58
Chapter 4 Communication… .................... 4-1
GSM-Based Wireless Communication ........................... 4-3
Installing the GSM Module ............................................ 4-5
Gathering Pa rts and Supplies .................................. 4-6
Installing the Wireless Antenna ............................... 4-8
Installing the SIM Card ......................................... 4-13
Installing the GSM Module ................................... 4-17
Installing an EM U ........................................................ 4-20
Installing the Communication Cable ..................... 4-20
Installing the EMU ................................................ 4-26
Installing an EM UX ..................................................... 4-40
Installing the Communication Cable ..................... 4-40
Installing the EMUX ............................................. 4-41
Connecting the Co mmunicati on Cable to the
Monitor .......................................................... 4-46
Installing a Wireless Antenna ................................ 4-47
Connecting the RTU to the EMUX ....................... 4-49
Providing E xternal Power to the EMUX ............... 4-49
Connecting to the Monitor in the Field (Direct
Connection) .................................................... 4-52
Table of Contents v
Chapter 5 External Power…. .................... 5-1
Installation ...................................................................... 5-2
DC Power Requirements and Consumption ............ 5-3
Installing and Wiring the IETG-Supplied Power
Supply to the EMU or EMUX ......................... 5-4
Chapter 6 Configuration and Activation .. 6-1
Hardware and Software Compatibility .................... 6-2
Configuring the Monitor Location ................................. 6-3
Starting the Profile Software ................................... 6-4
Creating a Monitor Location ................................... 6-5
Adding a Second Monitoring Point ....................... 6-10
Creating an Installation Table ............................... 6-11
Selecting and Editing Devices ............................... 6-17
Setting the Communication Parameters ........................ 6-58
Activating the Monitor ................................................. 6-63
Setting Up the RTU to Retrieve the Current Data
through Modbus ............................................. 6-67
Designating the Data for Retrieval ........................ 6-67
Verifying the Mo dbus Output Data ....................... 6-67
Running Sensor Diagnostics ......................................... 6-69
Ultrasonic Depth Diagnostics ................................ 6-71
Pressure Depth Diagnostics ................................... 6-74
Velocity Diagnostics ............................................. 6-76
Smart Depth Diagnostics ....................................... 6-79
Temperature Diagnostics....................................... 6-82
Activating the Monitor .......................................... 6-84
Collecting Data from the Monitor ................................ 6-86
Upgrading the Monitor Firmware ................................. 6-95
Viewing Diagnostic a nd Data Logs .............................. 6-98
Chapter 7 Monitor Installation .................. 7-1
Mounting the Monitor on Manhole Rung ....................... 7-2
Mounting the Monitor Handle to the Manhole Wall ...... 7-3
vi IETG FlowHawk Manual
Chapter 8 Maintenance and
Troubleshooting…………. ..................... 8-1
Maintaining the System Co mponents ............................. 8-2
Gathering Replacement Parts and Supplies ............. 8-2
Inspecting the Monitor ............................................ 8-3
Inspecting, Cl eaning, and Handling the Senso rs ... 8-17 Replacing the SIM Card and Desiccant in the
GSM Module ................................................. 8-21
Replacing EMU Components ................................ 8-25
Replacing the SIM Card in the EMUX ................. 8-30
Replacing the Regulator and Fuses in the
Monitor .......................................................... 8-31
Troubleshooting ........................................................... 8-38
General Monitor Problems .................................... 8-39
Communication Problems ..................................... 8-43
Ultrasonic Depth Subsystem ................................. 8-47
Upward Depth Subsystem ..................................... 8-52
Peak Velocity Subsystem ...................................... 8-55
Surface Velocity Subsystem .................................. 8-58
Pressure Depth Subsystem .................................... 8-60
Temperature Subsystem ........................................ 8-61
Appendix A Specifications….. .................. A-1
FlowHawk Flow Monitor ....................................... A-1
Intrinsically-Safe Sensors ....................................... A-4
Direct Connect Cable ........................................... A-11
Wireless GSM Module ......................................... A-12
External Modem Unit ........................................... A-13
External Modem Unit/Multiplexer ....................... A-14
Power Supply ....................................................... A-15
Appendix B Part Numbers…… ................. B-1
Appendix C Monitor Activity Codes ......... C-1
Table of Contents vii
Appendix D Modbus/EMUX Configuration
and Diagnostics…………. ..................... D-1
Setting up PC-to-EMU Communication ................. D-2
Running the Onboar d Diagnostics .......................... D-3
Modbus Data Registers .......................................... D-7
EMUX LED Window .......................................... D-10
Appendix E System Configuration and
Setup to Support the Telog Ru-33 ....... E-1
Configuring the Monitor to Support the Ru-33 ....... E-2
Connecting the Monitor to the Ru-33 ...................... E-2
C H A P T E R 1
Introduction
The IETG Intrinsically-Safe FlowHawkflow monitor (powered by
®
) measures open channel flow in sanitary sewers, storm
ADS
sewers, combined sewers, and other environments to assist municipalities and other industry in address ing the following issues:
Planning sewer systems (sizing and rehabilitation) Reducing infiltration and inflow (I/I) Monitoring combined sewer overflows (CSOs) Detecting and monitoring surcharges
1-1
Managing inter-agency billing Monitoring sewage handling facilities (wastewater treatment
plants and pump stations)
The battery- or externally-powered FlowHawk monitor provides exceptional accuracy and reliability in measuring open-channel flow depth and velocity to determine flow rate (quantity) in pipes. This flow data is the essential element required to successfully perform investigative, analytical, and reporting activities.
