MPS_ADS4_Manual_Redacted.pdf

Manatee ADS (Acoustic Detection Sensor) Protection System for Navigation Locks

2018 Technical Documentation Package:

Describes ADS Version 4. Upgrades and Provides

Training for Service Technicians

Canaveral, Moore Haven, Ortona, Port Mayaca, St. Lucie and W.P. Franklin Locks, Produced for the U.S. Army Corps of Engineers

Contract: W912EP-16-C-0005

Manatee ADS Protection System for Sector Gates ADS4 Technical Documentation Package Contract # W912EP-16-C-0005

Revision: A Date: 24 May 2018 Page 2

Prepared By:

Underwater Engineering Services Inc.

and Harbor Branch Oceanographic Institute at Florida Atlantic University

Contractor Contact Information:

Andrew Connelly Construction Manager Underwater Engineering Services 3306 Enterprise Rd Fort Pierce, FL 34982 772-337-3116

Larry Taylor Coordinator, Research Program Services Harbor Branch Oceanographic Institute at

FLORIDA ATLANTIC UNIVERSITY

5600 U.S. 1 North Fort Pierce, FL 34946 772-242-2258

Revision: A Date: 24 May 2018 Page 3

List of Revisions:

Original Release: 5/16/2018 Rev A, 5/24/2018 – Format Change, Added Appendix F.

Revision: A Date: 24 May 2018 Page 4

Table of Contents

1 ADS‐4 MANUAL RELEASE NOTES 13

2 INTRODUCTION 15

3 GLOSSARY OF TERMS 16

4 GENERAL SYSTEM DESCRIPTION 17

4.1 SITE LAYOUTS 18

4.1.1 Locks with Two Control Stations: Canaveral, Ortona, Port Mayaca, and W.P. Franklin 19

4.1.1.1 Canaveral Lock Layout 19

4.1.1.2 Canaveral Lock Control and MPS Configuration 20

4.1.1.3 W.P. Franklin Lock Layout 22

4.1.1.4 W.P Franklin Lock Control and MPS Configuration 23

4.1.1.5 Port Mayaca Lock Layout 25

4.1.1.6 Port Mayaca Lock Control and MPS Configuration 25

4.1.1.7 Ortona Lock Layout 28

4.1.1.8 Ortona Lock Control and MPS Configuration 29

4.1.2 Locks with One Control Station: Moore Haven and St. Lucie 32

4.1.2.1 Moore Haven Lock Layout 32

4.1.2.2 Moore Haven Lock Control and MPS Configuration 32

4.1.2.3 St. Lucie Lock Layout 36

4.1.2.4 St. Lucie Lock Control and MPS Configuration 37

4.2 ADS SYSTEM COMPONENTS 41

4.2.1 Acoustic Transmitter/Receiver Arrays 41

4.2.1.1 Sensor Technology 42

4.2.1.2 Sensor Placement 42

4.2.1.3 Acoustic Coverage 44

4.2.1.4 ADS2 vs ADS3 Acoustic Coverage 46

4.2.1.5 Lock Differences ‐ Acoustic Sensor Cartridges 48

4.2.1.6 Cautions: Environmental Conditions 49

4.2.2 Water Level Sensors 50

4.2.2.1 Water Level Sensor Location 50

4.2.2.2 Water Level Sensor Technology 50

4.2.2.3 Water level Sensor Mounting 51

4.2.2.4 Water Level – Calibration for Displaying Depth over Sill 52

4.2.2.5 Optional Display of Water Level as Elevation 53

4.2.2.6 Calculating Water Level Mask – “Mask Level” 53

4.2.2.7 Operator’s Water Level Offset 53

4.2.3 Gate Position ‐ MPS Operational Zones 54

4.2.3.1 ADS3 and ADS 4 Updates to Gate Position Sensor Zones 55

4.2.3.2 Setting MPS Gate Zones 55

4.2.4 Gate Position Sensor Technology 57

4.2.4.1 Lock Differences – Gate Position Sensors 57

4.2.4.2 Incremental Encoders – Canaveral, Port Mayaca, W.P. Franklin, Taylor Creek 57

4.2.4.3 Analog Gate Position Sensors – St. Lucie, Ortona and Moore Haven 60

4.2.4.4 Gate Position Signal Processing 65

4.2.5 Distributed Controllers and Network 66

4.2.6 Operator’s MPS Touch Screen and MPS Switch Panels 71

4.2.6.1 Touch Screen Fundamentals 72

4.2.6.2 Touchscreen Operations for Operators 74

4.2.6.3 ADS MAIN Screen – Locks with 2 Control Stations 74

4.2.6.4 Setting the Clock in the Touch Screen 81

4.2.6.5 ADS4 Main Screen – St. Lucie Lock and Moore Haven Lock 81

4.2.6.6 Status Detail Screen 82

4.2.6.7 Setup Screen 86

4.2.6.8 Skin Side Receiver Alarm/Bypass Screen 92

4.2.6.9 Timber Side Receiver Alarm/Bypass Screen 93

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4.2.6.10 Manatee Sighting Screen 93

