Data Sheet

Sonar Interface
Sludge Level Monitoring
Principle of Operations
The ORCA Sonar Series transducer emits a high powered
acoustic pulse, which is refected from the interface density
selected. The refected signal is processed using specially
developed software algorithms, that eliminate lighter foating
densities and stratifed layers, allowing measurement of
RAS or BED levels. It can be calibrated to measure lighter
densities like FLOC or one of the outputs could be used for
a CLARITY output, similar to a basic turbidity transmitter
measuring solids in suspension.
By choosing the correct sonar transducer frequency, the Orca
sonar guarantees the optimized performance when measuring
both light and heavy density interfaces.
Primary Areas of Applications
Sewage & Wastewater
Primary Sedimentation Blanket level.
Secondary and fnal Clarifers RAS Blanket and fuff/pin
foc layer.
Thickeners and DAF Bed level and clarity of water.
Sequential Batch Reactors Blanket monitoring (foating
sonar).
Lagoons Bed sludge level.
Lamella Clarifer Bed level and foc level.
Mining / Process
Clarifers, thickeners, CCDs, settling ponds/lagoons, water
treatment, carbon columns.
Function
The ORCA Series Sonar, sludge blanket and interface control-
ler, consists of a microprocessor based transmitter, with easy
menu driven programming via keypad, PC combinations or GSM
modem, COMMS, GSM interface. The Orca controller works
together with appropriate sonar transducer and transducer
cleaning mechanism.

A higher level of performance

- Sonar Level System
Features:
Dual independent analogue
outputs to track two different
interfaces, or clarity
simultaneously, with the one sonar sensor
Full range of sonar transducers to optimize
detection of heavy and light density interfaces
Widest range of sonar frequencies to optimize
performance
Easy calibration to track specifc density interfaces,
eg: RAS blanket - 4g/l, foc/fuff layer - 1g/l
Industrial scum cleaning mechanisms, that do not
require maintenance
No wiper blade assemblies
Control room graphics of tanks and interfaces
Wide range of communications:
Devicenet, GosHawk, HART, Modbus, Profbus DP
Foundation Fieldbus and Profbus PA
CDMA/GSM remote support capability for calibra-
tion, commissioning or technical back-up
Relay alarms