This manual offers detailed instructions on installing, maintaining, and troubleshooting the FlowHawk flow monitor, sensors, and communication hardware.
1-2 IETG FlowHawk Manual

Intrinsic Safety

Intrinsic safety is an electronic hardware protection concept that ensures there a re no conditions under which the equipment can operate that could cause a release of energy sufficient to ignite a hazardous gas or dust mixture. Devices that meet the low power, current-limited design criteria are deemed Intrinsically Safe (IS). Special design, testing, quality, and inspection rules apply to manufacturers and users of IS equipment due to the critical nature of their deplo yment in hazardous areas. Areas where hazardous conditions can be expected to be present on a constant basis are classified (rated) as Class I, Division 1 or Zone 0.
The FlowHawk flow monitor (Models 8000-FHK and 8000-FHK­60C) is certified to ATEX (Atmosphere Explosibles) standards in Europe and is certified for use in all classified (hazardous) sanitary sewer and industrial hazardous areas. Many res t-of world countries accept ATEX certification in lieu of their country-specific requirements. It is the customer’s responsibil ity to ensure that
the certification(s) provided for the IETG equipment meets the applicable regulatory requirements.
Note: FlowHawk models include only the 8000-FHK and 8000-FHK-60C.
FlowHawk System Certification
The FlowHawk unit and associated telemetry equipment are certified for use only with approved sensors, communication cables, and telemetry equipment. Connection of any non-approved devices could result in unsafe operation and will immediately void the warranty and IS certification.
Note: Connecting the Te l og® Ru-33 to the IETG FlowHawk is an approved application and, therefore, will not void the Fl owHawk warranty. However, because the
Introduction 1-3
Telog unit is not IS certified, the installation will not be considered intrinsically safe if the Ru-33 is installed in the manhole with the monitor.
Sensors
The FlowHawk monitor supports several approved IS sensors that vary in measurement methodology, red undancy, and other features. The monitor is approved for accommodating up to two of the same or different types of IS sensors. Following are the approved IS sensors:
Peak Combo Sensor Performs upward ultrasonic depth,
pressure depth, and peak velocity measurement and mounts at or near the bottom (or invert) of the pipe under the flow surface (p/n 8K-CS4-05-35, 8K-CS4-15-35, or 8K-CS4-30-1H).
Surface Combo Sensor Performs downward ultrasonic
depth, surcharge pressure depth, surcharge peak velocity, and surface velocity measurement and mounts at the top (or soffit/crown) of the pipe above the flow (p/n 8K-CS5-V2-05-30 or 8K-CS5-V2-15-30).
Ultrasonic Depth Sen sor (ultrasonic and optional
pressure depth only) Performs downward ultrasonic depth
and pressure depth (optional) measurement and mounts at the top (or soffit/crown) of the pipe above the flow (p/n 8K-CS3­V0-00-30, 8K-CS3-V0-05-30, or 8K-CS3-V0-15-30).
Slimline Peak Combo Sensor Performs upward ultrasonic
depth and peak velocity measurement and mounts at or near the bottom of the pipe under the flow surface (p/n 8K-CS4-35).
Extension cables are available for these sensors in lengths up to 91 meters (300 ft).
Note: Detailed descriptions and specifications for the sensors are available in Chapter 2, System Overview, and Appendix A, Specifications.
