KISTERS Hornet Plus 2 Series User Manual

Cableway system

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Hornet Plus Series 2

08-2024 – 01-01-000

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Page 1 User Manual Hornet Plus Series 2 08-2024 – 01-01-000...
Page 2: Table Of Contents
Installing the AC motor and the Motor drive controller Cabinets ..........11 2.2.1 Option 1, existing setup and custom bracket design ..............12 2.2.2 Option 2, new cableway setup using Kisters cableway and post head assembly ...... 14 Far side set up ..........................17 Installing the traveller block ......................18 2.4.1 Initial requirement .........................
Page 3 Dismantling / Disposal ....................... 80 Appendices Part IX Break-Away Kit ......................... 82 9.1.1 Introduction ......................... 82 9.1.2 Installation ........................... 83 9.1.3 Operation ..........................87 9.1.4 Introduction ......................... 88 9.1.5 Installation ........................... 89 9.1.6 Operation ..........................93 © 2024 | KISTERS...
Page 5: Scope Of Delivery
Battery Cables § Manual winch § Current meter counter cable § 1 × large stainless steel cabinet or 2 × smaller stainless steel cabinets for AC Motor assembly and AC drive control, depending on site setup © 2024 | KISTERS...
Page 6: Safety Instructions
KISTERS website. § Disposal instructions: After taking the KISTERS Hornet Plus Series 2 out of service, it must be disposed of in compliance with local waste and environmental regulations. The KISTERS Hornet Plus Series 2 is never to be disposed in household waste! §...
Page 7: Specific Safety Instructions
Always use the pins supplied with the breakaway kit and replace as instructed. § Always disconnect the battery connector, before beginning work. § Always when replacing a battery, disconnect negative terminal first and reconnect negative terminal last. © 2024 | KISTERS...
Page 8 Working over or near to water: Life jacket/ buoyancy aid should be provided to and worn by workers with risk of falling into water. Life jacket should be thoroughly checked by the user prior to use. © 2024 | KISTERS...
Page 9: Part I Introduction
Thank you for choosing our product. We hope you will enjoy using the device. KISTERS manufactures, sells, installs and operates quality instrumentation, data loggers and communication technology. Products are designed with passion for environmental monitoring and with a deep understanding of the quality, accuracy and robustness needed to fulfil the requirements of measurement practitioners in the field.
Page 10: Hornet Plus Series 2 - Using Adcp
The two female banana plugs on the remote control are connected to a current meter counter using the cable supplied by KISTERS to collect the current meter counts or read the velocity discharge measurement depending on the current meter counter type.
Page 11: Part Ii Installation
As mentioned previously in this manual, the traversing assembly is fixed to the site, and the installation of the cabinets is always performed using the two sheave head assemblies supplied by KISTERS. In a situation where an existing setup is available, designing a suitable mounting bracket to adapt to the existing cableway structure and sheave head assemblies would be the ultimate solution for a successful setup.
Page 12: Option 1, Existing Setup And Custom Bracket Design
Furthermore, the fasteners supplied by KISTERS must be used to attach the cabinet to the bracket. This will eliminate any structural failure in the future due to corrosion and use of dissimilar materials.
Page 14: Option 2, New Cableway Setup Using Kisters Cableway And Post Head Assembly
Installation In regard to the far side modification, KISTERS can also provide optional Far Side Sheave Block assembly. The same custom bracket used on the operating side can also be use on the far side. KISTERS recommends a certified structural engineer to be involved in the modification of the existing cableway.
Page 15 AC motor cabinet set up This setup will require the cableway to be purchased separately and installed prior to performing the Hornet Series 2 setup. During the following steps (1 - 6) the enclosure door must be open. © 2024 | KISTERS...
Page 16 Please note fasteners to secure the four brackets to the cabinet are supplied, fasteners to secure the cabinet to the wall are not supplied, a suitable M8 type fasteners can be used to perform the installation. © 2024 | KISTERS...