4.2.6.11 Navigation Screen 96

4.2.6.12 Calibrate Far/Near Gate Position Sensor Screens 100

4.2.6.13 Operator’s Water Level Over‐Ride Screen 101

4.2.6.14 Alarm History Screen 105

4.2.6.15 Alarm Simulation Screen 105

4.2.6.16 Test MPS Controls Screen 106

4.2.6.17 Set Auto Cal Gate Zones 107

4.2.6.18 Inspection Screen 109

4.2.6.19 Threshold Edit Screen 109

4.2.6.20 View Receiver Noise Floors Screen 111

4.2.6.21 Factory Defaults Screens 112

4.2.6.22 Daughter Card ‐ Controller Card (Inspection) Screen 113

4.2.6.23 Auto‐Manual Permanent Bypass Screen 113

4.2.7 Canaveral CCP Control Panel Description 114

4.2.8 Enclosures 116

4.2.8.1 System Interconnections 116

4.2.8.2 Master PLC 1 & 2 118

4.2.8.3 RX1 and RX2 Receiver Enclosures 124

4.2.8.4 TX 3 and TX4 Transmitter Enclosures 129

4.2.9 Alarm Horn and Light 130

4.3 MPS INTERFACE TO GATE CONTROLS 131

4.4 DESIGN PRINCIPLES 131

4.4.1 Do Not Corrupt Safety Interlocks 131

4.4.2 Immediately Release Control 131

4.4.3 Operate Controls in the same way as the operator 132

4.5 TYPICAL ADS OPERATION 133

4.5.1 Intervention 133

4.5.2 ADS Sequence of Operations 134

4.5.2.1 Power‐up 134

4.5.2.2 Normal Gate Operation 135

4.5.2.3 Gate Closure with Manatee Detection – Not in Crush Zone. 135

4.5.2.4 Gate Closure with Manatee Detection – Gates in Crush Zone. 136

4.5.2.5 Auxiliary Gate Stoppage 137

4.5.3 MPS Assisted Dual Gate Alignment – ADS3 Mode 138

4.5.4 ADS4 – Automatic All‐OFF test and Auto (permanent) Receiver Bypass 138

4.5.4.1 Auto All‐Off Self‐test 139

4.5.4.2 Manually Set Permanent Bypass 139

4.5.5 Auto Calibration 140

4.5.5.1 Auto Calibration Procedure 140

5 TECHNICAL REFERENCE 141

5.1 SENSORS 142

5.1.1 Procurement 142

5.1.1.1 Cartridge 142

5.1.1.2 Cable 142

5.1.1.3 Elements 142

5.1.1.4 Potting Compounds 146

5.1.2 Manufacturing 146

5.1.2.1 Element Prep 146

5.1.2.2 Cartridge Prep 148

5.1.2.3 Cable Prep 153

5.1.2.4 Cartridge Assembly 155

5.1.3 Replacing a Sensor 165

5.1.3.1 Sensor Removal 165

5.1.3.2 Replacement Sensor installation 166

5.1.3.3 Terminate replacement sensor cables 168

5.2 CUSTOM CIRCUIT BOARDS 168

Revision: A Date: 24 May 2018 Page 6

5.2.1 Mother Board 168

5.2.1.1 Mother Board Component Identification 168

5.2.1.2 Mother Board Versions 169

5.2.1.3 Mother Board Schematic Reference 170

5.2.1.4 Manufacturing 171

5.2.2 Card Rack Assembly 173

5.2.3 Controller Card 173

5.2.3.1 Controller Card Identification 173

5.2.3.2 Controller Card Schematic Reference 176

5.2.3.3 Manufacturing 179

5.2.4 Receiver Daughter Cards 182

5.2.4.1 Receiver Daughter Card Identification 182

5.2.4.2 Receiver Channel Signal Processing 184

5.2.4.3 Receiver Card Schematic Reference 185

5.2.4.4 Manufacturing 191

5.2.4.5 Receiver Card Microcontroller Programming 194

5.2.4.6 Receiver Card Calibration 195

5.2.5 Transmitter Daughter Card 200

5.2.5.1 Transmitter Daughter Card Identification 200

5.2.5.2 TX Daughter Card Microcontroller Program 202

5.2.5.3 Transmitter Card Schematic Reference 203

5.2.5.4 Transmitter Card Manufacturing 205

5.2.5.5 Transmitter Card Microcontroller Programming 217

5.2.5.6 Transmitter Card Testing 217

5.3 PLCS 219

5.3.1 Hardware 219

5.3.1.1 Introduction 219

5.3.1.2 Remove/Replace 220

5.3.1.3 Power Requirements 220

5.3.1.4 CPU Types 220

5.3.1.5 Module Types 222

5.3.2 PLC Programs 236

5.3.2.1 HMI/PLC Programming Tools 236

5.3.2.2 Monitoring a PLC Program with WindLDR 239

5.3.2.3 Master PLC 1 & 2 Program Description 240

5.3.2.4 Programming the MPLC 240

5.3.2.5 Receiver Enclosure 1 & 2 Program Description 241

5.3.2.6 Programming the RX PLC 241

5.3.2.7 Transmitter Enclosure 3 & 4 Program Description 245

5.3.2.8 Programming the TX PLC 245

5.3.2.9 Machinery House 3 & 4 Program Description 246

5.3.2.10 Programming the MH PLC 246

5.3.2.11 Web Server Module 249

5.3.2.12 Dealing with PLC Errors 249

5.4 TOUCHSCREEN –HMI (HUMAN‐MACHINE‐INTERFACE) 250

5.4.1 Hardware 250

5.4.2 Remove/Replace Screen 250

5.5 DATA LOGGER 250

5.5.1 Introduction 250

5.5.2 Data Logger Specification 251

5.5.2.1 Hardware Specification: 251

5.5.2.2 Software Specification: 251

5.5.3 Data Logger Main Screen 252

5.5.4 History Screen 253

5.5.4.1 Inspection Line 256

