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Sultan Sonar Manual Rev 1.0

A Higher Level of Performance

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Sultan

Acoustic Wave Series

Level, Flow, Positioning, Collision Protection

Manual

Summary of Contents for Acoustic Wave Series

Page 1: ...Sultan Sonar Manual Rev 1 0 A Higher Level of Performance www hawkmeasure com For more information please visit Sultan Acoustic Wave Series Level Flow Positioning Collision Protection Manual ...

Page 2: ...er 21 Diagnostics Software Overview 22 Quickset Flow Chart 23 Quickset Parameters 24 Quickset 24 Application Types 25 Display Mode 27 Average Level 28 Differential Level 29 Advanced Setup Menu 30 Advanced Parameters 31 Output Adjustment Setup Menu 32 Output Adjustment Parameters 33 Relay Switch Actions 34 Relay 1 5 34 Comm Types Setup Menu 35 Modbus 36 DeviceNet Setup Parameters Wiring 38 Profibus...

Page 3: ...4 RELAY 5 SULTAN 234 RELAY 3 Remote systems consist of an amplifier and separate transducer of varying size shape depending on frequency 10kHz Remote Transducer Flange Cone 40kHz Remote Transducer 50kHz SMART Unit 30kHz Integral Unit SMART Integral units combine both the amplifier and transducer functions in a single housing ...

Page 4: ...until the parts are tightly fastened COMPLETE ASSEMBLY 1 Remove red cap including cardboard 3 Screw the transducer tightly down onto the flange and cone assembly Note Direction of flange smallest ring this way up appearance above flange may differ for integral and smart units User mountings should only connect to the larger lower isolated mounting flange No other part of the sensor assembly should...

Page 5: ...d the white wire to A The black wire can be connected to the DC or GND terminal next to A Tighten cable entry gland s and cover to ensure sealing is effective Wiring The Unit Sultan Acoustic Wave Series Sourcing 4 20mA from Sultan Sinking 4 20mA from user device OR A 1 L N B RED BLACK BLUE WHITE Test In Is TRANSDUCER DC In AC In 4 20mA COMMS RELAY 1 NC COM NO RELAY 2 NC COM NO RELAY 3 NC COM NO RE...

Page 6: ...onnect a wire push down on the button above the terminal with a small flat head screwdriver and place the wire in the terminal Release the pressure on the button to close the terminal and then pull on the wire to check that it is secure If you are connecting HawkLink communications connect the blue wire to B and the white wire to A The black wire should be connected to the Shld terminal Tighten ca...

Page 7: ...wires into the open terminals and tighten until firm The transducer terminals are labeled by colour on the back panel If you are connecting HawkLink communications connect the blue wire to B and the white wire to A The black wire can be connected to the DC or GND terminal next to A A 1 L N B RED BLACK BLUE WHITE Test In Is TRANSDUCER DC In AC In 4 20mA COMMS RELAY 1 NC COM NO RELAY 2 NC COM NO REL...

Page 8: ...f you are connecting HawkLink communications connect the blue wire to B and the white wire to A The black wire can be connected to the DC terminal next to B Tighten cable entry gland s and cover to ensure sealing is effective IP68 Sealed Cable Version Connect the free ends of the cable following the wire colours as shown in the terminal diagrams GRN YEL 20mA 1 1 Sinking 4 20mA from user device loo...

Page 9: ...ive load PLC input indicator or other user device 4 20mA Voltage free user device NOTE Isolated current output can be made common with DC or GND if required e g RL connected to GND SINKING Type Output also 2 wire loop powered Sultan output is sinking current Voltage to drive current loop must be provided by PLC indicator other user device or external DC supply User device including 24VDC source NO...

Page 10: ... be used 2 At each individual unit wire a connection between a Relay eg Relay 1 Common terminal and the TEST terminal of the same amplifier 3 Wire a connection between the chosen Relay Normally Open terminals of all units to be linked parallel connection of all units 4 In the Output Adjust menu for each unit program the chosen Relay to FS Fail safe mode The units will now be linked so that they ca...