2
Orca Sonar Series
Cutting Edge Sonar Technology
c. The resultant design decreased beam spread from 15 - 20
down to 6 degrees and 3 degrees depending on the array confgu-
ration and frequency of the transducers.
d. The ORCA sonar transducer range has now grown from 5 sonar
frequency transducers to 15 sonar transducers including 10 new
array transducers. Power increases of 300% to 600% over the
standard sonar transducer range are common.
Part number example:
Water/Wastewater Industrial/Mining Mining/Heavy Industrial
OSIRT002 OSIRT302 OSIRT702
Blanking distances and operating characteristics remain the same.
Narrow beam spread also allows for more fexible mounting pos-
sibilities.
Conclusion:
The multiple crystal array sonar transducer will allow the following
improved capability in Thickeners and CCDs when monitoring BED
level.
1. Greater penetration through the clarifer level.
2. Greater penetration through the free settling zone.
3. Penetration into the hindered settling zone dependent on
frequency and array choice.
4. The compacted zone can also be monitored using the second
analogue output or one of the communication options: Modbus,
Profbus PA, Profbus DP, Foundation Fieldbus, DeviceNet, HART
etc.
The ORCA sonar transmitter can monitor two (2) different densities
from one sonar transducer simultaneously. The range of capabilities
and applications has just increased for the upgraded ORCA sonar
range.
Technological Breakthrough for ORCA
Sonar Transducer Range
Hawk has released the fourth generation sonar array trans-
ducers, designed to increase the overall power, penetration and
calibration density range of thickeners and CCDs.
Hawk has recognized that when monitoring thickeners and
CCDs, further penetration of the BED level interface was neces-
sary, to provide a wider density calibration range for the sonar
transmitter.
To achieve this both physics (frequency of transducer) and
mechanical design (multiple crystals in array patterns) were
employed to increase penetration power and decrease beam
spread by reducing beam angle of the sonar transducer.
a. The power of the sonar transducer is directly related to the
operating frequency (wave length). Lower frequencies have more
power but increase the beam spread (increase beam angle)
b. Penetration is improved by reducing beam angle, which
requires a larger transducer diaphragm. (See attached below) Ul-
trasonic-beam spread. Economically it is not feasible to produce
ceramic crystals and transducers with large diameters in small
quantities. Hawk mechanically overcome this by using multiple
crystals in an array pattern to duplicate a large diameter trans-
ducer characteristic.
Ultrasonic - Beam Spread
A round transducer produces a cylindrical sound feld in front
of the transducer. However, the energy in the beam does not
remain in a cylinder, but instead spreads out as it propagates
through the material. The phenomenon is usually referred to as
beam spread.
Beam spread for a fat piston source transducer is a function of
the transducer diameter (D), transducer frequency (F), and the
sound velocity (V) in the liquid or solid medium through which
the sound is travelling. This angle represents a measure from
the centre of the acoustic
axis to the point where the
sound pressure has de-
creased by one half (-6 dB)
to the side of the acoustic
axis.
3
Orca Sonar Series
3 Crystal Array
ORCA Sonar Sensor
7 Crystal Array
ORCA Sonar Sensor
Typical Bed Level Control Thickener, CCD, Clarifier
Green trend shows bed level (output 1)
Over 8hr period density is 10G/L
ORCA Sonar Transmitter provides 2 outputs
Bed Level Position (output 1) and
Clarity (output 2)
TME Clarity output is a 4-20mA output
proportional to the percentage of suspended
solids between the sonar sensor and the
Bed Level interface. This output could be
used in a PID Control of automatic floc
dosing.
REDTrend shows changes in
clarity over an 8hr period (output2)
Large spikes show major variations
in inflow media to the thickener.
FEEDWELL
Clearometer
White Trend
Clearometer
ORCA Sonar Transducer Option
CLARIFIED ZONE
FREE SETTLING ZONE
HINDERED ZONE
COMPACTED ZONE
Single Crystal Array
ORCA Sonar Sensor
Mounting Bracket and
Electro Actuator Cleaner
Copyright Hawk Measurement Systems 2009
Hawks ORCA Sonar Sensors
Sonar transducer penetration capability depending on power level.
Single crystal: PN Clarifer, clarifers, tailings dam
3 crystal array: Tailings thickeners, paste thickener, hi-rate thickener, CCDs
7 crystal array: Concentrate thickeners, CCDs
Mining Thickeners - choosing the correct transducer
Typically, the most diffcult task when wanting to determine
the level of an interface, lies in the correct selection of the
transducer frequency.
There are many other variables to consider. They include
particle size, fow, velocity, material, air bubble retention etc.
In general, the following should be undertaken:
It is recommended always to use an automated cleaner.
1. Identify a position away from direct infow, where turbulence
is minimized.
2. If air bubbles are present within heavy suspended solids,
use the scum cleaner.
3. Position sonar transducer 1/3 radius from circumference of
the tank away from the infuence of the feed well.
4. Submerge the face of the selected transducer by a minimum
of 20mm (0.79).
The higher the transducer frequency, the easier it becomes
to see smaller particle sizes. The disadvantage, is the lack of
penetration and a higher likelihood of air bubbles forming on the
sensor face, creating impedance to the transmit and received
signals.
Lower transducer frequencies will not see such small particles,
but will see a more clearly defned interface.
The frequency selection should be based upon the % solids,
plus a logical position for the placement of the sensor.
Please consult your local distributor for correct transducer
selection.
All sonar transducers will be affected by air bubble accumulation
on the sensor face. If the auto cleaner is used, the system will
operate to ensure accumulation of air bubble interface does not
cause operational problems.
Transducer Selection Guidelines
Transducer Selection Guide
4
Orca Sonar Series
Typical Applications
Area Functions
Water Treatment Plant
Primary Sedimentation Tank Floc level / sludge blanket level
Sludge Thickener Tank Sludge bed level / clarity suspended solids / foc level
Calcium Hydroxide Reactor Sand/pellet bed level
Sodium Hydroxide Reactor Sand/pellet bed level
Sewage Treatment Plant
Primary Sedimentation Tank Sludge blanket level
Secondary / Final Clarifer RAS blanket level / rag/pinfoc layer / clarity suspended solids
Sludge Thickener Tank Sludge bed level / clarity suspended solids
DAF Tank Sludge bed level / foating sludge level
Sequential Batch Reactor (SBR) Settling bed level / RAS blanket level
Industrial (food, paper etc.)
Primary Sedimentation Tank Sludge blanket level
Secondary Clarifer Tank RAS blanket level / clarity suspended solids / rag/pinfoc layer
Thickener Tank Sludge bed level / clarity suspended solids / foc level
DAF Tank Sludge bed level / foating sludge level
Sequential Batch Reactor (SBR) Settling blanket level / RAS bed level
Carbon Column Carbon bed level
Mining/Mineral processing
Clarifer Tank Blanket level / clarity suspended solids / stratifed foc layers
Thickener Tank Sludge bed level / clarity suspended solids / stratifed foc layers
CCDs Tank Sludge bed level / clarity suspended solids / stratifed foc layers
Settling Ponds Sludge bed level
Polymer Dosed Paste Thickener
Tailings Thickener
Paste Thickener
Secondary Clarifer
Primary Sedimentation
Gravity Thickener
ConcentrateThickener
SBR Tank
5
Orca Sonar Series
Primary Sedimentation
Dimensions
FLOATING SONAR SENSOR SONAR ACTUATOR CLEANER SONAR IMPACT PLATE
X - Pipe length to suit
* distance from safety rail or Bridge
may be varied
5
7
0
m
m