5.5.5 Manatee Sighting Log 257

5.5.6 Data Logger Program Files 258

5.5.6.1 Kepware Server 258

Revision: A Date: 24 May 2018 Page 7

5.5.6.2 Lookout 258

6 MPS MAINTENANCE 259

6.1 ROUTINE MAINTENANCE 259

6.1.1 ADS AC Power 259

6.1.2 Periodic Inspections: 259

6.1.2.1 Daily – 259

6.1.2.2 Monthly – 259

6.1.2.3 Semi‐Annually 261

6.1.2.4 Annually 262

6.2 DIAGNOSTICS AND REPAIRS: 262

6.2.1 Restoring a Bypassed Receiver 262

6.2.2 Diagnostics for TROUBLE or MALFUNCTION Status 262

6.2.3 Check Water Level Sensor for Slope 264

6.2.4 Sensor Cartridge Maintenance 265

6.2.4.1 Field Testing 265

6.2.5 Data Logger 265

6.2.5.1 Data Logger Diagnostics 265

6.2.5.2 Data Logger Re‐installation 265

7 ELECTRICAL INSTALLATION ‐ GENERAL DESCRIPTION 275

8 APPENDICES 276

8.1 APPENDIX A ‐ INSTRUCTIONAL VIDEOS 276

8.2 APPENDIX B ‐ QUALITY ASSURANCE RECORDS AND FORMS 277

8.3 APPENDIX C – MANUFACTURER’S CATALOG DATA. 277

8.4 APPENDIX D – DRAWING REPOSITORY 277

8.5 APPENDIX E – ADS4 SOURCE CODE 277

8.6 APPENDIX F ‐ IDEC REFERENCE MANUALS 278

8.7 APPENDIX G ‐ NATIONAL INSTRUMENTS LOOKOUT REFERENCE MATERIAL 278

8.8 PCB FABRICATION FILES 278

8.8.1 Mother Boards 278

8.8.2 Controller Card 278

8.8.3 Receiver Card 278

8.8.4 Transmitter Card 278

Revision: A Date: 24 May 2018 Page 8

TABLE of FIGURES

Figure 1. Canaveral West Gates with Manatee at surface Figure 2. Gate Mounted Transmitter/Receiver Arrays Figure 3. Basic ADS Components on set of Gates Figure 4. MPS Site Layout - Canaveral Lock Layout – Not to Scale Figure 5. Canaveral Gate Controls – West Gates Figure 6.Canaveral Gate Control Circuit – West Gates Figure 7. Intervention Settings – Factory Default Screen Page 4 Figure 8. MPS Site Layout – W.P. Franklin Lock – Not to Scale Figure 9. W.P. Franklin Lock Controls – Gate 1 and 3 (East Gates) Figure 10. Franklin MPLC and MPS Control relays Figure 11. MPS Site Layout – Port Mayaca Lock – Not to Scale Figure 12. Port Mayaca Gate Control Panel with MPS Auto-Shutdown Figure 13. Port Mayaca MPLC 2 Figure 14. Port Mayaca MPS Control Relays Figure 15. MPS Site Layout – Ortona Lock – Not to Scale Figure 16. Ortona Gate Controls Figure 17. Ortona Factory Defaults Page 3 – Gate Position Figure 18. MPS Site Layout – Moore Haven Lock – Not to Scale Figure 19. Moore Haven Lock Typical Gate Control Panel Figure 20. Moore Haven Gate Control – OPEN Latch Figure 21. Moore Haven Gate Controls at Safety Stop Figure 22. Moore Haven Gate Control – RE-START Operation Figure 23. Moore Haven MPS Gate Controls Figure 24. Moore Haven with Two Arm/Bypass Switches Figure 25. MPS Lock Layout – St. Lucie Lock – Not to Scale Figure 26. St. Lucie Lock Control Panel Figure 27. Lower Gates – 1 & 3 Controls Figure 28. St. Lucie / Moore Haven Fact. Def. Tab 4 - Partial Figure 29. St. Lucie MPS Output Control Relays Figure 30. St. Lucie Auxiliary Bypass Switches Figure 31. Plan View, Typical Sensor Mounting Figure 32. Typical Skin and Timber Sensor Arrays with Enclosure Figure 33. Vertical and Horizontal Acoustic Pattern Figure 34. Single Gate Open 48 in Figure 35. Transmit/receive angular response in the horizontal plane Figure 36. Standard Cartridge Assembly and Moore Haven Low Profile Assembly 49 Figure 37. Bubbles formed as Chamber Fills – Ortona Lock Figure 38. Water Level Pressure Sensor Figure 39. Water Level Sensor Mount Figure 40. Factory Default Page 2 Water Level Sensor Figure 41. Dual Gates with MPS Zones Figure 42. Set MPS Gate Zones Screen Figure 43. Encoder A-B Quadrature Signals - 360 Pulses per Revolution Figure 44. Encoder/Bracket Assembly – Canaveral Lock Figure 45. Incremental Encoder Mount on Cable Drum Figure 46. Forcing Gate Position to Fully Open Figure 47. St. Lucie Lock, Typical Gate Position Synchro Transmitter Figure 48. St. Lucie Synchro to (4-20mA) Converters Figure 49. MPS 4-20mA Repeaters at St. Lucie Lock Figure 50. St. Lucie and Moore Haven CALIBRATE GATE POSITION SENSORS screen 62 Figure 51. Ortona Single Turn Analog Encoder Figure 52. Ortona Gate Position Sensor with Backlash mitigation components. 63 Figure 53. Moore Haven String Pot location – Upper Gates Figure 54. Moore Haven String Pot Mounting Figure 55. Set-Up Screen with Gate Position ZERO Button