Page 11: ...DATE ALL DIMENSIONS IN MM APRVD CHECKED DRAWN A01 HAW_CLB_SUL_SEQ PLC DCS Sultan Sequencing DATE DATE COMPANY 5 6 7 8 VICTORIA AUSTRALIA 3131 SHEET 1 1 GR 27 04 2012 15 17 MAURICE COURT NUNAWADING Rio Tinto Cape Lambert B A 1 L N B RED BLACK BLUE WHITE Test In Is TRANSDUCER DC In AC In 4 20mA COMMS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Sultan Terminal Rail PLC DCS Relay On PLC DCS Min 120mS Running ...

Page 12: ... examples of common INCORRECT mountings which can prevent the unit from operating correctly Do NOT mount near infeed Do NOT mount cone or transducer face above roofline Do NOT mount over or adjacent to any obstacles Do NOT mount on angle in liquid applications ...

Page 13: ...13 Correct Mounting Sultan Acoustic Wave Series Mount away from infeed Mount away from all obstacles Mount perpendicular to liquids Mount cone transducer face within the vessel ...

Page 14: ... the panel and install supplied screw clamps into the slotted holes in the amplifier housing Tighten the screws until just firm to secure the amplifier in place Connect wiring as required to the correct terminals on the removable rear panel connectors When plugging connectors in to the rear panel ensure that they are re installed in the correct position Transducer Selecting a suitable position to ...

Page 15: ... respected Where possible use the conservative values and increase this distance by 50 if there is foam dust steam or condensation in the vessel being monitored Refer to Blanking Distance table If using a flange mounting use a rubber or neoprene gasket and washers If using a nipple mounting ensure that the mounting bracket is 6mm 0 24 in from the rear of the transducer Do not over tighten the lock...

Page 16: ...DUAL OUTFEED Two transducers may require anti crosstalk wiring setup see manual Minimum 50mm MOUNTING POSITION Vessel Infed Pipe 1 3 2 3 Minimum 50mm 2 VERSION min 20mm inside tank Intrusive pipe Correct Incorrect Vessel roof Threaded mounting should only be used where a flange cone mounting is impossible Hawk recommends supplies focaliser cones for all transducers Incorrect Face must not be insid...

Page 17: ...cer face Feet Metres Centimeters Inches QuickSet Unit Low Level High Level Position Slurry Solids Liquids App Type Empty Rate Fill Rate Adjust vessel fill rate Adjust vessel empty rate Fail Safe 3 50mA 3 80mA 20 20mA Last Known Adjust Fail time seconds Fail Time CAL Display Mode CAL CAL CAL CAL CAL CAL CAL CAL CAL CAL Avg Matrl Diff O P Space Material CAL Material Flow Volume Flow Tbl Select unit ...

Page 18: ...NPT All cones must protrude into the main volume of the vessel by at least 50 mm 2 inches past the lower end of the mounting nozzle Cone Transducer Dimensions Table Sensor Frequency Selected Flange A B C D mm in mm in mm in mm in 5 kHz 10 236 10 0 455 17 9 840 33 1 750 29 5 10 kHz 10 236 10 0 455 17 9 540 21 3 450 17 7 8 195 8 0 280 11 1 540 21 3 450 17 7 15 kHz 10 236 10 0 455 17 9 440 17 3 350 1...

Page 19: ... 8 8 8 8 8 12 12 12 12 Standard ANSI DN JIS Flange Dimensions Size Flange Type E PCD F OD G ID H Hole No Holes mm in mm in mm in mm in 4 FA4 ANSI class 150 190 5 7 5 229 9 0 100 4 19 0 75 8 FD4 DIN100 PN10 16 180 7 1 220 8 7 100 4 18 0 71 8 FJ4 JIS B2220 1984 10kg 175 6 9 210 8 4 100 4 19 0 75 8 6 FA6 ANSI class 150 241 5 9 5 279 11 0 150 6 22 0 87 8 FD6 DIN150 PN10 240 9 4 285 11 2 150 6 23 0 91 ...

Page 20: ...p of flange down depending on model Sensor Face Flange Always use conservative nominated distances if possible Part No Frequency Minimum Nominal Conservative AWRT50 50kHz 0 25m 10 0 3m 1ft 0 35m 1 2ft AWRT40 40kHz 0 3m 1ft 0 35m 1 2ft 0 4m 1 3ft AWRT30 30kHz 0 35m 1 2ft 0 4m 1 3ft 0 5m 1 6ft AWRT20 20kHz 0 45m 1 5ft 0 6m 2ft 0 7m 2 2ft AWRT15 15kHz 0 6m 2ft 0 7m 2 2ft 1 0m 3 2ft AWRT10 10kHz 0 75m...