(
2
2
.
4

)
7
6
2
.
5
m
m

(
3
0

)
156* mm (6.1)
X
379.60mm (14.9)

5
7
0
m
m

(
2
2
.
4

)
7
6
2
.
5
m
m

(
3
0

)
156*mm (6.1)
423mm (16.6)
X
42.5
o
5
7
0
m
m

(
2
2
.
4

)
8
3
1
m
m

(
3
2
.
7

)
156*m (6.1)
512.6mm (20.1)
X
X
42.5
o
OSIRT Transducer
1" BSP Nipple
75mm (2.9)
OSIRT Fibreglass Transducer
1" BSP Nipple
75mm (2.9)
135 mm (5.3)
330mm (12.9)
= Decant Range
Note: Advise physical dimension of surface
scum rake.
6
Orca Sonar Series
Dimensions
REMOTE ENCLOSURE
BACK
FRONT
3 x 20mm, 1x16 mm
Knock outs
DIN Rail or screw mountable
SIDE
165mm (6.5)
190mm (7.5)
1
6
0
m
m

(
6
.
3

)
1
6
0
m
m

(
6
.
3

)
190mm (7.5)
145mm (5.7)
1
0
6
m
m

(
4
.
2

)
5
4
m
m

(
2
.
1

)
151mm (5.9)
107mm (4.2)
69mm (2.7)
Radio link option
RAIL BASE PLATE
4
.0
0
(
0
.1

)
2
8
.7
5
(
1
.1

)
2
9
.2
5
(
1
.1

)
4
1
.5
0
m
m
(
1
.6

)
2
0
(
0
.7

)
1
1
1
.5
0
m
m
(
4
.3

)
1 1 1 . 5 0 m m ( 4 . 3 )
8
.5
0
1
1
1
.5
0
m
(
4
.3

)
5
9
.2
5
m
m
(
2
.3

)
5
7
0
m
m
(
2
2
.4

)
1
9
.2
5
(
0
.7

)
1 9 . 2 5
( 0 . 7 )
1
0
0
.7
5
m
m
(
3
.9
)
2
x
5
m
m
(
0
.2

)
4
.2
5
(
0
.1

)
1 5 0 m m ( 5 . 9 )
1 1 1 . 5 0 m m ( 4 . 3 )
6 2 m m ( 2 . 4 )
5 m m
( 0 . 2 )
5 m m
( 0 . 2 )
1 9 . 2 5 ( 0 . 7 )
6
0
m
m
(
2
.3

