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Hornet-Plus-SS Manual

1. ccccccccccccccccssssssssccccceessceeeeeees 44 Appendix D Corrected Depth Calculation sssssssssssssseeeseee 51 Appendix E Ground Feeler Device Model GED sssessssesssssseeeeeseeee 52 Appendix F Adding Control to Drum Cable 55 Appendix G Sediment Sampler Holst scscccccccccsssssssssssscccccsssseeeeesees 56 Appendix H Far Side Installation Guide ccccccccccsssssssssscccceccceeeeeeees 60 Hornet Plus Cableway Gauging System Copyright Page 2 Issue 1 9 23 Sep 15 Hyquest Solutions Pty Ltd 1 Introduction The Hornet Hornet Plus Sediment Sampler has been developed to replace manned cableways thus removing the personal injury risk associated with this type of gauging The standard Hornet can use an ADCP to measure discharge and the Hornet can use either an ADCP or a mechanical Current Meter attached to a suitable Gauging weight to measure discharge and the Sediment Sampler can use an ADCP mechanical current meter and a Depth Integrating Sediment Sampler 2 x Batteries 12VDC 38Ah Hornet amp Hornet 24VDC 20Ah Sediment Sampler Traveller ste Block Er Winch for the Hoist Hoist a W Connector Gauging Weight A i Remote Va Control E L _ Operating Side Post s 4 4 gt n z Le Ca ey ngs A 1000W AC Generator Ps o a The Hornet Plus uses an advanced Hoist that can measure
2. 3 Hoist cover turn on the circuit breaker refit the clear cover and plug back in the generator Please be careful as Mains Voltages are present inside this enclosure iii Check that the generator is operating and creating the correct mains voltage using a DVM a Hoist clicks and doesn t move up or down i Check the battery connections When the Hornet or Hornet Plus Hoist motor operates it draws 50A from the batteries A loose bolt connection or a badly crimped terminal will cause the voltage to droop under load and the hoist controller to reset ii Check the plug in power connectors that a terminal hasn t been dislodged in the housing iii Check both fuses are OK if one is blown then the Hoist will only be running on one battery iv Make sure that the hoist cable is wrapped properly on the drum and is not jamming the drum rotation b The Sediment Sampler Hoist moves upward very slowly All of the Hornet family Hoists have limit switches to stop the upward operation at the end of the cable to prevent damage The Hornet and Hornet Plus Hoists operate relatively slowly and so the limit switch on its own is sufficient However the Hornet Sediment Sampler with hoist speed adjustment can operate very fast and the limit switch on its own would not stop the hoist upward operation fast enough to prevent damage therefore additional protection has been added The hoist remembers the position of the drum when
3. This menu displays the present condition of the Hoist battery Hoist Batt OK and the NiMh batteries inside the Remote Control My Batt My Batt OK Hoist Battery states Greater than 11 7V gt OK Between 11 4V and 11 7V gt Low Less than 11 4V gt Flat No Hoist Comms gt My Battery states Greater than 3 7V gt OK Between 3 45V and 3 7V gt Low Less than 3 45V gt Flat 4 3 9 3 Drive Interlock Status This menu displays the present condition of the Drive Control Drive LLock OK Interlock that is the proximity sensor and inclinometer that Alarms bolts onto the main cable and plugs into the motor Interlock states Plugged in and nothing is close gt OK Plugged in and object too close gt Stp Not plugged in gt Fit Disabled in Interlock menu gt Dis No Drive Control Comms gt Hornet Plus Cableway Gauging System Copyright Page 35 Issue 1 9 23 Sep 15 Hyquest Solutions Pty Ltd 4 3 9 4 Return to Alarms Press the menu scroll button to return to the Alarms Menu RETURN TO ALARMS 4 3 10 Return to Main Display Press the menu scroll button to return to the Main Display menu RETURN TO MAIN DISPLAY 4 4 System Operational Steps The following steps should be followed when setting up a system for gauging l dE a a 10 11 12 Fit batteries and hand winch onto the carriage Raise the Hoist into position using the hand winch and secure the carr
4. 26 channels 1MHz spacing Operating Range 1km 0 62 miles line of sight Indicators LEDs for comms and fault indication Outputs Current Meter Output Open Collector Sounder for current meter pulses Power Source 3 x NiMh 2 5Ah AA batteries with built in charger 3 x AA Alkaline batteries in an emergency Hornet Plus Cableway Gauging System Copyright Page 40 Issue 1 9 23 Sep 15 Hyquest Solutions Pty Ltd Appendix A Routine Maintenance There are a few routine maintenance steps that should be performed to ensure continued safe operation of your Hornet system Drive Control l Grease the Drive Control tension pulley shaft Hoist 2 TANYNT LA Laka AA Grease the Hoist sheave guide pulley shaft Lightly grease the Hoist guide shaft 3 Check that all nuts and bolts on traveller block are still tight and that turnbuckles and traversing tension is appropriate 4 Check traversing cable for any visible signs of wear Check Manual Winch cable for fraying 6 Check that Hoist cable is laid neatly on to the hoist drum Un Hornet Plus Cableway Gauging System Copyright Page 41 Issue 1 9 23 Sep 15 Hyquest Solutions Pty Ltd Appendix B Startup Guide Hornet Plus I 10 11 12 13 14 15 16 17 Assure that traveler block is located over a safe working space If it is not plug in Drive Control Box turn on the Remote Control and drive Traveler Block over a saf
5. Copyright Page 14 Issue 1 9 23 Sep 15 Hyquest Solutions Pty Ltd Step 4 Fitting the Turnbuckle to the end of the cable First the two supplied swages through the cable Hook the Thimble to the end of Loop the end of the cable the Turnbuckle as shown around the Thimble as shown Slide the swage over the Minimum 2 x Swages are looped cable and crimp it required Note Ensure that the Turnbuckles are loose to allow for cable tensioning later on Hornet Plus Cableway Gauging System Copyright Page 15 Issue 1 9 23 Sep 15 Hyquest Solutions Pty Ltd Step 5 Fitting the Turnbuckle to the Traveller Block Hornet Plus Cableway Gauging System Copyright Page 16 Issue 1 9 23 Sep 15 Hyquest Solutions Pty Ltd Step 6 Fitting the Turnbuckle to the other side of the Traveller Block Hornet Plus Cableway Gauging System Copyright Page 17 Issue 1 9 23 Sep 15 Hyquest Solutions Pty Ltd Step 7 Fitting the other end of the Traversing cable to the Turnbuckle Follow instruction below on how to cut and install the Traversing cable to the Turnbuckle Pull the excess cable across the span until you achieve reasonable sag below the main cable Cut the wire with one metre in excess to allow for tensioning and adjustment Feed the 2 supplied swages through the cable Attach the cable to the turnbuckle but do not crimp yet Adjust the traversing cable to achieve the correct tension using the Turnbuckles
6. Copyright Page 50 Issue 1 9 23 Sep 15 Hyquest Solutions Pty Ltd Appendix D Corrected Depth Calculation Main Cable B A Airline A Waterline N Plos Wetline Corrected Depth Ce Look at the right angle triangle above the water cos 8 A A C A C A cos 0 C A cos0 A Air Line Correction Airline A C Wetline B C A cos A Total Cable Airline Airline A cos 0 Wetline Total Cable A cos 0 Consider the cable under the water Waterline Corrected Depth using curved Depth assuming wetline straight wetline v x As displayed on Hornet LCD Wetline Sey Ener Aer cure NOTE The Corrected Depth is calculated due to the force of water on the cable EES l dynamically using a proprietary formula developed by Hyquest Solutions The resultant Corrected Depth is in accordance with the USGS Measurement and Computation of Stream Flow Vol 1 Water Supply Paper 2175 Hornet Plus Cableway Gauging System Copyright Page 51 Issue 1 9 23 Sep 15 Hyquest Solutions Pty Ltd Appendix E Ground Feeler Device Model GFD Introduction The Ground Feeler Device is a mechanical spring loaded attachment that can be used in conjunction with any Hornet Plus gauging winches fitted with Amergraph cable and connected to a Columbus pattern gauging weight The unit is designed to alert the operator that the gauging weight has come in contact with the streambed during a gaugin
7. Gripping the metre tail tension cable up as much as possible and crimp it Cut any excess wire that 1s not required Hornet Plus Cableway Gauging System Copyright Page 18 Issue 1 9 23 Sep 15 Hyquest Solutions Pty Ltd 3 6 Attaching the Batteries and the Winch to the Traveller Block Install the first battery opposite to the winch side and in place using the hinged pin Install the manual winch to the bottom of the battery box as shown Slots for the Manual Winch Install the second battery in place and use the hinge pin to lock both the battery and the winch in place Locking pin used to hold battery and winch in place Hornet Plus Cableway Gauging System Copyright Page 19 Issue 1 9 23 Sep 15 Hyquest Solutions Pty Ltd 3 7 Installing the Hoist Straighten the Antenna on the Hoist as shown Warning Before installing the Hoist inspect the manual winch cable and ensure the cable wires are intact and show no signs of fraying If the cable is frayed do not use the winch as it is not safe to do SO Use the manual handle supplied with the winch DO NOT USE ANY POWER TOOLS to operate the manual winch as excessive torque generated from these power tools could damage the cable manual winch and detach the hoist from its location When lifting the hoist ensure no one is standing directly under the hoist for safety reasons Release the cable on the manual winch and feed it through th