Page 21: ...ELAY 5 NC COM NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 B RED BLACK BLUE WHITE Test In TRANSDUCER COMMS 4 20mA A Shld Shld Sinking 4 20mA from user device 1 2 3 4 5 6 7 8 9 10 11 12 AC In is replaced by 36 60VDC with Power Input Option C AWR234 RELAY 1 NC COM NO RELAY 2 NC COM NO COMMS A B Shld DC In Test In 4 20mA Is 1 L N AC In COMMS A B Shld 4 20mA Test...

Page 22: ...it is currently applying on top of normal gain to track the level External noise level of similar frequency to Transducer eg bulk solids filling Temperature at sensor face Tracking Window starting distance Tracking Window finishing distance Unit operational mode Normal operation if tracked echo is above minimum threshold Default minimum is 0 4V Recover if below minimum threshold the unit will sear...

Page 23: ...ty rate fast med slow custom Fail Safe 3 50mA 3 80mA 20 20mA Last Known Adjust Fail time seconds Fail Time CAL Display Mode Offset CAL CAL CAL CAL CAL CAL CAL CAL CAL Avg Matrl Diff O P Space Material CAL Material Flow Volume Flow Tbl See Display Modes on page CAL Adjust offset value CAL Select unit of measurement from Note If using GosHawk PC comms after changing app type you need to reset fill e...

Page 24: ... monitored 20mA analog output level Note There must be a minimum span of 100mm between high low levels Fail Safe Allows the user to select their preferred fail safe condition the 4 20mA output will transmit when the unit enters fail safe mode There are 5 possible mA output failure values They are 20mA 4mA Last Known 4 00mA and 20 00mA Application Type Allows the user to select the type speed of th...

Page 25: ... Fill 100m h Empty 100m h Med Fill 50m h Empty 50m h Slow Fill 10m h Empty 10m h Conveyor Fast Fill 6000m h Empty 6000m h Med Fill 3000m h Empty 3000m h Slow Fill 1000m h Empty 1000m h Crusher Fast Fill 800m h Empty 800m h Med Fill 200m h Empty 200m h Slow Fill 20m h Empty 20m h Detection Fast Fill 6000m h Empty 6000m h Med Fill 3000m h Empty 3000m h Slow Fill 1000m h Empty 1000m h Iron Ore Fast F...

Page 26: ...ast Fill 100m h Empty 100m h Med Fill 50m h Empty 50m h Slow Fill 10m h Empty 10m h Slurry Fast Fill 100m h Empty 100m h Med Fill 50m h Empty 50m h Slow Fill 20m h Empty 20m h Solids Fast Fill 100m h Empty 100m h Med Fill 50m h Empty 50m h Slow Fill 10m h Empty 10m h Stockpile Fast Fill 200m h Empty 200m h Med Fill 50m h Empty 50m h Slow Fill 20m h Empty 20m h Sump Fast Fill 200m h Empty 200m h Me...

Page 27: ...nnect the other transducer to the junction box which will be ID1 to complete the measurement pair required for Average Differential measurement The Flow option can be used for basic open channel flow applications with a known Exponent value of the flume channel weir and the known max flow rate Low High level need to be set to represent the distance from the transducer face of 0 100 possible flow o...

Page 28: ... should be set considering the average space values at which the relay is required to switch Setting Sensor ID You will need to assign one transducer to ID2 To do this perform the following steps 1 Connect only one of the transducers 2 Enter Quickset and change the display mode to AvgMatrl 3 Scroll down until you see 1 Sen Add 1 option 4 Press CAL to edit Select 1 for current transducer and press ...

Page 29: ... is calculated according the following equation Current mA 16 Diff LowLevel1 HiLevel1 4mA Setting Sensor ID You will need to assign one transducer to ID2 To do this perform the following steps 1 Connect only one of the transducers 2 Enter Quickset and change the display mode to AvgMatrl 3 Scroll down until you see 1 Sen Add 1 option 4 Press CAL to edit Select 1 for current transducer and press CAL...