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Figure 56. Basic Site Communication Plan – Canaveral, Port Mayaca, Ortona, W.P. Franklin Lock

Figure 57. PLC/HMI Component layout diagram for locks with 2 control stations. Layout identical at both ends of lock

Figure 58. PLC/HMI Component layout diagram for Moore Haven lock. One Master PLC at upper gates, gate position sensors are string pot’s connected to the RX and TX enclosures

Figure 59. Component layout for St. Lucie lock. Single master PLC and Central control House. Gate position signals are sourced in the Central control House

Figure 60. Operator’s MPS Touch Screen Figure 61. Canaveral MPS Pushbutton Panel Figure 62. Typical Action Button with Outline Figure 63. Typical Pop-up ALPHA and Numeric keypads Figure 64. MAIN Screen – Locks with 2 Control Stations Figure 65. Operation and Speed Indicators Figure 66. MPS Operational Zones and Gap Display Figure 67. Main Screen – Status Panel Display Figure 68. Five States of Main Screen ARMED Indicator Figure 69. Main Screen – Attempted Close without ARMING Figure 70. Water Level Display Panel Figure 71. Message Panels Figure 72. Main Screen – Screen Selection Buttons and Aux. Data Indicators. 80 Figure 73. Clock Set Screen and Instructions Figure 74. ADS4 Main Screen – St. Lucie and Moore Haven Lock Figure 75. Status Detail Screen – All O.K Figure 76. Status Detail Screen with TRX Trouble and TX Malfunction Figure 77. System Status Indicators Figure 78. RX Daughter card Status Screen Figure 79. TX Power Supply Status Screen Figure 80. Status Screen – St. Lucie and Moore Haven Figure 81. SETUP Screen - Canaveral Lock Figure 82. Setup Screen – Ortona Lock Figure 83. Setup Screen – Port Mayaca Lock Figure 84. Setup Screen – W.P. Franklin Lock Figure 85. Setup Screen – Moore Haven Lock Figure 86. Setup Screen St. Lucie Lock Figure 87. Gate Position ZERO Warning Screen Figure 88. Typical Alarm Bypass Screen Figure 89. Manatee Sighting Screen Figure 90. Change (Operator) Initials Screen Figure 91. Navigation Screen – Two Control Station Locks Figure 92. Navigation Screen – St. Lucie and Moore Haven Figure 93. Single ACAL Selection Pop-up Screen Figure 94. Universal ACAL Screen Figure 95. Title Screen Figure 96. DESCRIPTION Screen – Press RETURN to Close Figure 97. Gate Position Sensor Calibration Screen Figure 98. Adjust Water Level Sensor Screen Figure 99. Adjust Water Level Sensor – Level Adjusted Down Figure 100. Water Level Adjustment – Adjustment Range Error Figure 101. Sensor Override Screen Figure 102. Alarm History Screen Figure 103. Alarm Simulation Screen and Help Screen Figure 104. Test MPS Controls Screen Figure 105. Universal ACAL Screen Figure 106. Set Auto Cal Gate Zones Figure 107. Inspection Screen Figure 108. Threshold Edit Screen

Revision: A Date: 24 May 2018 Page 10

Figure 109. View Receiver Noise Floors Screen Figure 110. Factory Defaults Screen Figure 111. Factory Def. Page 4 – St. Lucie and Moore Haven Figure 112. Permanent Bypass Screen Figure 113. Canaveral CCP Control Panel Figure 114. ADS Typical Detail Block Diagram – One End of Lock Figure 115. Master PLC Components – Canaveral Lock Figure 116. Master PLC at Franklin Lock Figure 117. Ortona Lock MPLC Configuration Figure 118. Master PLC at Moore Haven Lock Figure 119. Master PLC at St. Lucie Lock Figure 120. Port Mayaca Master PLC Gates 1&3 Figure 121. Master PLC Port Mayaca Gates 2&4 Figure 122. RX/TX Enclosure Mounting Configurations Figure 123. RX and TX Dual Enclosures at Moore Haven Upper Gates Figure 124. Photograph of RX-2 Enclosure and components Figure 125. 3 Assemblies in RX Enclosure Figure 126. HG1F Drop-Down Hinge Figure 127. RX Controller Assembly Figure 128. TX Rack with 1 controller and 25 TX Driver Cards Figure 129. Factory Def. Tab 4 Select Intervention Cancel Modes Figure 130. Start-Up Prompt Figure 131. MPS Stop Messages: Manatee Detect and Safe Zone Figure 132. MPS Stop – Water Level Sensor Malfunction Figure 133. Example of Element Potting Void Figure 134. ADS Element Acceptance Test Form QA 1-1-1 Figure 135. Sanding Elements Figure 136. Elements Ready for Cartridge Assembly Figure 137. Warped Cartridge Rejects Figure 138. Sand Blasting Flaw Figure 139. Sensor Cartridge: Cable Pedestal Modification Figure 140. Cartridge Sensor-Slot Modification Figure 141. Sensor Cartridge Labels Figure 142. ¼-20 Cartridge Hold-down fasteners Figure 143. Cartridge Production Testing Form QA 2-1-1 Figure 144. Cable Clamp Figure 145. Cable Clamp Installation Figure 146. Temporary Clamp and Gluing Precautions Figure 147. Post-Soldering Gluing Examples Figure 148. Clear Flex 95 Pour Pictures Figure 149. Sensor Cartridge Over-Pour Figure 150. Heel Mold Assembly Figure 151. Cartridge secured to backing board Figure 152. Sensor Cable Clamps and Bonding Screws Figure 153. Cable Access Plate at top of Cable Cover Stack Figure 154. Sensor Prepped for Installation Figure 155. Mother Board Component Identification Figure 156. Mother Board Slot 1 and 15 Schematic with ID Pin Code Figure 157. Mother Board Controller – Card Slot 26 Connection Diagram Figure 158. Controller Status “Cheat Sheet” Codes Figure 159. Controller Card Features Figure 160. Partial Schematic – Controller Card Figure 161. Controller Card Quad-RS-232 Driver/Receiver Figure 162. Controller External Serial Port Configurations Figure 163. Controller Card I/O Connection to Mother Board Figure 164. AVRISP MKII Programming Adapter Figure 165. Receiver Card Figure 166. Receiver Channel LED indicators and Element connectors Figure 167. Channel Reference on each Receiver Card