8. This will only move slightly Try to drive the system again b The Drive Control doesn t have enough power to drive the loaded carriage up the main cable Systems supplied before Apr 2011 may have had the AC motor wired in a Star configuration which limits the drive capability Rewiring this in a Delta configuration dramatically improves the drive capability Contact Hyquest Solutions for a data sheet on how to correct this the change only takes 10 minutes and should only be attempted by qualified personnel c The numeric display in the Drive Control cabinet is flashing It does depend what is flashing if it 1s just a number flashing then there is no problem this is normal Other flashing codes could indicate a problem OV Over Voltage check generator output LV Low Voltage check generator output OH Over Heating power down and wait for it to cool down OC Over Current power down and up again maybe the motor cable is jammed d Drive Control cabinet isn t working there are no LEDs on the drive controller 1 Check that the cable between the generator and underneath the Drive Control cabinet is plugged in firmly ii Look inside the Drive Control enclosure with the clear lid and see if the Circuit Breaker has tripped If so turn off the generator remove the enclosure clear Hornet Plus Cableway Gauging System Copyright Page 45 Issue 1 9 23 Sep 15 Hyquest Solutions Pty Ltd
9. be indicated later in this manual Step 1 From the reel to the far side From Reel To the Bottom of the Far Side Sheave Run the Traversing Cable from the Reel to the Far Side Post Wrap Cable ge Around the Pulley Wrap the Cable around the Return sheave from underneath around the top and out Run the Cable and pass it under the small pulley on the middle of the Traveller Block Hornet Plus Cableway Gauging System Copyright Page 12 Issue 1 9 23 Sep 15 Hyquest Solutions Pty Ltd Step 2 From far side to Traveller Block Run the end cable back to the operating side and pass it through the Traveller Block beneath the Guide pulley as shown Please Note The distance between the main cable and the top of the endless cable should be approximately 140mm Hornet Plus Cableway Gauging System Copyright Page 13 Issue 1 9 23 Sep 15 Hyquest Solutions Pty Ltd Step 3 From Traveller Block to the Operating Side Double Wrap Feed the cable from the top Keep running the cable till you get to the operating side Feed the cable from the top as shown Cable Going to Wrap the cable around the d the top Operating Side S Guide Pulley a b Wrap the cable around the Guide Pulley c Wrap the cable around the d second Groove This side of the cable is attached to the Traveller Block using a e Turnbuckle Hornet Plus Cableway Gauging System
10. check that the ribbon cable is firmly pushed into the multipin socket on the LHS of the circuit board 11 Remove one battery from the holder and then put it back in again to force the Remote Control to perform a hard reset c Remote Control battery is not lasting after being charged Check the Remote Control software revision by navigating through More to the Remote menu s Make sure it has software Rev 2 4 or higher this will ensure it has the correct NiMH battery charging algorithm When the charger is plugged into the Remote Control the display will automatically come on and the battery symbol will indicate it is charging leave it charging for 4 to 4 5 hours after this time it will automatically drop back to a trickle charge Remove the 3 x NiMH batteries and try charging them in a commercial NiMH battery charger if they still won t hold their charge replace them with new NiMH batteries and recharge the Remote Control d Green light is flashing but the Red light is also on The green LED flashes each time it communicates with either the Hoist or the Drive Control unit the red LED on does mean there is a problem Navigate through More to the Alarms menu to see what the problem is It could be one of the following i Hoist or Drive Control comms error ii Hoist battery is low iii My battery is low ie Remote Control battery Hornet Plus Cableway Gauging System Copyright Page 44 Issue
11. depth cable angle and current meter counts and sends the information to the Remote Control 2 Product Overview The Hornet Hornet Plus Sediment Sampler is operated from the bank of a stream or river Using a handheld remote control the operator can maneuver the flow sensing device with the push of a switch to traverse the waterway section to be measured The control system operates an electric motor to drive the carriage and hoist from the operating side to the far side of the waterway and back to the starting point The operator uses the Remote Control to raise and lower the flow sensing device from the water via the Hoist Hornet Plus Cableway Gauging System Copyright Page 3 Issue 1 9 23 Sep 15 Hyquest Solutions Pty Ltd 3 Installation 3 1 Unpacking Your Hornet Hornet Plus When you receive the Hornet Hornet Plus you will receive the following with it Hoist Remote Control Remote Control Battery Charger Safety Sensor Controller amp Motor Drive Far Side Return Sheave 2x Battery Boxes Traveller Block Assembly Manual Winch for the Hoist Traversing Cable Optional Turnbuckles Thimbles amp Wire Rope Grips Optional 2 Spare 50 Amp Fuses for Hoist Weather Cover ee ee UE me e e AUN gt OO 14 The seal is essential in wet weather to minimise the amount of water going inside the enclosure Note Hyquest Solutions can supply drawings for the steelwork if a new Travellerway
12. internal inclinometer to measure the cable angle Hornet Plus Cableway Gauging System Copyright Page 22 Issue 1 9 23 Sep 15 Hyquest Solutions Pty Ltd 3 9 Attaching the Current Meter and Gauging Weight to the Hoist Open the Cover at the bottom of the Hoist Turn the Hoist Power On Use Lower to release the Cl connector Release the C1 Connector from the spring Lower the cable to attach the Cl Connector to the Hanger Bar Hornet Plus Cableway Gauging System Copyright Page 23 Issue 1 9 23 Sep 15 Hyquest Solutions Pty Ltd 4 Operation 4 1 Initial Power Up Once the system is assembled as described in section 3 simply apply power to the Drive Controller either from the mains or from a small 1000Watt petrol generator Press the button under the Hoist to turn it on This button is a push on push off type the blue LED under the hoist indicates power is on Press and hold the Power button on the Remote Control and the LCD will come on The red LED on the Remote Control should turn off when communications is established The green LED will flash as the Remote Control communicates with the Hoist and Drive Controller LCD View Distance Angle Speed Voltage Ctatiie Variable Speed Control HYDROLOGICAL SERVICES PTY LTD ZERO Power amp Zero Turn power on off Zero when prompted Navigate Menus Rotate to scroll through menus and LOWER p
13. loop is used to ensure that the pulse rate measured at the Hoist is the same as the pulse rate output by the Remote Control A one second buffer is used so that any missed communication messages do not interrupt the output pulse data stream In the same way that a walkman has anti jump data buffering Due to this you will notice a 1 second delay between the input and output at fast pulse rates This has been done to ensure your data integrity To your favorite current meter counter Hornet Plus Hoist Current Meter Fan Remote Control Hornet Plus Cableway Gauging System Copyright Page 37 Issue 1 9 23 Sep 15 Hyquest Solutions Pty Ltd 4 5 2 The Hoist Depth and Angle Measurement Hornet Plus only The Hornet Plus Hoist has an optical encoder that measures the cable drum rotation so that vertical depths can be measured An inclinometer built in to the Hornet Plus Hoist also measures the angle of the cable The Hoist pivots on the main cable and when heavy gauging weights are used the angle of the Hoist is approximately the same as the angle of the cable Using this information the Airline Wetline and corrected depths are automatically calculated See 4 3 2 4 6 The Drive Control System The Drive Control system consists of several parts The electric motor gearbox and brake assembly drives the pulley arrangement An encoder on the motor allows horizontal distance information to be calculated The brake stop
14. taken The cable angle is measured from this reference point 4 3 5 More This menu item is the door to Hoist Drive Control Remote and Alarms menu Press the menu scroll knob to enter the Hoist menu Hornet Plus Cableway Gauging System Copyright Page 31 Issue 1 9 23 Sep 15 Hyquest Solutions Pty Ltd 4 3 6 Hoist This menu is the entry point to view Hoist information Cable Length Angle Vertical Distance Battery Voltage S W Rev and change Hoist parameters signal processor config Mag Head CatsWhisker or Norm Slow operation Rotate the menu scroll knob to step to the Drive Control menu or press the menu scroll knob to view Hoist information 4 3 6 1 Hoist Cable Length and Angle Hornet Plus only The top line displays the total cable length that has been fed out with the cable angle Note the special symbol that indicates an angle The bottom line displays the corrected depth that is the vertical depth of the weight below the water line Note the symbol indicating vertical depth 15 95m 16 5 f 3 92m Hoist Main Cable 16 5 15 95m Water Flow gt 3 92m 4 3 6 2 Hoist CMC Signal Processor Hornet Plus only The Hoist has an inbuilt Current Meter Signal Processor that 1s used to clean up the current meter signal When the Hoist 1s raised asHd Nrm Hoist or lowered the signal processor is forced into a calibration whic