Page 30: ...ducer face Unit will not track within this distance Vessel empty distance Unit will not track beyond this distance Adjust temperature trim compensation Press RUN twice to revert to normal operation CAL Advanced CAL CAL CAL CAL CAL CAL Adjust distance trim compensation CAL Adjust sound velocity compensation for applications where speed of sound is different CAL Echo Mapping Distance to be mapped fr...

Page 31: ... hold to the EchoSize Blanking The Blanking Distance is the minimum amount of space which should be between the transducer face and the product being monitored This distance is a blank zone the unit will not track anything within this distance Where possible use the conservative values and increase this distance by 50 if there is foam dust steam or condensation See also Minimum Measurement Range E...

Page 32: ...ote indicator L1 Relay ON dist L2 Relay OFF dist DEN EN FS OFF See Comms Types on page 31 CAL CAL CAL CAL CAL CAL CAL Continues with Rly Modes 2 5 all with same menu as Rly Mode 1 CAL CAL RlyL1 RlyL2 CAL Bk Light DispChar CAL Switch on off LCD backlight CAL Adjust number of characters per line on display 8 or 12 Press RUN twice to revert to normal operation V in Chk CAL When active the unit will s...

Page 33: ...s vary the distance on the display The current output and any relays used will behave exactly as they should do if the measured distance in SPACE mode without damping was that shown on the display This mode can be used to test correct behavior of outputs or externally connected equipment Relays Allows the user to set the relays for switching The relays are programmed in a distance from the transdu...

Page 34: ...st Relay switch point L2 must be L1 Adjustable Energise EN DeEnergise DEN NC NO COM NC NO COM NC NO COM POWER FAILURE State 1 State 2 Relay Action FailSafe FS FailSafe FS NC NO COM Relay Status LED Status Remote Amplifier terminal function labels NC NO COM NC NO COM NC NO COM NC NO COM NC NO COM NC NO COM NC NO COM NC NO COM NC NO COM NC NO COM NC NO COM system operating normally OFF power system ...

Page 35: ... Modbus CAL Device ID CAL Baud Rate CAL CAL Device ID Baud Rate F BusAdd CAL CAL CAL FF PA Fieldbus Profibus PA All HAWK products come standard with Modbus If a unit supports additional communications protocols it will be indicated on the wiring label inside the unit and the part number Foundation Fieldbus and Profibus PA have stand alone manuals located in the downloads manuals section of www haw...

Page 36: ...0 GAIN at Echo detection point in 7 5 40131 NOT USED Gain Limit 40132 RECOVER GAIN in 7 5 40133 NOISE in 7 5 40134 TEMPERATURE in Degrees K 10 DegreesC 273 2 10 40136 CONFIRM COUNTER current value 40137 HOLD COUNTER current value 40139 WINDOW FORWARD POSITION in mm 40140 WINDOW BACK POSITION in mm Span Adjustment Read Write MUST Read Write SINGLES NOT BLOCKS 40011 LOW LEVEL span set point in mm 40...

Page 37: ...1 Solid 2 Slurry 3 Position 40017 FILL RATE metres per hour 10 40018 EMPTY RATE metres per hour 10 40019 DISPLAY MODE 1 Volume 2 Flow 3 Material 4 Material 5 Space 6 Differential Output 7 Average Material 40032 OFFSET mm 40020 LOCK CODE 40021 FILL DAMPING 40022 EMPTY DAMPING 40063 ANALOG 0 4 20mA 4mA low 20mA high standard 1 20 4mA 20mA low 4mA high inverted 40447 GAIN parameter setting in 7 5 404...

Page 38: ...on and use the Up and Down push buttons to modify this value 10 Press CAL button again when finished 11 Press RUN to save and several times again to return the unit to operating mode Output Data Profibus DeviceNet now transmit 18 bytes 9 words description of the words is as follows For firmware version 5 54 and above 1 Displayed Distance Space Distance is the Primary Variable 2 Percentage Percent ...

Page 39: ... the FieldBus Address is 126 Press CAL button and use the Up and Down push buttons to modify this value 9 Press CAL button again when finish 10 Press RUN several times to return the unit to operating mode Output Data DeviceNet now transmits 18 bytes 9 words description of the words is as follows For firmware version 5 54 and above 1 Displayed Distance Space Distance is the Primary Variable 2 Perce...