Revision: A Date: 24 May 2018 Page 11

Figure 168. Receiver Channel Operation – Block Diagram Figure 169. Schematic – 1 of 4 Analog Receiver Channels Figure 170. AD608 Functional Block Diagram Figure 171. RSSI & Pulse Stretcher Waveforms – Large and Small Signal Figure 172. Ideal RSSI Transfer Function and ADS Signal Range Figure 173. Receiver Microcontroller Signal Pin Assignments Figure 174. Programming Port Wiring – Controller, Receiver and Transmitter 189 Figure 175. RX/TX Daughter Card – Main Mother Board Connector Figure 176. Parts for Assembling the Receiver Card Shield Figure 177. Attaching copper shield “Fingers” to inside of Shield lid Figure 178. Receiver Board with Surface Mount Components Figure 179. Close-up of Crystal Filter Lead Forming Figure 180. HP 355D Attenuator Figure 181. ADS-ADSP1 Interface Module Diagram Figure 182. Controller Terminal Program – MAIN Screen as Receiver Figure 183. Controller Terminal Program – Diagnostic Menu as Receiver Figure 184. Controller Terminal Program – Card Screen as Receiver Figure 185. Example ADS Receiver Card Calibration Form Figure 186. Transmitter Daughter Card Features Figure 187. Transmitter Channel LED indicators and Element connectors Figure 188. Transmitter Quadrature-Controlled Output Signals Figure 189. Transmitter Card Microcontroller Connections Figure 190. Transmitter Card FET Driver Figure 191. Transmitter Card Output Driver Schematic Figure 192. Transformer Parts and Materials Figure 193. Transformer Assembly Part Details Figure 194. Initial Wire Placement Figure 195. Completed Secondary Winding Figure 196. Bobbin with Secondary and Primary Coils Taped Figure 197. Wound Bobbin and Core Figure 198. A – Wound Bobbin in ½ Pot Core; B – 2nd ½ Pot Core set in place and aligned; C – Terminal Carrier and Core Assembly Figure 199. Assembly on Base – prior to installing Yoke Figure 200. Assembly Upside Down for Final Latching of Yoke Figure 201. Post Assembly QA Tests Figure 202. Transformer Soldering Fixture (Elevated Sockets) Figure 203. Wrapping and Trimming Wires on Base Pins Figure 204. View of Wire/Pin Soldering Figure 205. Final Electrical Acceptance Test Figure 206. ADS ADSP2 Transmitter Card Test Adapter Figure 207. ADS Transmitter Daughter Card Test Form – Example Figure 208. Index – IDEC Reference Appendix F Figure 209. FC5A-D12K1E CPU Module I/O Figure 210. FC5A – D12K1E Input Channel Circuit Figure 211. FC5A-D12K1E Transistor Sink Output Circuit Figure 212. FC5A-D16RK1 CPU Module Figure 213. FC5A-SIF4 RS-485 Communications Module Figure 214. Modbus SIF4 Connectors at Moore Haven and St. Lucie Locks Figure 215. Web Server Module Figure 216. FC4A-J2A1 2 Channel Analog input Module Figure 217. FC4A-J2A1 Input Circuit Figure 218. Main Program Ladder with ANST Command Figure 219. ANST Command Slot Selection Figure 220. FC4A-J2A1 Configuration Options Figure 221. FC4A-J2A1 Channel Status Values Figure 222. FC4A-J8C1 8-Channel Analog Input Module Figure 223. FC4A-J8C1 Input Circuit Figure 224. FC4A-JC81 ANST Command Slot Selection Figure 225. FC4A-JC81 Configuration Options