15. 1 9 23 Sep 15 Hyquest Solutions Pty Ltd iv Drive Interlock cable fault ie Motor Drive Interlock Inclinometer box is enabled but not plugged into the Motor Drive cabinet If you don t have the box you can navigate to the Drive Control menus and Disable the ILock Angle function v Hoist Cable Fault The Hoist cable is loose on the drum and touching the sense bar e Traversing Distance not measuring correctly The angle measurement on the main cable isn t being measured properly i If the error is small maybe the Motor Drive Interlock Inclinometer box isn t plugged in to the Motor Drive Cabinet or it is disabled and so an angle of 0 degrees is assumed ii If the error is large then maybe the Motor Driver Interlock Inclinometer is mounted upside down on the main cable and hence the angle is measured as 45 degrees Navigate to the Drive Control menu and see what angle is being measured Sometimes the lid of the Interlock Inclinometer box is removed and put back on upside down and so the This Way Up arrow appears to be OK iii The mounting of the Motor Drive Interlock Inclinometer on the main cable is important make sure that the two top bolts sit down on the cable and that it is not mounted at a strange angle 2 Drive Control Cabinet a Driving forward but the traveler block is not moving This may mean that the drive control motor has ceased Manually release the brake using the manual brake release lever
16. 23 Sep 15 Hyquest Solutions Pty Ltd 4 3 Menu Operation As previously stated the controller menu is navigated by rotating and pressing the Scroll Menu knob The navigation structure is shown on the back of the Remote Control as a handy reference and duplicated here The two main menus show the most used information Pressing the scroll menu knob while in these menus allow zero functions to be performed Stepping into the More menu allows data specific to the Hoist Drive Control Remote Control and Alarms to be displayed Z gt Zero P gt Press Blank gt Rotate Horiz Speed Vert Set at Water Level Set Waters Edge i Set Main Cable to Weight Dist Wet P Air Wet Angle Corrected 7 tole IAE Set Offset from weight to Meter Signal Strength BattV Return to Main Display More Hoist MH Cable Angle Vert P CMC Status Config P gt Comms BattV S W Rev Return to Hoist DriveControl Cable Angle Horiz P Return to MotorDrive P Interlock En Dis Comms lt lt S W Rev Remote S W Rev Batt V P Sounder Blight Units lt P Frequency Chg Status Return to Remote P Alarms gt Comms Battery Status InterLock Status Return to Alarms Return to Main Each menu display item will now be described in detail Note that if a measurement cannot be displayed due to a comms error the data will be disp
17. FEELER DEVICE PART No GFD le Hanger bar is attached to bottom section Hornet Plus Cableway Gauging System Page 53 Issue 1 9 23 Sep 15 Hyquest Solutions Pty Ltd Operation e The GFD contact plunger shown in normal gauging position when Columbus weight is attached i e no contact Gauging weight is attached The contact pin moves away from the angle plug contact sleeve open contact e The GFD spring moves plunger into contact position when Columbus weight reaches the streambed i e continuous beep or no signal received from current meter _ This side is attached to This side is attached to Amegraph cable angle plug current meter cable a GFD02 AA or GFD RB or GFD02 OSS Customer to specify lead when ordering Gauging weight attached The pin is making contact with the Angle Plug connecting sleeve closed contact Gauging weight has reached streambed Hornet Plus Cableway Gauging System Copyright Page 54 Issue 1 9 23 Sep 15 Hyquest Solutions Pty Ltd Appendix F Adding Control to Drum Cable This feature has been added to prevent the drum from continuing to feed out cable after the gauging weight has already reached the streambed Hence the cable stays reasonably tensioned and does not tangle causing improper winding on the drum when the gauging weight is lifted back up from the water The addition of this feature has been implemented by adding a
18. Hyquest Solutions Pty Ltd INSTRUCTION MANUAL Hornet Hornet Plus Sediment Sampler Cableway Gauging System Model Hornet Hornet Plus Hornet SS RS HYQUEST SOLUTIONS QUALITY SYSTEM ISO 9001 CERTIFIED Nooo V HYQUEST SOLUTIONS PTY LTD PO BOX 332 LIVERPOOL B C NSW 1871 AUSTRALIA Phone Int 612 9601 2022 Fax Int 612 9602 6971 Phone Nat 02 9601 2022 Fax Nat 02 9602 6971 Email sales hyquestsolutions com au Web www hyquestsolutions com au Hornet Plus Cableway Gauging System Copyright Page 1 Issue 1 9 23 Sep 15 Hyquest Solutions Pty Ltd TABLE OF CONTENTS PTNEE OCU CUO Misses cascavsscescecuvenscecweessescen E EE 3 Product OVCEVICW corason r aeaa ie 3 T stallati IN 8 88 nsc 4 3 1 Unpacking Your Hornet Hornet PIUS cccccccssssssssssssccccccscescsssssccooees 4 3 2 Installing the Controller amp Motor Drive 5 3 3 Ins Gallin the Far SIA a E 8 3 4 Installing the Traveller Block ss sssssssssssssssssssseeessssesssseeeesss 10 3 5 Installing the Traversing Cable cccccccssssssssssssccccccssssssssssccccssssesssssssccooees 12 3 6 Attaching the Batteries and the Winch to the Traveller Block 19 3 7 Enstallins the HOISt ss sn nn A nn ea E 20 3 8 Fitting the Drive Control Interlock Box to the Main Cable ss 22 3 9 Attaching the Current Meter and Gauging Weight to the Hoist 23 ODEIO eaesccsccesets case cse
19. Issue 1 9 23 Sep 15 Hyquest Solutions Pty Ltd contact was closed then it would give the same effect as the ground feeler contact being closed iii Check the amergraph angle plug signal pin is screwed in securely when it is screwed up tight it makes electrical contact to the amergraph signal wire d The Current Meter connected to the Hoist is not generating pulses as the fan rotates i Make sure there is communications between the Hoist and the Remote Control 11 Check that the Remote Control Hoist menus have the current meter options set to MagHd and Nrm i If the blue LED is flashing as the Current Meter rotates maybe there is a connection problem between the Remote Control banana socket and the Current Meter Counter iv Use the following Troubleshooting Chart Unplug the Angle plug from the Ground Feeler Device GFD Touch the Angle plug centre pin onto the amergraph shield YES NO Blue LED on Remote Control flashes Touch the Angle plug centre pin onto the Hoist chassis touch a bolt not the powder coat YES NO Blue LED on Remote Control flashes Unsure of where the problem is continue troubleshooting onto the next page Lt Copyright Page 47 Issue 1 9 23 Sep 15 Hornet Plus Cableway Gauging System Hyquest Solutions Pty Ltd Remove Hoist electronics lid Unplug 2 pin connector from Hoist electronics in in Blue LED on Remot
20. Output Torque 32 Nm Safety Factor 1 8 Power Requirement 0 75kW 110 VAC 240 VAC Hoist Hornet and Hornet Plus Lifting Capacity 100 Kg 220 lbs 135kg 300lbs also available Power Requirements 2 x 12 VDC 38 Ah Batteries 2 x 50 Amp Fuses Cable 45m of Amergraph cable Depth Measurement 0 01m 0 01ft resolution Hornet Plus only Conforms to USGS Water Supply Paper 2175 Ground Feeler Detects river bed Inclinometer 45 measurement Hornet Plus only Current Meter Built in signal processor Hornet Plus only Hoist Sediment Sampler Lifting Speed Control 0 01 to 0 73m s 0 02 to 2 3 9ft s Lifting Capacity 45 Kg 100 Ibs Power Requirements 2 x 24 VDC 20 Ah Batteries ABS 24V20T4LT 181mm x 149mm x 167mm 7 1 x 5 9 x 6 6 2 x 40 Amp Fuses Cable 45m of Amergraph cable Power driven sheave and grooved drum to ensure cable lays evenly Depth Measurement 0 01m 0 01ft resolution Conforms to USGS Water Supply Paper 2175 Ground Feeler Detects river bed Inclinometer 45 measurement Current Meter Built in signal processor Hornet Plus Cableway Gauging System Copyright Page 39 Issue 1 9 23 Sep 15 Hyquest Solutions Pty Ltd Remote Control completely wireless Controls Raise Lower Control Battery Voltage monitoring Forward Reverse Speed control LCD 16 char x 2 line with backlighting Calculates horizontal distance and vertical depth etc Radio Frequency USA 902 5 to 914 5 MHz AUS 915 5 to 927 5 MHz
21. This menu is the entry point to view Drive Control information Angle Horizontal Distance S W Rev and change Drive Control parameters Drive interlock En Dis Rotate the menu scroll knob to step to the Remote menu or press the menu scroll knob to view Drive Control information 4 3 7 1 Drive Control Distance and Angle The top line displays the total distance the carriage has traversed down the main cable with the main cable angle Note the special symbol that indicates an angle The bottom line displays the equivalent horizontal distance taking the angle into account Note the arrow indicating it is the horizontal distance 125 75m N 4 5 lt 125 36m Driv Rotate the menu scroll knob to step between the Drive Control menus 4 3 7 2 Drive Control Interlock and Inclinometer The Drive Control Interlock is a small black box that bolts onto the main cable This box has 2 functions to measure the angle of Hlock Angle En the main cable and to monitor the position of the carriage as it Prite 1 approaches the Drive Control System using an ultrasonic proximity sensor When the carriage is within about 0 5m of the interlock the Drive Control Motor is shut down preventing it from being driven into the Drive Control enclosure If the interlock inclinometer is misplaced the system cannot be used so a facility is provided to disable the requirement of the interlock NOTE that disabling the interlock is a safety hazard and s