1-4 IETG FlowHawk Manual
Power
The FlowHawk flow monitor can be powered by an internal 12-volt IS battery pack (p/n 8000-0043) or an external DC power source through an external modem unit (EMU, p/n 3800-0148) or EMU/multiplexer (EMUX, p/n 106226E)).
Telemetry
Wireless communication is available for the FlowHawk monitor via connection to an IS quad-band GSM/GPRS module (p/n 8000-
0052), an EMU (p/n 3800-0148), or an EMUX (p/n 106226E). Connecting the FlowHawk to the Telog RTU (Model Ru-33) also supports wirel ess communication via the Telog “passthrough” mode.
The GSM module is certified for installation and operation in the hazardous area and receives power from the FlowHawk. The antenna may be located either inside or outside the manhole; however, IETG recommends installing the antenna outside the manhole to maximize signal strength. Several antenna models are available to mitigate signal strength is s ues.
The EMU is mounted outside the hazardous area and receives power from an external DC power source supplied by the user. It is delivered with the antenna installed on the inside of the EMU enclosure. However, the antenna may require installation outside the EMU if the material and/or construction of the enclosure and/or housing in which the EMU enclosure is installed imped es the signal from the wireless provider.
The EMUX is mounted outside the hazardous area and receives power from an external DC power source supplied by the user. It is delivered without an antenna; therefore, an antenna must be attached to the EMUX. However, it may r e quire installation outside the enclosure in which the EMUX is installed if the material and construction of the enclosure impedes the signal from the wireless provider.
The Telog Ru-33 is mounted next to the FlowHawk in the hazardous area and connected to the monitor using the Triton-Telog Comm Cable (p/n 8000-0054-01). However, please note that,
because the Telog unit does not possess IS certification, the installation will not be considered intrinsically safe if the Telog unit is installed in the manhole with the monitor.
Installati on a nd IS Considerations
When installing the FlowHawk flow monitor, carefully follow any local regulations for the installation of IS equipment. For example, many clients only allow the use of special hazardous area tools (flashlights, radios, etc.) in manholes. Some clients will not allow the use of an electric drill, either battery-powered or AC-powered, in a manhole. Und er these conditions, use air (pneumatic) tools. When in doubt as to the applicable regulations, check with the client or the client’s designated safety representative.
Special Conditi ons f or Safe Use
During the ATEX /IECEx approval process, certain conditions are set forth that must be observed when using the certified equipment. These “Special Conditions for Safe Use” can be found in the body of each ATEX Certification (referenced in this manual), as well as on a page attached to the Declaration of Conformity. A summar y of these Safe Use Instructions is as follows:
Introduction 1-5
The Models 8000-FHK and 8000-FHK-60C shall use only the
12-volt IS Battery Pack (p/n 8000-0043) for internal power.
The Models 8000-FHK and 8000-FHK-60C shall be used in
the hazardous area only when fully assembled. Do not perform any maintenance of internal parts, replacement o f battery packs, or replacement of fuses unless the unit is located in a safe area.
Only approved sensors shall be connected to the Models 8000-
FHK and 8000-FHK-60C: sensor types 8K-CS1, 8K-CS3, 8K­CS4, and 8K-CS5.
1-6 IETG FlowHawk Manual
Note: The 8K-CS1 is no longer available; however, IETG
will continue to provide support for this sensor.
As aluminum is used at the acce ssib le surface of this unit, in the
event of rare incidents, ignition sources due to impact and friction sparks may occur. This shall be considered when it is being installed, particularly in locations that require equipment with a Group II Ga level of protection.
The only communication devices that may be connected to the
COMM conne ctor on the FlowHawk are the GSM Wireless Module (p/n 8000-0052), the EMU/EMUX Communication Cable (p/n 106227B), and the Direct Connect Interface (p/n 8000-0054)
Note: The Triton-Telog Comm Cable (p/n 8000-0054-01) also may be connected to the COMM connector on the FlowHawk to provide communication between the Telog Ru-33 and the monitor. However, since the Ru-33 is not certified for IS operation, an installation involving a connection between these units will not be considered intrinsically safe, unless the Telog unit is installed outside the hazardous area.
Never rub any plastic parts (specifically, the ABS plastic
connector potting boots and the Peak Combo Sensor and Slimline Peak Combo Sensor housings) with a dry cloth. This could result in the buildup of dangerous s t atic charges.