)
2
1
1
.5
0
m
m
(
8
.3

)
5
1
m
m
(
2
.0

)
5
1
m
m
(
0
.2

)
5
m
m
(
0
.2

)
5
m
m
(
0
.2

)
RR
1
2
7
.5
0
m
m
(
5

)
1
3
1
.
5

m
m

(
5
.
2

)
7
.
5

m
m

(
0
.
3

)
192.5 mm (7.6)
1
4
1
.
5

m
m

(
5
.
6

)
1
9
0

m
m

(
7
.
5

)
182.5 mm (7.2)
147 mm (5.8)
1
6
7
.
5

m
m

(
6
.
6

)
147 mm (5.8)
3
0
.
7

m
m

(
1
.
2

)
158 mm (6.2)
14 mm (0.6)
74 mm (2.9)
78 mm (3.1)
1
0
7

m
m

(
4
.
2

)
111.5 mm (4.4)
4 mm (0.2)
50 mm (2)
1
0
8

m
m

(
4
.
3

)
1
9
0

m
m

(
7
.
5

)
174 mm (6.9)
192.5 mm (7.6)
182.5 mm (7.2)
7
Orca Sonar Series
Communication Network Overview
Modbus and Profbus
Laptop or PC Communications
or PLC / DCS with
MODBUS RTU Port
GosHawk Software for
inventory monitoring on PC
GSM Network
or
CDMA Network
Flotation Cells
Sultan Acoustic
Wave Transmitter
Slurries
Gladiator
Admittance
Switch
Sultan Acoustic Wave Transmitter
Silo, bin levels, coal, plastic powder,
woodchip, sawdust, cement,
clinker, iron ore, lime etc.
Orca Sonar Interface
Thickener, CCD
GSM or CDMA Network
Typically up to 31 transmitters or switches per string.
Maximum 250 transmitters or switches.
Using GSM/CDMA network, transmitters and switches can be
monitored, calibrated remotely.
Alarm status, diagnostics can be monitored.
Support from factory engineering for customer application problems.
Sultan Acoustic Wave Transmitter
Stockpiles, Stackers,
Reclaimers
Sultan Acoustic
Wave Switch
Blocked Chute Detection
Sultan, Gladiator & Guided Radar
Farm Tanks, Grain Terminals
Orca Sonar Interface
Clarifer
SULTAN 234
SULTAN 234
Gladiator
Admittance
Switch
Gladiator
Admittance
Switch
Gladiator
Admittance
Switch
GLadiator
Microwave
Low Level
Gladiator
Microwave
Low Level
Sultan Master/Slave Positioning System
Gladiator
Conductivity
Switch
Gladiator
Conductivity
Switch
(Limited Modbus query rate for Switches only)
Sultan Acoustic
Wave Transmitter
8
Orca Sonar Series
Wiring Diagrams
OSIR SONAR SERIES TRANSMITTER
Remote Version (3 Relays) (2 Analogues)
Modulating
4-20mA from
PLC input
Driving 4-20mA from
ORCA to user PLC
+
I
s

4-20mA
AC-IN
+
DC-IN
RELAY1 RELAY2 RELAY3
4-20mA COMMS TRANSDUCER
1
L N
4-20mA
+
24vdc
90 - 260vac
N
C
C
O
M
N
O
N
C
C
O
M
N
O
N
C
C
O
M
N
O
R
E
D
B
L
K
B
L
U
E
W
H
I
T
E
T
e
s
t


i
n
BA
SONAR 234 REMOTE TRANSMITTER
- - +
+
RELAY 1 RELAY 2 RELAY 3 ACTUATOR
N
C
C
O
M
N
O
N
C
C
O
M
N
O
N
C
C
O
M
N
O
B
L
K
B
L
U
B
R
N
G
R
N
Y
E
L
S
H
L
D
ANALOG1 TRANSDUCER COMMS DC-IN AC-IN
R
E
D
B
L
K
B
L
U
W
H
T



T
e
s
t
BAN
L
1
4-20mA 12-30VDC 90-265 VAC
Is
+
-
4-20mA
B
O
T
T
O
M
T
O
P
P
o
t

C
a
b
l
e
M
o
t
o
r

C
a
b
l
e
TRANSDUCER
T
r
a
n
s
d
u
c
e
r

C
a
b
l
e
ANALOG2
Belden 3084A cable
Max 700 m (2000ft)
Refer to Graph 1 for cable selection
(See instruction manual)
Junction
Box
SONAR 234 REMOTE TRANSMITTER
-
- +
+
RELAY 1 RELAY 2 RELAY 3 ACTUATOR
N
C
C
O
M
N
O
N
C
C
O
M
N
O
N
C
C
O
M
N
O
B
L
K
B
L
U
B
R
N
G
R
N
Y
E
L
S
H
L
D
ANALOG1 TRANSDUCER COMMS DC-IN AC-IN
R
E
D
B
L
K
B
L
U
W
H
T



T
e
s
t
BAN
L
1
4-20mA 12-30VDC 90-265 VAC
Is
+
-
4-20mA
B
O
T
T
O
M
T
O
P
TRANSDUCER
T
r
a
n
s
d
u
c
e
r

C
a
b
l
e
ANALOG2
9
Orca Sonar Series
Remote Sonar Transducer

OSIRT Acoustic Wave Remote Transducer
Transducer Application
0 Water / Wastewater
3 Industial / Mining (select 150kHz Transducer only)
7 Heavy Industry / Mining (select 150kHz Transducer only)
Transducer Frequency
02 (150kHz)
03 (300kHz)
04 (450kHz)
05 (700kHz)
Temperature and Facing material selection
S Standard Temperature Version (50C)
G Fiberglass High Temperature (80C)
H Fibreglass High Temp Version with external preamplifer on 6m cable (110C)*
Transducer Housing Material
4 Polypropylene
H Fibreglass (must be selected if using Fibreglass facing options S & G)
Z Special Request
Approval Standard
A0 ATEX CAT1 EEx_ia (Zone 0)
A1 SAA Ex_m ( Zone 1)
X Not Required
Connection Cable IP68
C6 6m (standard)
C15 15m
C30 30m
C50 50m