Page 40: ...he software allows easy access to unit setup menus using a PC rather than the keypad and gives a visual representation of what the unit is seeing all echoes which pass the unit filter transmitting and displaying on the unit face The best and easiest way to set up troubleshoot and monitor a HAWK unit is via GosHawkII To connect to a unit using this software you need either a HawkLink modem or HawkL...

Page 41: ...e card is secured by a small brown plastic lock Gently lift both tips of the plastic lock until they click up to release the lock Gently lift the card out and flip to the required mode Place the card back in and re lock down the plastic bracket The procedure is delicate it is recommended to be performed in a workshop or lab and not in the field Remove screws SMART Card Orientation Refer to manual ...

Page 42: ...e that is higher than the actual level unit is locking on high level 40 Output doesn t match level during filling emptying 40 Output is erratic inconsistent 40 Replacing the amplifier or transducer 41 Hardware checks Voltage Resistance Remote Integral 42 Error Codes 43 Contacting HAWK ...

Page 43: ...ring the High Level value below the Dist Step3 If you cannot do this lower the Gain4 value also located in Advanced incrementally until the unit cannot see the problem echo Lowering the Gain4 will affect overall sensitivity of the unit It will reduce unit capability If you need to lower this value by 5 10 to avoid the unit locking onto an obstacle you must consider step 1 adjusting mounting locati...

Page 44: ... Output is erratic inconsistent Increase the damping values to stabilise unit response times The settings are in Output Adjustment menu as FillDamp and EmtyDamp If material being measured forms angle of repose try adjusting Transducer mounting angle to get better reflections For analogue output related problems it is important to isolate the Sultan disconnect from the network and use a multimeter ...

Page 45: ...below 9VDC If V in chk is on the unit will trigger its failsafe routine If V in chk is off the unit will display V fail on the LCD Sultan 2 Specified ranges 12 30VDC Unit performance will be affected if power drops below 7VDC If V in chk is on the unit will trigger its failsafe routine If V in chk is off the unit will display V fail on the LCD Transducers The Transducer power red wire should draw ...

Page 46: ...ed to a different transmitter Re connect the unit to the previous transmitter and change the ID via Quickstart SenAdd CAL TxAdds Error 01 It can also be caused by power supply related issues See Unit Voltage Specs Checks Error 02 Communication data corruption between Transmitter and Transducer It can be a result of noise in data lines or one of data lines white or blue being open circuit Make sure...

Page 47: ... down the Diagnostics displayed on the unit to assist with support speed See DIAGNOSTICS SOFTWARE OVERVIEW for further information Also include a diagram or drawing of the vessel marked with where the transducer is installed along with photographs of the installation and what is below the transducer ...

Page 48: ...t E1 4 20mA with Modbus over Ethernet TCP IP This option is no longer available X Option no longer available Approval Standard X Not Required i03 IECEx Zone 0 Ex ia IIA T4 IP67 Tamb 20 C to 70 C A03 ATEX Grp II Cat 1 GD IP67 EEx ia IIA T4 i203 IECEx Zone 20 DIP A20 TA85C IP68 Tamb 20 C to 75 C A203 ATEX Grp II Cat 1 D T85 C IP67 Tamb 20 C to 75 C A22 ATEX Grp II Cat 3 GD T85 C IP67 Tamb 40 C to 70...

Page 49: ...d Standard Flange Mount 30 3 BSP 50 3 5 BSP Approval Standard X Not Required i0 IECEx Zone 0 Ex ia IIA T4 IP67 Tamb 20 C to 70 C A0 ATEX Grp II Cat 1 GD IP67 EEx ia IIA T4 i1 IECEx Zone 1 Ex mb II IP68 T5 Tamb 20 C to 65 C T6 Tamb 20 C to 50 C A1 ATEX Grp II Cat 2 GD EEx m II IP68 T5 Tamb 20 C to 65 C T6 Tamb 20 C to 50 C i20 IECEx Zone 20 DIP A20 TA85C IP68 Tamb 20 C to 75 C A20 ATEX Grp II Cat 1...