Page 17: Far Side Set Up
Far side set up The sheave block assembly for the far side is an optional accessory. When using the KISTERS cableway set up it is advisable to order the far side sheave block assembly to facilitate the installation and improve the operation process.
Page 18: Installing The Traveller Block
2.4.1 Initial requirement During the purchase process the customer has to provide the main cable size and the traversing cable size, this will allow KISTERS to provide the traveller block assembly with the right sheave sizes. © 2024 | KISTERS...
Page 19: Installation Procedure
Installation 2.4.2 Installation procedure 2.4.2.1 Attaching the traveller block to the main cable © 2024 | KISTERS...
Page 21: Traversing Cable Installation
Installation Traversing cable installation Note: The traversing cable is not a part of the Hornet Plus standard kit, but it can be ordered separately from KISTERS to suit the site span a length can be specified on order. Caution: Do not cut the traversing cable even though you know the distance required. The cable is cut at the final step, which will be indicated later in this manual.
Page 22 Run the traversing cable all the way towards the traveller block. Step 4 Run the traversing cable under the Guide pulley across to the operating side. Step 5 Feed the traversing cable from the top, over the pulley groove closet to the motor side. © 2024 | KISTERS...
Page 23 10 of this section. Step 7 Pull the end of the traversing cable and wrap around the far side guide sheave. Step 8 Wrap the traversing cable around the second groove of the operating side sheave. © 2024 | KISTERS...
Page 24 Attaching the traversing cable to the turnbuckle, using the three wire grips and thimble supplied. Ensure turnbuckles are in the fully open position to allow of tensioning later on. Note: Turnbuckles already attached to the Traveller Block. © 2024 | KISTERS...
Page 25 Once done, secure the Cable Puller to the fixed end of the Traveller Block. Hook the Cable Grip to the Cable Puller, and start tensioning the traversing cable till you are satisfied with the sag. © 2024 | KISTERS...
Page 26 Once satisfied with the sag, cut the wire with minimum 1 metre of excess and repeat step 10 by looping the cable and securing the wire grips. Once completed, use the turnbuckle to fine-tune the tension. © 2024 | KISTERS...
Page 27: Attaching The Batteries And The Winch To The Traveller Block
Install the manual winch to the bottom of the battery box as shown. Step 3 Install the second battery in place and use the spring-loaded pin to lock both the battery and the winch in place. © 2024 | KISTERS...
Page 28: Installing The Hoist
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. © 2024 | KISTERS...
Page 29 Release the cable on the manual winch and feed it through the Traveller Block plate above the roller and down to the hoist as shown. Note: The manual winch is used to avoid lifting the hoist. © 2024 | KISTERS...
Page 30 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. Note: Excessive force exertion is not required as this may damage the hook, cable and winch. © 2024 | KISTERS...
Page 31 Installation Step 3 Remove the R-clip and pin and keep lifting the Hoist till it coincides with the Traveller Block. Step 4 Re-attach the R-clip and pin. © 2024 | KISTERS...
Page 33: Fitting The Drive Control Interlock Box To The Main Cable
Connect the Drive control interlock cables to the labeled position on the operating side cabinet and control drive cabinet. Finalizing the Installation: Connect a Flow Meter or Sediment Sampler Step 1 Pull the Tee Plug and Angle plug, release the R-clip and Pin for the C1 or C2 connector. © 2024 | KISTERS...
Page 34 Installation Step 2 Turn the ON switch on both the hoist and remote control and press the remote lower to release more cable. © 2024 | KISTERS...
Page 35 Installation Step 3 Attach the Breakaway kit to the C1 or C2 connector. Refer to Breakaway instruction for details. © 2024 | KISTERS...
Page 36 Installation Step 4 Connect the Breakaway kit to the hanger bar holding the current meter and gauging weight/sediment sampler or Ground feeler weight. © 2024 | KISTERS...