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Figure 226. FC4A-N08All 8 Channel AC Input Module Figure 227. FC4A-N08A11 AC Input Circuit Figure 228. Moore Haven MPLC Assembly with AC Input Modules Figure 229. FC4A-N08B1 8 pt. DC Input Module Figure 230. DC Input Module – Input Circuit Figure 231. FC4A-N16B1 16 Point DC Input Module Figure 232. FC4A-R08B1 8 Pt. Relay Output Module Figure 233. FC4A-R161 16 pt. Relay Output Module Figure 234. Programming Cable 1 – USB to Mini A Figure 235. USB to Serial Adapter and FC2A-KC4C Programming Cables Figure 236. Idec FC2A-KC4C Programming Cable – Wiring Diagram Figure 237. Ethernet Straight-through Patch Cable and Cross-Over Cable Figure 238. Programming Cable for HG1X Figure 239. Mini USB Maintenance Port on HG3G Enclosure Figure 240. WindLDR Configuration for PLC Monitoring Through HG3G Figure 241. WindLDR Communication Settings for Programming RX/TX PLC Figure 242. HG1F LCD Display in TX Enclosure Figure 243. HG1F with Programming Cable Figure 244. WindO/I-NV2 PROJECT - SYSTEM Settings for HG1F Figure 245. WindO/I-NV2 PROJECT – COMMUNICATION - SETTINGS for HG1F Figure 246. WindO/I-NV2 Communications Settings for HG1F Project Download. 245 Figure 247. WindLDR Communication Settings for Programming MH PLC Figure 248. Machinery House HG1X Display Screens 1,2,3 Figure 249. HG1X Power, PLC and Programming Ports Figure 250. WindMsg Menu Panel Figure 259. Data Logger Panel PC Bottom View Figure 260. Canaveral Lock Data Logger Main Screen Figure 261. Data Logger Main Screen Indicator Icons Figure 262. Typical Data Logger History Screen Figure 263. Historical Data Time Controls Figure 264. Search Window Figure 265. Removing/Replacing Water Level Sensor in Stilling Well Figure 266. Water Level Sensor Servicing Guidelines Figure 267. Gate 1 Status LED Graphic

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1 ADS-4 Manual Release Notes This Documentation Package is designed to provide in-depth explanation on how the Manatee Protection System functions. The author presumes that the reader has a basic understanding of the features and functions of the navigation locks. The original release of the MPS O&M Manuals covered only ADS versions 1 and 2. This manual adds the explanations of ADS-3 and ADS-4 version revisions.

This written manual has been adapted from the earlier O&M Manuals and much of the introductory material utilizes the same text and graphics. This is intentional as this manual is intended to replace the original O&M Manuals in order to eradicate the information that is no longer accurate.

The Documentation Package includes both this written manual and the training/explanation videos associated with the subjects. When an explanation in this manual requires, the reader will be instructed to stop and look at a specific video. In this way, the reader may grow from a basic set of knowledge to an in-depth understanding of the Manatee Protection System.

The video files are provided in MP4 format that should easily open in any Windows™ compatible video player. They are isolated files arranged in indexed folders for easiest access to specific information. The videos are not provided in a DVD – Player format with menus or burdensome scrolling in order to reach content. This also enables the authors to produce corrections or additional videos of new ADS features that may be added at a later date in order to keep the content current.

This Package applies to six of the US Army Corps of Engineers Navigation Locks: Canaveral, St. Lucie, Moore Haven, Port Mayaca, Ortona and W.P.

Franklin. There are also some references to the Taylor Creek Lock in Okeechobee that is operated by South Florida Water Management District. After this manual for the USACE Locks is completed, the author will integrate all of the information for Taylor Creek Lock and release a Revised Version.

The control systems for operating the locks are not identical. Throughout this package the common information will be presented first. Where there is specific information that applies to an individual lock, details will be provided following the common information.

Note: Screen Captured images or videos may include program file names that were current when the image was captured. They may not match the current file names that are installed at the locks.

This manual also includes a full explanation of the latest ADS-4 Revisions to the software programs.

ADS Version Revision Summary List:

ADS-1 First installation of ADS Hardware and Software.

ADS-2 Hardware change for improved signal range and enhanced transmitter control based on field trials of ADS-1. Added calculation of “GAP” between gates – in both single-gate closure and dual-gate closure. The ADS2 system always chose either the Skin Side Receivers or the Timber Side Receivers to monitor for alarms. The ADS2 software would dynamically switch between these receivers based on the relative alignment of the gates.

ADS-3 – Software upgrade to add simultaneous Skin and Receiver detection to cover both sides of pinch zone. This requires a good alignment of the gates during closure. ASDS-3 includes selectable “MPS assisted Gate Alignment”. The

Revision: A Date: 24 May 2018 Page 14 controls were adapted to use the GAP calculation for arming and transitioning from 2-Beam to 1-Beam modes. This makes it easier to relate to the effect that the setting has on protecting the manatee. For example, instead of entering “10.2% of Fully Open” as the position where 2-Beam detection is armed, the entry is now set at “48 inches of GAP”. The transition from 2 Beam detection to 1-Beam detection can be entered as “24.0” inches of GAP. ADS-3 also included automatic switching between ADS2 & ADS3 modes. The Operator no longer has to change the configuration of the MPS System when he needs to change the operation of the gates. If two gates are closing and they are not aligned, the MPS will automatically switch to ADS-2 Mode where only the SKIN Receivers or the Timber Receivers are monitored for alarms. If the gates move back into alignment, the MPS switches to ADS3 Mode where BOTH the Skin and Timber Receivers are monitored. The combination of MPS-assisted Gate alignment and the auto-switching of ADS protection modes greatly enhances manatee protection while achieving an improvement toward hands-off-operation by the busy operators.