Page 50: ... 65 C T6 Tamb 20 C to 50 C A1 ATEX Grp II Cat 2 GD EEx m II IP68 T5 Tamb 20 C to 65 C T6 Tamb 20 C to 50 C i20 IECEx Zone 20 DIP A20 TA85C IP68 Tamb 20 C to 75 C A20 ATEX Grp II Cat 1 D T85 C IP67 Tamb 20 C to 75 C A22 ATEX Grp II Cat 3 GD T85 C IP67 Tamb 40 C to 70 C GP CSA Equip Class 2 Pollution deg 2 Tamb 20 C to 75 C Ordinary Locations RN CSA Class I Div 1 2 Group D Zone 0 AEx Ex ia IIA T4 KN...

Page 51: ...80 C 176 F Y4 Titanium 80 C 176 F Transducer Housing Material 4 Polypropylene This option is no longer available X Option no longer available This option is no longer available X Option no longer available Additional Communication S1 No additional communications 5 Relays Modbus X 4 20mA analogue H5 4 20mA analogue with HART 2 wire I1 4 20mA analogue with HART Isolated 4 wire A Profibus PA F Founda...

Page 52: ...unting Thread Sizes 20 2 thread Additional Communication S1 No additional communications 5 Relays Modbus X 4 20mA analogue H2 4 20mA analogue with HART 2 wire I1 4 20mA analogue with HART Isolated 4 wire A Profibus PA F Foundation Fieldbus Approval Standard X Not Required i03 IECEx Zone 0 Ex ia IIA T4 IP67 Tamb 20 C to 70 C A03 ATEX Grp II Cat 1 GD IP67 EEx ia IIA T4 i203 IECEx Zone 20 DIP A20 TA8...

Page 53: ... 08 15 8 cone for 15kHz 08 10 8 cone for 10kHz 10 15 10 cone for 15kHz 10 10 10 cone for 10kHz and 9Hz 10 05 10 cone for 5kHz and 4kHz Cone Material 4 Polypropylene 7A Carbon Fibre Includes matching ANSI Flange 4 8 or 10 7D Carbon Fibre Includes matching DN Flange 4 8 or 10 7J Carbon Fibre Includes matching JIS Flange 4 8 or 10 8 Polyurethane C 04 4 Additional Cone Options1 C04 4 ZOD90 C04 4 trimm...

Page 54: ...le Accessories HAWKLink Data Modem Transducer Cone Flange Option 1 Flange Option 2 Flange Option 3 Flange Option 4 50 40kHz C02 F_3A F_4A 30kHz T6 C02 F_3A F_4A 30kHz T4 C03 4 Z F_3A C04 F_3A F_4A F_6A F_8A 4 C4 Back Cap Mount TB30 F_4A FA6A 20kHz C03 4 Z F_3A C04 F_3A F_4A F_6A F_8A 4 C4 Back Cap Mount TB30 F_4A F_6A 15kHz C04 F_4A F_6A C08 F_8A F_10A F_6D50 4 C10 F_8A F_10A F_6D50 4 Back Cap Mou...

Page 55: ...section Maximum Range 5m 16ft 50kHz liquids 7m 22ft 40kHz liquids 10m 33ft 30kHz liquids 5m 16ft solids 20m 65ft 20kHz liquids slurries 10m 33ft solids 30m 98ft 15kHz liquids slurries 20m 65ft solids 60m 196ft 10kHz liquids slurries 40m 165ft powders solids 60m 196ft 5kHz liquids slurries powders solids 180m 588ft 4 9 kHz for extended range position applications Resolution 1 mm 0 04 50 40 30 20 15...

Page 56: ...plifier with 6m cable 1 2 2 Remote Amplifier with 15m cable 3 6 6 Remote Amplifier with 30m cable 6 13 2 Remote Amplifier with 50m cable 10 22 0 Typical Weight Sultan Integral Transducer with appropriate flange and cone 4 5kHz Transducer 13kg 28 6lb 9 10kHz Transducer 10kg 22lb 15kHz Transducer 8kg 17 6lb 20 30kHz 3 Transducer 3kg 6 6lb 2 30 40 50kHz Transducer 1kg 2 2lb IECEx Zone 0 Ex ia IIA T4 ...

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