22. cacenacixcucarenccscceasens dadeneixvesseneeeceseeaxeucesseseieedsense 24 4 1 liniar Power UD ne nn Rs tveeess 24 4 2 Brief Description of Controls ssh danse tetesltes 25 4 3 Menu Operati OTs E hs Nr trente 27 ASL Mam Display ersin A 28 4 3 2 Airline Wetline Corrected Depth Display Hornet Plus only 29 4 3 3 Signal Strength and Battery Voltage ssssseccccoccsssssecccosssssscccosossssesecesossssssssee 29 AIA Aero BUNCUONS cerai aa a aaae eaae 30 RS MONE eaae araa Re 31 4S0 HO ne E A Le N 32 4 527 Drive COMTOLS end nn nr tes EEEE ESAE ENNAN Eo test es ice 33 49 0 IRCMOLR rs nd ds le 34 M NAS lected etaneies a lea eats ued eee E E E 35 4 3 10 Return to Main Display vss ccctsvsssccccscsccceseiscbcccecictetsvesicccsteticeeseasebecceceatetseestacentesses 36 4 4 System Operational Steps sseeccoossssssececoccossssscecoososssssecccoosssssssecesossssssseeesossssoe 36 4 5 TENG LOIS E EE E E EE O E OEI EE EE E E 37 4 5 1 The Current Meter Hornet Plus only ssecccocsssssscecccoosssececccosssseseecsosossssssee 37 4 5 2 The Hoist Depth and Angle Measurement Hornet Plus only 000 38 4 6 The Drive Control Systemi secrcrsin nn tente 38 SP CCH CATION S aisnean aaa 39 Appendix A Routine Maintenanc cccccccccssssssscccccsssssssscccsscesssssccsees 41 Appendix B Startup Guide Hornet PIUS ccssssscsscscccccccceeeeeeeees 42 Appendix C Troubleshooting Guide
23. device on the cable will press onto the rollers causing a limit switch to stop the hoist This prevents the hoist from self destructing if it is wound up too far A limit switch is also operated if the cable is let out too far This will stop the drum with about 3 wraps remaining to hold the heaviest weight used 4 5 1 The Current Meter Hornet Plus only The Hornet Plus Hoist has a current meter signal processor built in to clean up the current meter signal Whenever the hoist is raised or lowered the current meter signal processor performs a calibration so that water conductivity is accounted for when monitoring the current meter signal The operator can also select the type of filtering depending upon the type of current meter fan that is connected The operator can select either Mag Head or Cats Whisker as well as Normal or Slow operation See 4 3 5 2 After the signal is cleaned up the pulses are counted and transmitted to the handheld Remote Control that outputs the pulses to the users favorite current meter counter Tech Talk In any radio transmission system there will be the occasional missed message Due to the critical nature of the current meter pulse accuracy special precautions have been taken in the software to ensure that the pulse count and the pulse rate is maintained even in the event of communication errors The system uses message numbering in the protocol to ensure that the pulse count is 100 accurate A PID control
24. e Control flashes Problem is in the Amergraph cable to PCB connector Continue on to isolate this problem The Amergraph cable on the Hornet Hoist drum has an outer shield and inner signal wire which follow different paths to the Hornet Hoist control electronics 2 pin header The amergraph cable shield follows the path Cable Shield to Drum body through to Drum bearing to Bolt and washer supporting the drum to Screws in washer to Hoist chassis side plate to Black wire screwed to side plate that goes to electronics 2 way screw terminal J5 The amergraph cable signal wire follows the path Centre wire of angle plug to Amergraph signal wire to Drum slip ring to Brush to Red wire to the electronics 2 way screw terminal J5 Hornet Plus Cableway Gauging System Copyright Page 48 Issue 1 9 23 Sep 15 Hyquest Solutions Pty Ltd Disconnect the Hornet Plus 12V and turn off the Remote Control The following tests can be done with a multimeter NOTES a When a multimeter is in Continuity Mode beep mode it is difficult to know what the actual resistance is because all multimeters have a different threshold So it is better to put it into Resistance mode so you can tell the actual resistance There are also two diodes in series between J5 and J5 on the circuit board that may confuse multimeter readings in the continuity mode b Itis also important to have the electronics powered down when measuring resi
25. e Traveller Block plate above the roller and down to the hoist as shown Note The manual winch is used to avoid lifting the hoist Cable released from the manual winch down to the hoist Hook the cable to the hoist as shown Hornet Plus Cableway Gauging System Copyright Page 20 Issue 1 9 23 Sep 15 Hyquest Solutions Pty Ltd Lift the Hoist using the manual winch Warning As the hoist engages inside the traveler block a small force should be exerted on the manual handle of the winch so that the holes align sufficiently to allow the pin to be inserted Please note excessive force exertion 1s not required as this may damage the hook cable and winch Remove the pin and keep lifting the Hoist till it coincides with the traveller block NI 3408 L14 Replace the pin Replace the R pin Connect the batteries to the Hoist as shown Hornet Plus Cableway Gauging System Copyright Page 21 Issue 1 9 23 Sep 15 Hyquest Solutions Pty Ltd 3 8 Fitting the Drive Control Interlock Box to the Main Cable 5 A i To the Hoist HORS The Drive Control Interlock Box also contains an Inclinometer to measure the angle of the main cable which will allows the true horizontal distance across the river to be automatically calculated When tightening the knobs make sure that the cable is in contact with the two lower studs so that the box is aligned with the cable This allows the
26. e displayed on the LCD while the switch is being operated Raise Lower The Raise Lower toggle switch controls the hoist via radio communications If there is any problem the cause will be displayed on the LCD while the switch is being operated Red Green and Blue LED When the red Status LED is on it indicates there is a problem This could be due to Hoist or Drive Control communications Hoist battery is low Remote Control Battery is low or the Drive Control Interlock proximity and EAS inclinometer sensors is not plugged in properly The green LED flashes whenever comms is successful to either the Hoist or the Drive Controller The blue LED flashes as the current meter signal is operating and comes on steady 1f the ground feeler detect shorts the current meter signal See Appendix E Menu Navigation The menu navigation is performed by rotating the Scroll Menu knob clockwise and anticlockwise Pressing the same knob allows the operator to select options etc See the section on navigating the menus for a full description LCD Backlight The LCD has backlighting which can be always OFF always ON or on for several seconds when anything is touched The LCD backlighting option can be changed in the Remote menu When communicating with a standard Hornet all reference to vertical distance airline wetline corrected depth hoist cable angle and current meter count is automatically rem
27. e space DISCONNECT power to the Drive Control Box until Hoist is fully set up Attach the supplied 12V power leads to the 40Ah batteries Place batteries in boxes and attach the Manual Winch in the order explained below Page 19 IMPORTANT Place battery opposite from where winch goes first securing the latch then attach winch and last attach battery above the winch as per manual This keeps balance and helps maintain safety Feed Manual Winch Cable through the hole in the Traveler Block plate ensuring the cable is aligned in the brass roller Lower the Manual Winch Cable and attach to the Hoist Page 20 IMPORTANT Check that there are no signs of fraying on the winch cable prior to raising Raise and secure Hoist antenna Page 20 Lift Hornet Hoist and secure to Traveler Block using pin and R clip Page 21 Connect power from both batteries to the Hoist using the red anderson plugs Attach Drive Control Interlock to the top of the main cable Page 22 IMPORTANT Box must be parallel with the main cable to ensure correct angle measurement Plug the Drive Control Interlock into the Drive Control Box using mil spec connector Attach the antenna to the Drive Control Box Assemble gauging equipment including the current meter to the hanger bar Attach the GFD to the top of the hanger bar Turn on Hoist using blue push button Page 23 Turn on Remote Control Page 23 Using the remote control lower the Hornet Hoist cable to re
28. em Copyright Page 61 Issue 1 9 23 Sep 15
29. f 26 different frequencies and press the knob again to save the selected frequency and issue a request to the Hoist and Drive Control electronics to Hornet Plus Cableway Gauging System Copyright Page 34 Issue 1 9 23 Sep 15 Hyquest Solutions Pty Ltd change their frequency as well The communications will continue seamlessly at the new frequency If for some reason there is no communications between the Remote Control and either the Hoist or Drive Control then simply return to the last frequency used or step through select and save each of the 26 different frequencies one at a time until it picks up communications again and then step to the new required frequency 4 3 8 4 Return to Remote Press the menu scroll button to return to the Remote Menu RETURN TO REMOTE 4 3 9 Alarms This menu is the entry point to view the Alarm Status NOTE If the red LED is on then it will be due to one of the following alarms information Communications battery voltages and Drive Control Interlock status Rotate the menu scroll knob to step to the Return to Main Display menu or press the menu scroll knob to view the Alarm Status 4 3 9 1 Communication Status This menu displays the present communication status of the Hoist Comms OK Hoist and the Drive Control Note that 2 consecutive missed Drive Comms OK communication polls is classed as a communication fault 4 3 9 2 Battery Voltage Status