ADS-4 – Software upgraded to add:

Permanent Bypass Screen for receiver channels that must be (permanently) bypassed until repaired. Previously, if an operator bypassed a channel that was causing false alarms, they were encouraged to return later and clear the bypass for another attempt at closure.

This procedure served to place receiver channels that were temporarily faulty back online. An example would be some debris caught on the gate and then later flushed through with the water movement from the lockage. However if there were several receivers that were bypassed and then all cleared at one time to try again, the operator would have to experiment with multiple gate closures in order to ferret out the ones that were working and not working. The approach of placing a channel offline on the Permanent Bypass screen(in the case of a damaged transmitter or receiver element) is that those bypasses are not cleared on the operators bypass panel and time and equipment operation is not wasted each time a channel is being tested for reliability.

Archive Screen – this is a screen addition to show the Gate positions and Receiver channels that caused the 6 most recent alarms – this provides the operator readily accessible information to make judgements regarding false alarms and to help them determine when to bypass a receiver channel that is triggering false alarms. Previously, this information was only available in the data logger and required scrolling back in time to find the data. With ADS-4, two screen clicks jumps to a chart showing the last 6 alarms on one screen.

Modified Gate Zone and Auto-Cal setting controls so that input is simpler and we added “linked relationships”. This means that the settings cannot be changed for one feature and corrupt the operation of another. Previously, the MPS Zones could be set independently of the Auto-Cal zones. The problem showed-up when Auto-Cals were executed and the Gates would not open enough to ARM the system. The Auto-Cal would fail. Automatically linking some of these settings maintains performance across all features of the MPS while leaving the Gate Zone settings specifically related to manatee detection and intervention.

This is a much more intuitive approach.

Adaptive Margin and threshold Calculation. Prior to ADS – 4, the service technician was required to spend a great deal of time adjusting the margin tables after an auto Cal. In ADS – 4 an adaptive algorithm has been designed and implemented that will provide all of the insight

Revision: A Date: 24 May 2018 Page 15 that a service technician would provide and automatically set the margins and threshold values. After an auto Cal is completed, the MPS is configured to automatically run this algorithm to adjust the thresholds for optimum performance. Also, there is a screen for optionally adjusting the algorithm and rerunning the calculations of thresholds. The inclusion of these features enables the service technician to efficiently make adjustments and to keep receivers on line over long periods of time.

2 Introduction

The Canaveral Lock West Gates are shown in Figure 1. The Canaveral Lock has two separate control stations; one at either end of the Lock. The operator must travel from one end to the other in order to complete the lockage. The water depth and visibility can prevent the operator from visually tracking the travels of a submerged manatee.

The Manatee ADS (Acoustic Detection Sensor) Protection System can detect the submerged manatee that is between the closing gates and provide automatic intervention by stopping the gate before it can touch the manatee. The ADS system will act as the “eyes beneath the surface” to detect the slow moving mammal and keep it from being injured.

Figure 1. Canaveral West Gates with Manatee at surface

The detection of the manatee is accomplished using sound waves in the water (acoustics). However, unlike sonar systems or fish finders which send-out acoustic pulses and then receive the reflected signals with the same transducer, the Acoustic Detection System uses an acoustic emitter (transmitter) and a separate receiver. The manatee detection is simply the blocking of the line-of-sight coupling between the transmitter and receiver.

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An array of transmitters is attached to one gate sector and a matching array of receivers is attached to the opposite gate sector. The arrays include multiple sensor cartridges that each have 10 transducer elements to provide sensing channels that are vertically-spaced every 6 inches in the water column. Each receiver produces a “1 or 0” output signal to represent when acoustic energy is, (1) being received, or (0) isn’t reaching the receiver.

When the Gap between the gates is less than the 48” (adjustable set point) and the gates are closing, a receiver “0” becomes an “Alarm” and the Gates are stopped to prevent injury to the manatee. If the gates are deemed close enough to present a pinch hazard, the gates are automatically opened by the MPS to provide the manatee a safe passage. See Figure 2.

Figure 2. Gate Mounted Transmitter/Receiver Arrays

3 Glossary of Terms

Sensor Element – a 2” Tall x ½” wide device that can convert electrical signals to acoustic sound waves (Transmitter) or can convert acoustic sound waves to electrical signals (Receiver).

Sensor Cartridge – an assembly of 10 sensor elements spaced 6” center-to-center and potted into one monolithic cartridge.

Includes electrical cable to conduct signals to/from the surface electronics.

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Sensor Array – 2 to 5 cartridges stacked above a bottom cartridge and bolted to the gate.

Line-of-site coupling – a direct path between a transmitting element mounted on one gate, and a receiving element mounted on the opposing gate. An alarm occurs when a target BLOCKS the line-of-site coupling path.

Two Beam blockage – when 2 sequential receiver elements in the vertical sensor array are shadowed by a target to create an alarm.

One Beam Blockage – when a single receiver element is shadowed by a target to create an alarm.

Skin Side Array – sensor array mounted near the bull-nose – on the curved SKIN Plate of the sector gate.

Timber Side Array – sensor array mounted near the bull-nose – on the flat side of the sector gate where the protective Timbers are attached.

Dual Gate Operation – when 2 opposing sector gates are opened or closed at the same time to lock boats or manatees.