Parts of the enclosure may be non-conducting and may generate
an ignition-capable level of electrostatic charge under certain extreme conditions. Therefore, do not install this equipment in a location where it may be subject to external conditions (such as high-pressure steam or dust) that may cause a buildup of electrostatic charge on non-conducting surfaces.

Maintenance Restrictions

As mentioned earlier, all FlowHawk flow monitors are manufactured to meet IS standards. The monitor’s IS certification
can be voided instantly if proper maintenance and service procedures are not followed. IETG must restrict certain
maintenance tasks to IETG IS-certified technicians. IETG-certified technicians carefully inspect and document their
repairs of IS monitors. This inspection and documentation process provides legal protection should the monitor's performance or safety be in question.
If you experience trouble with this equipment, please refer to this manual for troub l eshooting guidelines. The following maintenance procedures may be performed in the field, but they must be performed as described in this manual:
Install and swap monitor Install and swap sensors Install and swap battery pack
Introduction 1-7
Swap fuses in power regulator in monitor Install and swap GSM wireless module Install and swap EMU and modem in EMU Install and swap EMUX Install and swap SIM cards (EMU, EMUX, and GSM module) Replace pressure depth sensor dryer tube and desiccant beads Replace desiccant pack (GSM module) Clean sensors Confirm sensors
Note: Please note that, in all applications, only IETG IS­certified Service Technicians are authorized to perform component-level service on the FlowHawk.
1-8 IETG FlowHawk Manual
If you have any questions about the procedures, warranty information, or the level of service you are allowed to perform on a monitor, contact IETG through the contact information listed at the end of this chapter.
Introduction 1-9

Warnings, Certifications, GSM/GPRS Compliance, and Conformi ty

Manhole and sewer system work involves confined space entry and is inherently dangerous. Therefore, installers and technicians should comply with all local and governmental regulations concerning confined space entry.
In addition, personnel installing and maintaining this equipment should follow all gui delines presented in this manua l concerning monitor installation and maintenance. Failure to strictly adhere to these guidelines can result in personal injury and/or damage to the monitor.
Note: The certifications included in this chapter identify the FlowHawk, IS GSM Module, combo sensors, and Direct Connect Interface as products of ADS. The FlowHawk and its communication modules and sensors are designed specifically for IETG by ADS.
Changes or Modifications
Changes or modifications to the FlowHawk flow monitor not expressly approved by the party responsible for compliance will void the IS certification.
Personnel performing installation of the FlowHawk flow monitor should carefully follow the guidelines contained in this manual when installing and maintaini ng the monitor. Failure to strictly adhere to these guidelines can result in personal injury and can cause damage to the monitor, which would invalidate its warranty.
The FlowHawk flow monitor is designed to be installed in combined and sanitary sewer lines and manholes. This installation work is inherently dangerous. All applicable safety guidelines
1-10 IETG FlowHawk Manual
should be followed and carried out by at least two fully trained and qualified persons.
Control Drawing
This drawing depicts the interconnections allowed for the FlowHawk. It is intended for use by inspection professionals for audit certificate compliance; however, it is a good tool to understand the FlowHawk flow monitoring system structure. This drawing is divided in two sections with a match point indicated.
Control Drawing – Part 1 (right side from part 1 continues on part 2)
Introduction 1-11
Control Drawing – Part 2 (left side on 2 cont i nues from drawing 1)
Note: These are excerpts from an agency controlled document for ill ustration purposes only. Changes to the base controlled document require the approval of the certification body. For a full-size PDF copy of this drawing, please contact IETG and request drawing number 8000BK0009-CERT.
Note: The Telog R u-33 can be connected to the COMM port on the FlowHawk monitor using the Telog-Triton Comm Cable (p/n 8000-0054-01). However, this configuration has not been included on thi s drawing because the Telog unit is not certified for IS opera tion. Therefore, an installation involving this configuration will be considered intrinsically safe, unless the Ru-33 is installed outside the hazardous area.
1-12 IETG FlowHawk Manual
GSM/GPRS Modem Information
Wireless telemetry is provided via attachment of the GSM Module to the FlowHawk monitor. The GSM Module contains a third­party, R&TTE-CE-certified, commercial GSM/GPRS modem. Integration of the modem into the GSM Module was performed in accordance with guidelines set forth in the third party’s Integration Manual in order to maintain the FCC approval.
Use of the modem, as installed in the GSM Module, is considered a Mobile wireless application, meaning the module is capable of being moved between locations. However, it is NOT considered a Portable device, which indicates it is used in close proximity to a user’s body (like a handset). Users of the GSM Module must maintain a distance from the antenna of at least 200 mm (7.87 in) when the unit is operational.