30. g operation Note A current meter cable is supplied with the Ground Feeler Device GFD so it can be connected to the operator s current meter The customer must specify the lead type when ordering the GFD GFD02 AA for AA type current meters GFD02 RB for Redback type current meters GFD02 UNI for Universal Type Current Meters OSS BI OTT C31 een GFD02 RB GFD02 UNI Current Meter Cable When the gauging weight contacts the streambed the GFD causes the current meter signal to short circuit The blue led on the remote control with software version 1 5 or above will turn ON there will be no signal received from the current meter This indicates that the gauging weight is in contact with the streambed Once the weight is raised slightly off the streambed the blue led will turn OFF and normal current meter signal operation will commence The GFD eliminates the need to observe the main cable movement on a cableway to determine if the gauging weight comes into contact with the streambed In situations where the distance is too far to observe the main cable movement or in a harsh weather conditions the GFD makes streambed sensing an easy and accurate procedure Hornet Plus Cableway Gauging System Copyright Page 52 Issue 1 9 23 Sep 15 Hyquest Solutions Pty Ltd Installation C1 Connector 1s attached to top section Angle Plug connects the amergraph cable to the Ground Feeler Device GROUND
31. h automatically compensates for water conductivity The top line of the LCD displays the status of the CMC Signal Processor as either OK Cal calibrating or Flt faulty The faulty condition may occur if there is a short circuit on the current meter contact input Press the menu scroll knob and the MagHd option will flash Rotate the menu scroll knob to select the CatsWhisker option and press the menu scroll knob again to save it When the menu scroll knob is pressed again the Nrm Normal mode option will flash Rotate the menu scroll knob to select Slo Slow mode and press the menu scroll knob again to save it The most common option is MagHd Nrm See the current meter section for more details Hornet Plus Cableway Gauging System Copyright Page 32 Issue 1 9 23 Sep 15 Hyquest Solutions Pty Ltd 4 3 6 3 Hoist Comms and Battery Voltage The top line of the LCD displays the Hoist Comms status and the bottom line displays the Hoist battery voltage BV 12 7V Hoist Rotate the menu scroll knob to step to the next Hoist menu 4 3 6 4 Hoist S W Rev The top line of the LCD displays the Hoist Software Revision S W Rev 1 20 This allows us to check compatibility without opening up any equipment A after the software revision means you are communicating with a Hornet Plus hoist 4 3 6 5 Return to Hoist Press the menu scroll button to return to the Hoist Menu RETURN TO HOIST 4 3 7 Drive Control DRIVE CONTROL
32. he Hoist to the bottom of the Weight and Set Main Cable to Weight Distance 3 Measure the distance from the bottom of the Weight back up to the center line of the current meter and Set Offset from Weight to Meter 4 Position the carriage and then Set the Waters Edge 5 Position the weight just above the water and Set at Water Level 4 3 4 1 Set at Water Level Hornet Plus Only This zero function appears first because it is the most commonly SET AT WATER used when taking measurements at each vertical Position the weight so that it is just above the water level Note the Z on the right hand side of the display is to prompt you to press the blue Zero button to zero the water level Any measurement below this level will be Wetline or Corrected depth and anything above this point will be Airline See the sketch on the previous page 4 3 4 2 Set Waters Edge Hornet and Hornet Plus Position the weight so that it is just above the closest waters edge SET WATERS Press the blue Zero button This will zero the horizontal distance EDGE counter so the river width can be measured 4 3 4 3 Set Main Cable to Weight Distance Hornet Plus only This function sets a reference point for the vertical distance SET MAIN CABLE l measurement Press the blue Zero button The HoistHt 0 65m will flash this is the distance from the main cable to the bottom of the hoist If a carriage extension 1s used this distance wil
33. hould only be done when absolutely necessary Press the menu scroll knob and the En or Dis will start flashing Rotate the menu scroll knob to select the desired option and press the menu scroll knob again to save the selection Hornet Plus Cableway Gauging System Copyright Page 33 Issue 1 9 23 Sep 15 Hyquest Solutions Pty Ltd 4 3 7 3 Drive Control S W Rev The top line of the LCD displays the Drive Control Software S W Rev 1 00 Revision This allows us to check compatibility without opening up any equipment S 4 3 7 4 Return to Drive Control Press the menu scroll button to return to the Drive Control Menu RETURN TO DRIVE CONTROL 4 3 8 Remote This menu is the entry point to view the Remote Control information Battery Voltage Charging Status S W Rev and change Remote Control parameters Backlighting Sounder Units Operating Frequency Rotate the menu scroll knob to step to the Alarms menu or press the menu scroll knob to view Remote Control information 4 3 8 1 Remote S W Rev and Battery Voltage The top line of the LCD displays the Remote Control Software Hornet Plus V170 U Revision and the bottom line displays the voltage of the batteries BV 3 8V Remote inside the Remote Control 4 3 8 2 Remote Sounder Backlight and Units 7 The top line of the LCD displays the present state of the Sounder Sndr En B L 3Sec Enabled or Disabled and the present state of the Backlight Units m Rem
34. iage with the locking pin and spring clip Raise the Hoist aerial connect the batteries and turn on the Hoist Fit the weight and current meter onto the Hoist Hornet Plus only Measure the distance from the bottom of the Hoist to the bottom of the weight and set the Main cable to weight distance See 4 3 3 3 sets a vertical reference Hornet Plus only Zero the Hoist angle See 4 3 3 4 Hornet Plus only Fix the Drive Control Interlock onto the main cable and plug it in Apply generator power to the Drive Control Position the weight and Set the Waters Edge See 4 3 3 2 sets a horizontal reference Traverse to where vertical measurements will be taken lower the weight and Set the Water Level See 4 3 3 1 Hornet Plus only Lower the weight and read the corrected water depth Hornet Plus only Perform gauging on this vertical and go to step 10 When using the Hornet Hornet Plus with an ADCP only the horizontal distance is important Therefore omit steps 5 6 10 11 and 12 Hornet Plus Cableway Gauging System Copyright Page 36 Issue 1 9 23 Sep 15 Hyquest Solutions Pty Ltd 45 The Hoist Under the hoist there is a push on push off type power switch Push it and the blue LED under the hoist indicates power is on There are 2 x 50A Fuses inside the Hoist The hoist cable has a conical device clamped near the end of the cable As the hoist cable is almost completely wound in the conical
35. installation is required Hornet Plus Cableway Gauging System Copyright Page 4 Issue 1 9 23 Sep 15 Hyquest Solutions Pty Ltd 3 2 Installing the Controller amp Motor Drive Note This paragraph applies to the three options of installation indicated in this manual The four bolts used to mount the Motor assembly to the enclosure are removed The top 2 bolts and nuts will be re used when mounting the Controller amp Motor Drive to the Bracket The 2 bottom bolts are replaced by the studs on the bracket and the nuts are re used 2 Counter sunk screws used to keep Motor Drive attached to the enclosure while mounting controller amp motor drive to the bracket A Frame Option 1 Typical A Frame installation Mounting Bolt the Motor Drive Assembly to the A Frame using supplied bolts washers and nuts Optional Custom bracket required for installing the Motor Drive Hornet Plus Cableway Gauging System Copyright Page 5 Issue 1 9 23 Sep 15 Hyquest Solutions Pty Ltd a Use the 2 Studs to locate the Controller amp Motor Drive Assembly in position b Use the 2 nuts to tighten the Controller amp Motor Drive Assembly to the Bracket Hornet Plus Cableway Gauging System Copyright Page 6 Studs used to facilitate the installation of the Controller amp Motor Drive to the Bracket c Use the 2 top bolts amp nuts to tighten the Con