Page 37 Connect the angle plug to the current meter or sediment sampler. In a situation where ground feeler device is used, connect the Tee plug to the ground feeler device and the angle plug to the current meter. © 2024 | KISTERS...
Page 38: Part Iii Operation
AC Motor Control cabinet and the Hoist. The green LED will flash as the Remote Control communicates. The Remote Control is the brains of the system. Radio communication messages are initiated from the Remote Control to both the Hoist and the AC Drive Control. © 2024 | KISTERS...
Page 39: Brief Description Of Controls
HINT: Start a FWD/REV move with the Speed knob set low and increase to the desired speed – and then reduce the speed before releasing the FWD/REV – this limits the swing of the gauging weight to a safer level. © 2024 | KISTERS...
Page 40 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 if the “ground feeler detect” shorts the current meter signal. © 2024 | KISTERS...
Page 41 A current meter can be connected to the Hoist, and the contact closure information is transmitted to the Remote Control – which has an output that can be connected to your favourite Current Meter Counter. The current meter input on the Hoist © 2024 | KISTERS...
Page 42 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 500 mA, and when fully charged drop back to a trickle charge – so there is no problem with leaving it plugged in for extended periods. © 2024 | KISTERS...
Page 43: Menu Navigation
The three 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, AC Drive Control, Remote Control and Alarms to be displayed. © 2024 | KISTERS...
Page 44: Main Display
(corrected depth – note the arrow pointing vertically that touches the horizontal line at the bottom) and the depth to the centre of the current meter (note the arrow pointing vertically that doesn’t quite touch the horizontal line at the bottom). © 2024 | KISTERS...
Page 45: Airline / Wetline / Corrected Depth Display
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. © 2024 | KISTERS...
Page 46: Signal Strength And Battery Voltage
Measure the distance from the bottom of the Weight back up to the centre line of the current meter – and Set Offset from Weight to Meter § Position the carriage and then Set the Waters Edge § Position the weight just above the water and Set at Water Level © 2024 | KISTERS...
Page 47 0.95m, so rotate the menu scroll knob to toggle between 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. © 2024 | KISTERS...
Page 48 – 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 ch. Main Display to see how and where the depth to the current meter is read! © 2024 | KISTERS...
Page 49 After entering the function, the operator is reminded to remove the Current Meter. Then fit the Sediment Sampler as shown. Press the blue Zero button to continue (or rotate the menu scroll knob to exit). © 2024 | KISTERS...
Page 50 "SMPL:OFF" indicates 48 V is removed and sampler nozzle will close. Press the blue Zero button again to toggle the SMPL: ON/OFF. When the sampling is complete, rotate the menu scroll knob to exit Sediment Sampler mode. © 2024 | KISTERS...
Page 51: More
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.) © 2024 | KISTERS...
Page 52 Current Meter signal. You may need to disable this feature if it triggers while lowering, due to the current meter stopping with the contacts closed. Rotate the menu scroll knob to step to the next Hoist menu. © 2024 | KISTERS...
Page 53 The LCD will indicate the Hoist Serial Number (also on the Hoist S/N label) and the symbol between S/N will rotate each time they communicate (/ then – then \ then |). 3. Press the menu scroll knob and pairing is complete. © 2024 | KISTERS...
Page 54: Drive Control
The bottom line displays the equivalent horizontal distance – taking the angle into account. (Note the arrow indicating it is the horizontal distance.) Rotate the menu scroll knob to step between the Drive Control menus. © 2024 | KISTERS...
Page 55 Controls from operating the same unit. To pair with a different Drive Control follow these 3 steps: 1. Press and hold the menu scroll knob for 5 seconds, until the LCD displays “New Pair with… S/N XX-XXX”. © 2024 | KISTERS...
Page 56: 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. © 2024 | KISTERS...