Users cannot provide their own antennas due to strict limitations on antenna gains and other variables that may produce a dangerous RF condition and violate IS and European safety requirements. Only antennas provided by IETG for use with the GSM Module may be used.
Compliance with applicable European Directives is demonstrated through the following marking:
CE 0889
This marking indicates that the Enfora GSM0308 OEM module is entirely encapsulated to meet IS requirements. The o nly user­accessible part of the modem is the SIM card carrier.
European ATEX Hazardous Area Compliance
The following instructions apply to equipment covered by certificates numbered Sira 09ATEX2027X (FlowHawk, Direct Connect Interface, and Combo Sensors CSX Series), 09ATEX2053X (IS GSM modem), and 03ATEX2482 (IS Comm Interface). Reference European ATEX Directive 94/9/EC, Anne x II, 1.0.6:
Introduction 1-13
The equipment may be used with flammable gases and vapors
with apparatus groups IIA and IIB and with temperature classes T3 (152
o
C), T4, T5, and T6.
The equipment is only certified for use in ambient temperatures
in the range of -20
o
C to +60oC and should not be used outside
this range.
The certificate number has an ‘X’ suffix, which indicates that
special conditions apply to installation and use. Those installing or inspecting this equipment must have access to the contents of the certificate.
Installation shall be carried out in accordance with the
applicable code of practice by suitably-trained personnel.
Repair of this equipment shall be carried out in accordance
with the applicable code of practice.
If the equipment is likely to come into contact with aggressive
substances, it is the responsibility of the user to take suitable precautions that prevent it from being adversely affected, thus ensuring that the type of protection is not compromised.
Aggressive substances such as acidic liquids or gases that
may attack metals or solvents that may affect polymeric materials
Suitable precautions such as regular checks as part of
routine inspections or establishing from the material’s data sheet that it is resistant to specific chemicals
There are no special inspections or maintenance conditions
other than a periodic check.
FlowHawk monitors and GSM modem modules delivered to
Europe must bear the following label to substantiate conformance to ATEX standards as certified through Sira Certification Services:
1-14 IETG FlowHawk Manual
Sira FlowHawk Certification Label
Sira Combo Sensor CSX Series Certif i cation Label
Introduction 1-15
Sira Direct Connect Interf ace Certification Label
Sira GSM Certifi cation Label
Sira Communicat i on I nterface (EMU/EMUX) Certification Label
EC Type Examination Certificates Sira 09ATEX2027X, Sir a 09ATEX2053X, and Sira 03ATEX2482 can also be used to substantiate conformance to applicable EU laws for IS equipment.
1-16 IETG FlowHawk Manual
The following pages provide a copy of the first page of each certificate.
Note: These copies were current at the time of publication of this manual. To access the latest version and entire content of each certificate, please contact IETG Ltd.
Introduction 1-17
First page of the FlowHawk ATEX Certificate
1-18 IETG FlowHawk Manual
First page of the GSM Module ATEX Certificate
Introduction 1-19
First page of the Communications Interface Unit (from the EMU/EMUX)
ATEX Certificate
1-20 IETG FlowHawk Manual
IECEx (International Electrotechnical Commission Explos ive) Hazardous Area Compliance
The FlowHawk i s covered by certificates IECEx SIR 09.0020X (FlowHawk) and IECEx SIR 09.0021X (IS GSM modem). Reference IECEx standards IEC 60079-0 : 2004; IEC 60079-11 : 2006; and IEC 60079-26 : 2006. These IECEx certificates can also be used to substantiate conformance to applicable international standards for IS equipment. The following pages provide a copy of the first page of each certificate.
Note: The copies were current at the time of publication of this manual. To access the latest version and entire content of each certificate, please contact IETG.
Introduction 1-21
First page of the FlowHawk IECEx Certific at e of Conformity
1-22 IETG FlowHawk Manual
First page of the GSM Module IECEx Certifi cate of Conformity
Declaration of Conf ormity
For European (EC member country) applications, a Declaration of Conformity (DoC) is required to be kept on file at the facility responsible for repair and maintenance of this equipment. A copy of the relevant DoC is also shipp e d with each prod uct. If you have any questions about the Declaration of Conformity, contact IETG Ltd at the addresses given at the end of this chapter.
Introduction 1-23
Sample FlowHawk Declaration of Conformity – Page 1
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