36. its own would not stop the hoist upward operation fast enough to prevent damage therefore additional protection has been added The hoist remembers the position of the drum when power is switched on and it will only drive upwards slowly from that position So if the Hoist power is turned on while the lifting cable is extended it will only drive slowly from that position upwards If this issue is a problem drive the hoist upwards and when close to the fully up position cycle the hoist power Sample Depth When the Sampler is being lowered to the preset Sample Depth the speed and cable angle is monitored continually and the Sampler is commanded to stop so that it actually stops at the Sample Depth by using a predictive algorithm This has been tested and the Sampler stops within 20mm 0 02m 0 08ft of the preset Sample Depth no matter what speed is selected Hornet Plus Cableway Gauging System Copyright Page 59 Issue 1 9 23 Sep 15 Hyquest Solutions Pty Ltd Appendix H Far Side Installation Guide Main Cable 105 Operating Side amp Far Side Distance Between Main Cable amp Centre of Sheave Block Back Plate NOTE THE ABOVE DRAWING IS ONLY APPLICABLE IF THE POST HEADS FOR BOTH FAR SIDE AND OPERATING SIDE ARE SUPPLIED BY HYQUEST SOLUTIONS Hornet Plus Cableway Gauging System Copyright Page 60 Issue 1 9 23 Sep 15 Hyquest Solutions Pty Ltd eu TOM SIDE _ Hornet Plus Cableway Gauging Syst
37. l be 0 95m so rotate the menu scroll HoistHt Weight knob to toggle between Oom 082m these two values Press the menu scroll knob and the Weight 0 82m will flash this is the distance from the bottom of the Hoist to the bottom of the Weight Measure this distance and then rotate the menu scroll knob until the measured value is displayed now press the menu scroll knob to complete setting the reference height HoistHt 0 65m Weight 0 82m Hornet Plus Cableway Gauging System Copyright Page 30 Issue 1 9 23 Sep 15 Hyquest Solutions Pty Ltd 4 3 4 4 Set Offset from Weight to Meter Hornet Plus only This function sets the offset from the bottom of the weight back up SET OFFSET FRO to the center of the current meter Press the blue Zero button and the aia TO METER Offset 0 32m will flash measure this distance i then CaN Oler rotate the menu 0 32 m scroll knob until the measured value is displayed now press the menu scroll knob to complete setting the offset Setting this value allows the direct reading of the depth to the current meter see section 4 3 1 to see how and where the depth to the current meter is read Weight 4 3 4 5 Zero the Hoist Angle Hornet Plus only The size of the weight hanging from the Hoist will determine the initial angle that the Hoist settles to After hanging the weight from the Hoist Zero the Hoist Angle so that a reference point is
38. layed as The Drive Control makes all horizontal measurements and respective angles and the Hoist makes all vertical measurements and respective angles Hornet Plus Cableway Gauging System Copyright Page 27 Issue 1 9 23 Sep 15 Hyquest Solutions Pty Ltd 4 3 1 Main Display The top line on the display shows the horizontal distance traversed from the Waters Edge note the arrow pointing horizontally and the Drive Control Speed which 1s set with the Speed Control knob The bottom line shows the vertical water depth to the bottom of the weight corrected depth note the arrow pointing vertically that touches the horizontal line at the bottom and the depth to the center of the current meter note the arrow pointing vertically that doesn t quite touch the horizontal line at the bottom these only appear on a Hornet Plus Waters IMPORTANT Use the 99 Edge depth to the current meter W Lcos 90 when recording water velocity measurements for your gauging River cross section Calculating the horizontal distance W Corresponding symbols on Depth to Water Line Water Flow Depth to current bottom of meter weight Current Meter Offset Depth s displayed on LCD See section 4 3 4 4 to see how the Offset is set Rotate the Menu Scroll knob to move to the Air Wetline or Sig BattV or More display Press the Menu Scroll knob to
39. lease tension on the Cl Connector and remove from securing spring Page 23 While pulling down on the Hoist cable use the remote control to lower the C1 connector to the GFD and secure using the pin and R clip Hornet Plus Cableway Gauging System Copyright Page 42 Issue 1 9 23 Sep 15 Hyquest Solutions Pty Ltd 18 Attach angle plug to the GFD and secure with clamp Page 53 55 19 Raise the gauging weight slightly off the ground to assure that the GFD is in its open position 20 Power up the Drive Control Box a Open both doors on the Drive Control Box while operating the Hornet Plus system b Plug in portable generator to Drive Control Box c Turn the generator on Once the generator is supplying power the Drive Control Box will be operational 21 Using the Remote Control a Page 24 amp 25 outline the features of the Remote Control b Turn Remote Control on using blue power button if it 1s not already turned on c Connect current meter counter to Remote Control Spin the fan and the counter should register the pulses The blue light on the Remote control will also light up with each revolution Set Main Cable to Weight distance Page 30 4 3 4 3 Set Offset from weight to meter Page 31 4 3 4 4 f Zero the Hoist Angle Page 31 4 3 4 5 o 2 22 Conduct gauging as normal to local standards Hornet Plus Cableway Gauging System Copyright Page 43 Issue 1 9 23 Sep 15 Hyquest Solutions Pty Ltd Appendi
40. lock Traveller Block Installation 140mm 5 5inches from the top of the cable to the top of the endless cable for post heads supplied by Hyquest Solutions or existing A Frame Install Traveller Block on Main cable taking into consideration which side you want the manual Winch to be installed ensure the crank handle is on the Drive Control box side This side of the Traveller Block is where the Manual Winch will be installed This side of the Traveller Block is opposite to where the Manual Winch will be installed Traveller Block Hornet Plus Cableway Gauging System Copyright Page 10 Issue 1 9 23 Sep 15 Hyquest Solutions Pty Ltd Battery Mounting Box Installation This Battery box is This Battery box is installed opposite to gt installed where the where the Manual Winch i Manual Winch will be will be installed installed Note The same method is used to mount the battery box on the opposite side of the traveller block Hornet Plus Cableway Gauging System Copyright Page 11 Issue 1 9 23 Sep 15 Hyquest Solutions Pty Ltd 3 5 Installing the Traversing Cable Traversing Cable Installation Please note the traversing cable is not a part of the Hornet Hornet Plus standard kit but it can be ordered separately from Hyquest Solutions Caution Do not cut the traversing cable even thought you know the distance required The cable is cut at the final step which will
41. ng at the same time The transmitter power 1s 15dBm which is equivalent to only 32mW This provides a line of sight range of about 1km NiMh Battery Charging The handle of the Remote Control has provision for charging the internal NiMh batteries that power the Remote Control A mains power plug pack is provided but a vehicle cigarette lighter adapter could also be used The voltage required is 12VDC with a capacity of 1A A 9VDC to 18VDC plug pack can be used The connector is a DC Power 2 1mm connector with center pin ve The charging socket is polarity protected If the Remote Control is off when the charging plug is inserted the Remote Control will automatically turn on and indicate it is charging by scrolling the Remote battery indicator The batteries will be initially fast charged at about 500mA and when fully charged drop back to a trickle charge so there is no problem with leaving it plugged in for extended periods In an emergency you can use 3 x AA Alkaline batteries to power the Remote Control Simply remove the 4 screws that secure the front panel of the Remote Control then remove the lower screw on the strap over the 3 batteries and rotate the strap out of the way Replace the 3 x NiMh batteries with 3 x alkaline batteries and re assemble the Remote Control 1 NOTE Do not attempt to charge while alkaline batteries are installed Hornet Plus Cableway Gauging System Copyright Page 26 Issue 1 9
42. ngle of drift measurement to 45 Ground Feeler Device to detect river bed Automatically stops downward motion when cable tension 1s lost The Sediment Sampler Hoist can therefore be used with e an ADCP or e a mechanical current meter and Columbus weight up to 45kg 100 Ib or e a Depth Integrating Sediment Sampler A special Sediment Sampling function has been built into the Remote Control that allows the operator to dial in the depth where the sample is to be taken and set the vertical speed of the sampler The operator then simply holds the Lower button and the sampler lowers to the preset depth stops reverses direction rises back up and stops at the starting position indicating on the display that the Sample is complete Very Important Please make sure that 2 x 24V DC batteries are used on the Sediment Sampling Hoist The Power on off button for the Sediment Sampler Hoist is on the on the side of the Hoist Simply press the black button and the blue light next to the button will turn on When the Remote Control communicates with any Hoist it automatically detects if it is a Hornet Hornet Plus or Sediment Sampler and enables the appropriate menus on the LCD Hornet Plus Cableway Gauging System Copyright Page 56 Issue 1 9 23 Sep 15 Hyquest Solutions Pty Ltd Sediment Sample Sequence Step 1 Preparation Note The operation of the Hoist throughout Step 1 is the same as a Hornet Plu