Page 57 Frequency Hopping (70 frequencies) 863.05 to 869.95 MHz every 400 ms Displayed as “Band = 868 MHz” Hornet Series 2 – US Frequency Hopping (64 frequencies) 902.971 to 926.653 MHz every 400 ms Displayed as “Band = 915 MHz” © 2024 | KISTERS...
Page 58: Alarms
This menu displays the present communication status of the Hoist and the Drive Control. (Note that two consecutive missed communication polls is classed as a communication fault!) 3.2.10.2 Battery Voltage Status This menu displays the present condition of the Hoist battery and the NiMh batteries inside the Remote Control (My Batt). © 2024 | KISTERS...
Page 59 Hoist states Cable Tension on drum OK => Cable OK Cable loose / double wrapped => CableFlt No Hoist Comms => ---- 3.2.10.4 Return to Alarms… Press the menu scroll button to return to the Alarms… menu. © 2024 | KISTERS...
Page 60: Return To Main Display
Raise/Lower until the current meter is at the required depth. (Note the arrow symbol does not touch the bottom line.) 14. Perform a velocity measurement at this point on the vertical and move to the next point on this vertical or go to step 11. © 2024 | KISTERS...
Page 61: The Hoist
A limit switch is also operated if the cable is let out too far. This will stop the drum with about three wraps remaining, to hold the heaviest weight used. © 2024 | KISTERS...
Page 62: The Current Meter
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. © 2024 | KISTERS...
Page 63: The Drive Control System
(A manual brake lever provides an override mechanism.) The Drive Controller is mounted in separate stainless steel enclosures – one with the control electronics and the other with the AC motor drive. © 2024 | KISTERS...
Page 64 When the carriage comes within about one metre, 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. © 2024 | KISTERS...
Page 65: Part Iv Maintenance
Maintenance Maintenance There are a few routine maintenance steps that should be performed, to ensure continued safe operation of your Hornet system. 1. Drive Control 2. Hoist © 2024 | KISTERS...
Page 66 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. 5. Check Manual Winch cable for fraying. 6. Check that Hoist cable is laid neatly on to the hoist drum. © 2024 | KISTERS...
Page 67: Part V Troubleshooting
Remove the Remote Control front cover (remove the four corner screws), and check that the ribbon cable is firmly pushed into the multipin socket on the LHS of the circuit board. § Remove one battery from the holder and then put it back in again, to force the Remote Control to perform a hard reset. © 2024 | KISTERS...
Page 68: Ac Motor Drive Control Cabinet
It does depend what is flashing – if it is 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) © 2024 | KISTERS...
Page 69: Hoist
§ Check the plug in power connectors – that a terminal hasn’t been dislodged in the housing. © 2024 | KISTERS...
Page 70 Check that the Remote Control "Hoist" menus have the current meter options set to "MagHd" and "Nrm". § 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. © 2024 | KISTERS...
Page 72 1. With the red wire disconnected from the 12 way slip ring terminal, 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. © 2024 | KISTERS...
Page 73 5. To test the shield continuity, set the multi-meter to resistance and measure different parts of the same circuit to isolate a problem, referring to the "signal path list" on the previous page. E.g. from the drum to the black wire J5- (shown) or from the drum to the securing bolt washer…. © 2024 | KISTERS...
Page 74: Part Vi Repair
§ Please do not ship the goods prior to obtaining the reference number. KISTERS will not reject any equipment that arrives without reference number; however, it may take us longer to process. Custom requirements for items sent to KISTERS for warranty or non-warranty repairs: Check with your national customs/tax authorities for details, processes and paperwork regarding tax exempt return of products.
Page 75: Part Vii Technical Data
“Raise” current 20 A (no gauging weight) Cable 45 m of amergraph cable Depth Measurement 0.01 m / 0.01 ft resolution (Conforms to USGS Water Supply Paper 2175) Ground Feeler Detects River Bed Inclinometer ±45° measurements Current Meter Built in Signal Processor © 2024 | KISTERS...