OSIRT 3 02 S 4 X C6
OSIR Sonar Level Transmitter with 1 or 2 analoge outputs and 3 relay alarms
Power Supply
B 24 VDC
D 90-250VAC and 24VDC
Additional Communications (PC comms GosHawk standard)
X 1 x 4-20mA analogue output modules with Modbus Comms
Y 2 x 4-20mA analogue output modules with Modbus Comms
I 1 x 4-20mA analogue output modules with Modbus and HART Comms
J 2 x 4-20mA analogue output modules with Modbus and HART Comms
W Modbus comms only
P Profbus DP
A Profbus PA
F Foundation Fieldbus
D DeviceNet
Z Special Request


OSIR D Y
Part Numbering
ORCA Remote Electronics
Notes:
* Consult Factory for availability
10
Orca Sonar Series
Mounting Extension
OSIRME Mounting Extention Stainless Steel Pipe***
Length
L1 1 meter
L2 2 meters
L3 3 meters
L4 4 meters
OSIRME L2
Pole length must be specifed. For example 1m pole, L1.

Sunhood - Stainless steel sunhood for transmitters/amplifers
SUNHOOD
Automatic Scum Cleaner
OSIRSC Automatic Scum Cleaner
Type
A 24VDC Electric Actuator with Mounting Accessories
B Pneumatic Actuator (Please consult factory)
C Rotary Scum Brush Cleaner (secondary clarifers only)
D Floating Sonar with 24VDC Electric Actuator with Mounting Accessories
E Dual Impact Plate plus Mounting Bracket with Mounting Accessories

OSIRSC A

HawkLink
HL Hawk Link
Type
R Remote stand alone system mounted in a Sultan Remote Enclosure c/w antenna.
Power Supply
B 24 VDC
U Universal 90-260VAC
X No power supply for E Selection
Network Type
G6 GSM Quad Band Frequency 850/1900MHz and 900/1800MHz Band (worldwide)
Sim Card
S3 3 month sim card
S12 12 month sim card
X Not required
Data Card
D 2gig
X Not required

HL R U G6 S3 X
Part Numbering
Accessories
11
Orca Sonar Series
Hawk Measurement Systems (Head Offce)
15-17 Maurice Court
Nunawading VIC 3131
Australia
Phone: +61 3 9873 4750
Fax: +61 3 9873 4538
info@hawk.com.au
Contact
Hawk Measurement
7 River Street
Middleton, MA 01949
USA
Phone: +1 888 HAWKLEVEL (1-888-429-5538)
Phone: +1 978 304 3000
Fax: +1 978 304 1462
info@hawkmeasure.com
Global representatives on www.hawkmeasure.com
Represented by:
Rev 1.41, Dec 2010
Sonar Frequency Selection
150kHz, 300kHz, 450kHz, 700kHz,
Operating Voltage
90 - 260Vac 50/60Hz
12 - 30Vdc
(residual ripple no greater than 100mV)
Power Consumption
<10VA @ 240Vac
<10W @ 24Vdc
Analog Output
Either single or dual analogue
1 x 4-20mA (isolated) 600 ohms max.
1 x 4-20mA (non isolated) 600 ohms max.
Communications
GosHawk, HART, Modbus, Profbus DP,
DeviceNet, Foundation Fieldbus, Profbus PA.
Relay Output
3 x s.p.d.t. 0.5amp/240vac
Form c. type non-inductive load.
Fully programmable
Maximum Range
65 meters
Blanking Distance
450mm: 150kHz, 300kHz, 450kHz
600mm: 700kHz
Resolution
1mm
Accuracy
+/- 0.25%
Operating Temperature
Remote Electronics
-40C to 70C
Sonar Transducer Standard
-40C to 50C
Sonar Transducer High-Temp
-40C to 80C
Sonar Transducer High-Temp with external pre-amplifer
-40C to 110C
Transducer/Transmitter Separation
>500m
Note: Must be BELDEN 3084A

Cable (Sonar Transducer)
BELDEN 3084A
Sealing
Remote Electronics IP67
Remote Transducer IP68
Cable Entries
Remote Electronics: 3 x 20mm 1 x 16mm
Typical Weight
Remote Electronics 1kg
Remote Transducer 1kg
Cleaning Mechanism 5kg
Specifcations
Additional product warranty and application guarantees upon request. Technical data subject to change without notice. A
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I MPORTANT
USE SPECI FI ED CABLE ONLY