43. on and the display will show SampleWaterDepth with the depth flashing Rotate the Scroll Menu knob to set the required depth You need to set the depth slightly less than the actual water depth approx 0 3m or 1ft so the sediment sampler doesn t hit the river bed Rotating the knob fast will cause the numbers to jump farther so a larger depth can be reached quicker rotating the knob slower will cause the numbers to jump smaller so you can select the exact depth SCROLI MENI ER ISE e Press the Scroll Menu knob to lock in the depth The display will show Water re 15 Depth for Sample is Set and then it O sou N will display Hold Lower to Start rw d as i o O jai Sample The Hornet system is now in Sample Mode indicated by the blue LED flashing once a second RAISE e Please note Once in Sample Mode pressing Fwd Rev or Raise will abort the mode You must return to Set Water Depth and Sample again to prepare for a new sample e Now that Sample Mode is entered and the blue LED is flashing simply press and HOLD the Lower button The blue LED will flash faster and the Hoist will start lowering the Sampler at the selected speed Sample Sample LOWER Start Finish a Cc gt gt gt Hornet Plus Cableway Gauging System Copyright Page 58 Issue 1 9 23 Sep 15 Keep the Lower button held during the com
44. ote Always Off On for 1 Sec 2 Sec 9 Sec after a control is touched or always On The bottom line of the LCD displays the state of the system Units either meters or feet These options can be changed as follows Press the menu scroll knob and the sounder En will flash rotate the knob to change the selection and press the knob again to save the selection When the menu scroll knob is pressed again the backlight option will flash rotate the menu scroll knob to change the selection and press the knob to save the selection When the menu scroll knob is pressed for a third time the units m will flash rotate the knob to change the selection and press again to save the selection 4 3 8 3 Communication Frequency and Charger Status The top line of the LCD displays the present communication Frq 921 5MHz Au frequency selected 902 5MHz to 914 5MHz is license free in the US and 915 5MHz to 927 5MHz is license free in Australia and the bottom line of the LCD displays the Charger status either Off On or trickle charge NOTE Before changing the communication frequency make sure that both the Hoist and Drive Control are powered on and communicating properly When the Frequency is changed on the Remote Control it automatically updates it in the Hoist and Drive Control electronics When then menu scroll knob is pressed the frequency 921 5 and the Aus will flash rotate the knob to change to one o
45. ote Control battery voltage This is a new feature in Remote Control S W Rev 1 6 and above Hoist Y 4 H 12 7v The RF signal strength is represented as a triangle that gets larger as Drive Y 4R 3 6v the signal increases in a similar way as your mobile phone Since you are usually very close to the Motor Drive the RF signal strength should usually be very high As the Hoist moves away from you as it traverses the river the corresponding RF signal strength will reduce The Hoist battery symbol looks like a terminal style battery and the Remote Control battery looks like an AA style battery The symbols become less filled in as the battery capacity depletes the voltage 1s also displayed Rotate the Menu Scroll knob to move to the Main or Air Wetline or More display Press the Menu Scroll knob to select commonly used Zero functions Hornet Plus Cableway Gauging System Copyright Page 29 Issue 1 9 23 Sep 15 Hyquest Solutions Pty Ltd 4 3 4 Zero Functions The zero functions are selected by pressing the Menu Scroll knob while in the Main Display or the Airline Wetline Display These allow reference points to be entered for horizontal and vertical measurements Rotate the Menu Scroll knob to step through the various functions During a gauging session the Zeros would be performed in the following order 1 Hang the weight on the Hoist and Zero the Hoist Angle 2 Measure the distance from t
46. oved from the Remote Control LCD menus this is because these features are only present on a Hornet Plus Hornet Plus Cableway Gauging System Copyright Page 25 Issue 1 9 23 Sep 15 Hyquest Solutions Pty Ltd Sounder The remote control has an inbuilt sounder which beeps when the current meter input is pulsing The sounder function can be turned off in the Remote menu Current Meter Input and Output A current meter can be plugged into the Hoist and the contact closure information is transmitted to the remote control which has an output that can be connected to your favorite Current Meter Counter The current meter input on the Hoist accepts both Mag Head and Cats Whisker type meter inputs and performs signal processor filtering on the input to ensure that clean data is transmitted to the remote control unit The type of meter is selectable from the Hoist menu Operating Frequency The Hornet Hornet Plus components communicate to each other in the 915MHz band which is the ISM Industrial Scientific and Medical license free band There are 26 channels available which can be user selected at any time The frequencies used are 902 5MHz through to 914 5MHz in the USA with a 1MHz channel spacing and 915 5MHz to 927 5 MHz in Australia with a 1MHz channel spacing The only requirement when changing frequencies is that all 3 components Remote Control Hoist Drive Control must be turned on and communicati
47. plete sample sequence Hyquest Solutions Pty Ltd As shown diagrammatically on the previous page the Sampler will lower to the preset depth stop reverse direction rise to the starting position and stop The LCD will display the message End of Sample and the blue LED will stop flashing Keep the Lower button held during the complete sample sequence PLEASE NOTE The Sample sequence will Abort if e the Lower button is released during the sequence e the Sampler hits the river bed and the Cable Tension alarm occurs See Appendix F e the Fwd or Rev button is pressed Speed Control The one speed knob is used to control the horizontal and vertical speed When the Fwd or Rev button is pressed the speed displayed is the horizontal speed and a horizontal arrow will appear after the speed When the Raise or Lower button is pressed the speed displayed is the vertical speed and a vertical arrow will appear after the speed as shown The units m s or f s can be set in the More Remote set of menus All of the Hornet family Hoists have limit switches to stop the upward operation at the end of the cable to prevent damage The Hornet and Hornet Plus Hoists operate relatively slowly and so the limit switch on its own 1s sufficient However the Hornet Sediment Sampler with hoist speed adjustment can operate very fast and the limit switch on
48. power is switched on and it will only drive upwards slowly from that position So if the Hoist power is turned on while the lifting cable is extended it will only drive slowly from that position upwards To fix this problem drive the hoist upwards and when close to the fully up position cycle the hoist power c Can the SLA batteries on the carriage be mounted on their side 1 Yes sealed lead acid batteries can be used upright or on their side but should not be operated upside down If in doubt consult the battery manufacturer datasheet 1 When fitting the batteries to the carriage battery box ensure there is sufficient clearance between the battery terminals and the battery box itself fit rubber or plastic insulation 1f the clearance is tight d The Hoist bottom detect ground feeler doesn t appear to work properly i Remove the Angle plug from the ground feeler device and the current meter and touch the plug connector onto the outside of the amergraph cable this should turn on the blue LED the same as the ground feeler operating or the current meter turning Try turning the Hoist off and on again and retry ii Remove the Angle plug from the ground feeler device and try the Current Meter on its own to see 1f it generates pulses to see if it flashes the Remote Control blue LED Note that 1f the current meter isn t rotating and the internal Hornet Plus Cableway Gauging System Copyright Page 46
49. ress to select options www hydrologicalservices com AJ_AKM X ge LEDs Traveller Block Hoist Control Toggle Switch Toggle Switch Red indicates an error Forward amp Reverse Raise amp Lower Green flashes while communicating Direction Blue flashes when current meter op The Remote Control is the brains of the system Radio communication messages are initiated from the Remote Control to both the Hoist and the Drive Controller Remote Control Drive Control Hornet Plus Cableway Gauging System Copyright Page 24 Issue 1 9 23 Sep 15 Hyquest Solutions Pty Ltd 4 2 Brief Description of Controls Power Zero Press and hold the blue button to turn on the Remote Control wait until the pes LCD comes on When the Remote Control is on press and hold the blue button to turn off the Remote Control When a zero is required the user will be prompted to press the zero button with a Z and a down arrow symbol on the lower RHS of the LCD Speed The speed control knob sets the drive motor speed that controls the carriage movement When using an ADCP it is important to traverse the water at a constant speed The speed is displayed on the main menu in either m s or ft s depending on the units selected in the Remote menu Fwd Rev The Fwd Rev toggle switch controls the carriage movement via radio communications If there is any problem the cause will b