Page 76 Current Meter Output – open collector Sounder for current meter pulses and low Hoist battery Power Source 3 × NiMh 2.5 Ah AA batteries with built in charger (or 3 × AA Alkaline batteries in an emergency) © 2024 | KISTERS...
Page 80: Part Viii Obligations Of The Operator And Disposal
Instead, these old appliances must be collected separately and disposed of via the local collection and return systems. Integrated or provided batteries and accumulators must be separated from the appliances and disposed of at the designated © 2024 | KISTERS...
Page 81 At the end of its service life, the lithium-ion battery must be disposed of according to legal provisions. EU WEEE Directive As players in the environmental market, KISTERS AG is committed to supporting efforts to avoid and recycle waste. Please consider: §...
Page 82: Part Ix Appendices
9.1.1 Introduction KISTERS provides a Break-Away Kit with its Cableway Systems and Winches as a safety precaution against large debris causing damage or injury during a flood situation. The Break-Away Swivels provide an inexpensive fracture point between a pulling line and a water flow sensor to avoid an expensive cableway structure from getting damaged or a human dragged into the water when gauging using a winch board or a bridge crane from the side of a bridge.
Page 83: Installation
Break-Away Kit to perform as required using the specific load designated for it. Step 1 Note: In a situation where the Break-Away is released, and the sensor is detached and lost, only the small section of the Break-Away kit has to be reordered. Part No. MON99_SMATRSC127X07X. © 2024 | KISTERS...
Page 85 It is essential to have the pin located in the center position as shown above for the Break-Away to activate at the load specified. Failure to do so will result in the Break-Away activating at a higher load. © 2024 | KISTERS...
Page 86 Appendices Step 4 Note: The Break-Away Assembly is complete and ready to attach between the C1 connector (Winch) and the Sensor (The Stabilising Weight or Gauging Weight Hanger Bar on the sensor side). © 2024 | KISTERS...
Page 87: Operation
When using the Break-Away kit make sure you are wearing safety shoes and avoid having your feet directly under the gauging weight. § When gauging, personnel should not move or stand directly below the gauging equipment. After inspection, install the Break-Away kit as shown below: © 2024 | KISTERS...
Page 88: Introduction
9.1.4 Introduction KISTERS provides a Break-Away Kit with its Cableway Systems and Winches as a safety precaution against large debris causing damage or injury during a flood situation. The Break-Away Swivels provide an inexpensive fracture point between a pulling line and a water flow sensor to avoid an expensive cableway structure from getting damaged or a human dragged into the water when gauging using a winch board or a bridge crane from the side of a bridge.
Page 89: Installation
Break-Away Kit to perform as required using the specific load designated for it. Step 1 Note: In a situation where the Break-Away is released, and the sensor is detached and lost, only the small section of the Break-Away kit has to be reordered. Part No. MON99_SMATRSC127X07X. © 2024 | KISTERS...
Page 91 It is essential to have the pin located in the center position as shown above for the Break-Away to activate at the load specified. Failure to do so will result in the Break-Away activating at a higher load. © 2024 | KISTERS...
Page 92 Appendices Step 4 Note: The Break-Away Assembly is complete and ready to attach between the C1 connector (Winch) and the Sensor (The Stabilising Weight or Gauging Weight Hanger Bar on the sensor side). © 2024 | KISTERS...
Page 93: Operation
When using the Break-Away kit make sure you are wearing safety shoes and avoid having your feet directly under the gauging weight. § When gauging, personnel should not move or stand directly below the gauging equipment. After inspection, install the Break-Away kit as shown below: © 2024 | KISTERS...
Page 94: Contact Data
+64 7 857 0810 sales@kisters.co.nz www.kisters.co.nz Latin America | KISTERS Latin America +57 350 575 4079 sales@kisters-latam.com www.kisters-latam.com North America | KISTERS North America +1 561 459 4876 kna@kisters.net www.kisters.net Spain | KISTERS Ibérica info@kisters.es www.kisters.es © 2024 | KISTERS...

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