50. rod in parallel with the drum and updating the hoist software version to 1 5 Note any version above 1 5 will include this feature This rod is insulated from the hoist body and connected to a wire that is monitored by the hoist control box When the Gauging Weight touches the streambed the front layer of the cable on the drum will become loose and touch the rod this causes the rod signal monitored by the control box to change state and instantly stop the winch motor from feeding out more cable and displaying a message on the LCD Cable Tension This function assists in keeping the cable firmly wound onto the drum Rod parallel to Drum Wire connected to Hoist control box Hoist control box Hornet Plus Cableway Gauging System Copyright Page 55 Issue 1 9 23 Sep 15 Hyquest Solutions Pty Ltd Appendix G Sediment Sampler Hoist The Sediment Sampler Hoist has the following features e Variable speed raising and lowering 0 01m s to 0 73m s 0 02ft s to 2 39ft sec Precise constant speed provides accurate sampling e Automatically lowers to exact preset depth and rises back to the surface eliminating sampler clogging if accidentally lowered into the river bed Power driven sheave and grooved drum to ensure cable lays evenly Maximum lift capacity 45kg 100 Ib 2 x 24V 20Ah batteries required 40m of Amergraph cable Current Meter Signal Processing Depth measurement 0 01m 0 01 ft resolution A
51. s e Based on your site work out the location where samples will be taken eg A B and C Fit a Ground Feeler Device and a Depth Integrating Sediment Sampler or a Columbus Weight Locate and Set Waters Edge Move to location A and record the distance W1 See Page 30 Lower the weight to the water s surface and Set at Water Level See Page 30 Lower the weight to the river bed and the Ground Feeler will operate turning on the blue LED record the depth D1 e Repeat for locations B and C Waters WI Edge W2 W3 A op 4 PLE You will now have built up a table as follows Sample Distance Depth Vertical Sample Details W D Sample m m Speed pA 12 37 es B 2725 292 o C 734 92 wG y Hornet Plus Cableway Gauging System Copyright Page 57 Issue 1 9 23 Sep 15 Hyquest Solutions Pty Ltd Step 2 Sampling e With sample bottle installed fit the Sediment Sampler to the Hoist and move horizontally to location A W1 e Lower the Sampler to just above the water s surface e Set the required vertical speed of the sample by adjusting the speed knob and reading the vertical speed on the LCD Note the down arrow after the speed indicating that this is the vertical speed e Perform a Set at Water Level see page 30 e Press the Scroll Menu knob and rotate to select Set Water Depth and Sample e Press the Zero butt
52. s the pulley from rotating when the motor is stationary A manual brake lever provides an over ride mechanism The Drive Controller is mounted in a stainless steel enclosure The Drive Interlock is a black box that is mounted on the main cable This device has 2 functions to monitor the position of the Hoist carriage and to measure the angle of the main cable Make sure that the This Way Up indicator is pointing up and that the two lower mounting bolts are both in contact with the main cable This ensures that the internal inclinometer can accurately measure the angle of the main cable When the carriage comes within about 0 5m the Drive Control motor is shutdown preventing the carriage the pulley and personnel from being damaged Simply plug the mains output from a portable generator into the bottom of the Drive Control stainless enclosure and start the generator Hornet Plus Cableway Gauging System Copyright Page 38 Issue 1 9 23 Sep 15 Hyquest Solutions Pty Ltd 5 Specifications Drive Controller Enclosure Stainless Steel 600 x 600 x 300 mm 24 x 24 x 12 Power Requirements 0 8KW 110 VAC 240 VAC 2 separate models 1000 Watt Generator or Mains Power Overload Capacity 150 for 60 Sec Interlock Ultrasonic proximity set to 1 3m Inclinometer 45 measurement Electric Motor Motor Body IP65 Geared Motor Speed Drives carriage up to 1 m s 3 2 ft s Distance Measurement 0 01m 0 01 ft resolution
53. select commonly used Zero functions Hornet Plus Cableway Gauging System Copyright Page 28 Issue 1 9 23 Sep 15 Hyquest Solutions Pty Ltd 4 3 2 Airline Wetline Corrected Depth Display Hornet Plus only The top line shows the Airline that is the length of cable that is in the air and the Wetline that is the length of cable that is under the water The bottom line shows the corrected depth that 1s the vertical depth under the water and the cable angle Note that these measurements are dynamic they are continuously calculated If the angle changes then the airline wetline and corrected depth are all recalculated Note that the corrected depth takes into account the cable curve under the water All measurements are to the bottom of the weight Main s NOTE The Corrected Depth is Cable See Appendix D for calculated in accordance with the Airline more information USGS Measurement and Computation of Stream Flow Vol 1 Water Supply Paper 2175 Wetline A 3 75 W 2 53m CTD 2 51m 5 5 Water Flow O Corrected Depth Calculating the corrected depth Rotate the Menu Scroll knob to move to the Main or Sig BattV or More display Press the Menu Scroll knob to select commonly used Zero functions 4 3 3 Signal Strength and Battery Voltage The top line shows the Hoist RF signal strength and the Hoist battery voltage and the bottom line shows the Motor Drive RF signal strength and the Rem
54. stance as the currents flowing from the electronics can upset the multimeter resistance reading 1 With the red wire disconnected measure the resistance between the amergraph shield and the centre wire It should be open circuit in the Meg ohms otherwise you need to find where the short circuit is It is most likely in the Amergraph angle plug connector 2 With the red wire still disconnected check the resistance between the Amergraph connector centre pin and the brush housing This should be low resistance approx lt 10 ohm If it is open circuit the problem could be the Amergraph angle plug connector or the slip ring brush If you suspect the brush go to step 4 3 Remove the slip ring brush by undoing the bolt as shown and Hornet Plus Cableway Gauging System Copyright Page 49 Issue 1 9 23 Sep 15 Hyquest Solutions Pty Ltd 4 Extract the brush and spring Make sure the spring is not bent or distorted and the brush slides smoothly in the housing You can do a visual check that the brush touches the slip ring and makes proper contact Go back and repeat step 2 until the circuit is OK 5 To test the shield continuity set the multimeter to resistance and measure different parts of the same circuit to isolate a problem referring to the signal path list Eg From the drum to the black wire J5 shown or from the drum to the securing bolt washer Hornet Plus Cableway Gauging System
55. troller amp Motor Drive Firmly to the Bracket Issue 1 9 23 Sep 15 Hyquest Solutions Pty Ltd Option 2 Typical installation to an existing HS Post Head a Use the 2 Studs to locate the Controller amp Motor Drive Assembly in position menant c Use the 2 top bolts amp nuts to tighten the Controller amp Motor Drive Firmly to the Bracket b Use the 2 nuts to tighten the Controller amp Motor Drive Assembly to the Bracket Hornet Plus Cableway Gauging System Copyright Page 7 Issue 1 9 23 Sep 15 Hyquest Solutions Pty Ltd Option 3 Typical installation to a new HS Post Head a Use the 2 Studs to locate the Controller amp Motor Drive Assembly in position c Use the 2 top bolts amp nuts b Use the 2 nuts to to tighten the Controller amp tighten the Controller amp Motor Drive Firmly to the Motor Drive Assembly to Bracket the Bracket 3 3 Installing the Far Side Typical Far Side Installation for an A frame Optional Custom Bracket Tighten the supplied bolts as shown Hornet Plus Cableway Gauging System Copyright Page 8 Issue 1 9 23 Sep 15 Hyquest Solutions Pty Ltd Typical Far Side Installation to an existing HS Head Tighten the supplied bolts and Nuts as shown Hornet Plus Cableway Gauging System Copyright Page 9 Issue 1 9 23 Sep 15 Hyquest Solutions Pty Ltd 3 4 Installing the Traveller B
56. x C Troubleshooting Guide 1 Remote Control a Remote not communicating with Hoist or Drive Control Box Turn on both the Hoist and the Drive Control cabinet On the Remote Control navigate to the Remote menu that displays the operating frequency Press the Select button 1 If S W Rev 2 4 or above is installed and either the Hoist or Drive Control is not communicating it will display the message To Srch gt Press z When the blue Zero button is pressed the Remote Control will search through all 26 frequencies 3 times to find the Hoist and Drive Control If they are found it will tell them to change to the selected frequency If they are not found the Remote Control will just operate at the selected frequency 11 If the S W Rev is below Rev 2 4 you will need to Scroll to the first frequency and press the Select button If the Hoist and or Drive Control are found they will start communicating If they are not found press the Select button again and Scroll to the next frequency Repeat this process until the Hoist and Drive Control start communicating b Remote Control LCD not operating properly and cannot navigate menus 1 Make sure the Remote Control NiMH batteries are fully charged or replace them temporarily with 3 x 1 5V AA alkaline batteries DO NOT plug the charger into the Remote Control while alkaline batteries are installed 1 Remove the Remote Control front cover remove the 4 x corner screws and

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