Single Gate Operation – when one sector gate is left closed and the opposing gate is opened/closed to lock boats or manatees.

ADS-2 Mode – manatee protection where ONLY the SKIN Side OR ONLY the TIMBER Side receivers are monitored for Blocked Beams. ADS2 is required for Single-sector Gate Operation where one gate remains closed.

ADS-3 Mode – manatee protection where BOTH the SKIN Side receivers AND the Timber Side Receivers are monitored simultaneously. This Mode provides the best protection and is used when two sector gates are closing at the same time – Dual Gate Operation.

4 General System Description

A Basic arrangement of the MPS components associated with a pair of gate sectors is shown in Figure 3.

The Gate Position sensors provide a measurement of Gate Position. There is only a hazard to the manatee when the gates are closing and they are close enough to create a pinch-hazard. This hazard zone is called the “MPS Zone” – the area where the ADS system must be armed and ready to make the detection.

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The Water Level sensor is important because the acoustic transmitters are not able to transmit the sound waves through the air. The controller must know where the water level is in order to ignore the acoustic sensor elements that are above the water line.

The Operator Control Panel is an LCD Touch Screen that enables the operator to view the MPS system status and then make adjustments to the operation.

The Master PLC is a Programmable Logic Controller that communicates with the Transmitter and Receiver Electronics, monitors the Gate Position and water level sensors and processes the input/output with the gate controls of the lock.

Figure 3. Basic ADS Components on set of Gates

4.1 Site Layouts

The physical locations of the ADS components on a lock structure are lock-specific. Each installation was planned to use the most efficient installation methods and to ensure the best possible access for maintenance.

There are 2 configurations of ADS installations. At the Canaveral, Ortona, Port Mayaca, W.P. Franklin Locks there are two independent Lock Control stations and the operator generally must travel from end to end in order to operate these locks(1). At these locks, there are 2 Master PLCs and they are independent. If one system fails, the manatee protection at the other end of the lock is not affected.

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(1)At the W.P. Franklin Lock, wiring has been extended to the Central Lock Station to operate both ends of the Lock from a single location. However, the MPS still has two Master PLCs/touch screens that were installed prior to the central controls being added.

At the Moore Haven and St. Lucie Locks there is only one control station from which both ends of the lock can be operated. Therefore there is a single Master PLC and a single Touchscreen that handles the MPS control interface for both ends of the Lock.

4.1.1 Locks with Two Control Stations: Canaveral, Ortona, Port Mayaca, and W.P. Franklin

4.1.1.1 Canaveral Lock Layout

The Canaveral Lock Layout is shown in Figure 4.

The key-code at the bottom of the figure introduces more abbreviations that are referenced throughout this document. For example: RX refers to the “Receivers” and TX refers to “Transmitters”. Additionally, the Gate numbering convention of Odd numbers 1 & 3 for the upper or East NEAR and FAR Gate respectively is introduced, as well as the EVEN numbers for the lower or West gates. The 1/3 and 2/4 designations are used for all locks, and the East/West or North/South or River/Ocean designations are only used within the descriptions for the specific locks where the designation applies.

Note that the 1, 2 Gate Sectors are always the Near Side Gates – on the side with the Gate Control House(s). The 3, 4 Gates are always the FAR Gates.

Also introduced in this figure is MPLC-1 and it refers to the ADS Master PLC at Gate Control House #1. MPLC-2 Controls Gates 2 & 4.

KEY: TX = Transmitter Enclosure, RX – Receiver Enclosure, MH – Machinery

House, MPLC – Master PLC

Figure 4. MPS Site Layout - Canaveral Lock Layout – Not to Scale

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4.1.1.2 Canaveral Lock Control and MPS Configuration

Two Control Houses Hydraulic/Cable Operation Gate Controls – Relay Logic with added feature of Proportional Valves for Ramp-Up & Ramp-Down speed change (2 - Speeds: Fast, Slow).

MPS Configuration:

o Master PLC 1 with interface to Gate Position Sensor for Gate 1 o Master PLC 2 with interface to Gate Position Sensor for Gate 2 o Two RX Enclosures with Water Level Sensors – RX-1 Chamber Water

Level, RX-2 River Water Level o Two TX Enclosures – TX-3, TX-4 o Machinery House Enclosure MH3 with PLC and interface to Gate

Position Sensor for Gate 3 o Machinery House Enclosure MH3 with PLC and interface to Gate

Position Sensor for Gate 4 o Data Logger Panel-PC located in Control House 2.

o Fiber Optic link - RS-232 Serial Link for Data Logger communication between Control House 1 and Control House 2.

o Gate Position Type: Incremental Encoder with spring loaded pick-up wheel on cable drum. The Encoder Brackets are unique to Canaveral Lock.

o Sensor Coverage Gates 1/3 (East) – Vertical Array of 4 Cartridges

– 40 elements on Skin and Timber Sides of each sector – total 160 sensor elements -80 transmitters, 80 receivers o Sensor Coverage Gates 2/4 (West) – Vertical Array of 4 Cartridges

– 40 elements on Skin and Timber Sides of each Sector – total 160 sensor elements – 80 transmitters and 80 receivers.

4.1.1.2.1 Canaveral Gate Controls

The West Gates control panel at the Canaveral is shown in Figure 5.

Figure 5. Canaveral Gate Controls – West Gates

The Canaveral Gates are electrically controlled hydraulic drives with Cable Spooling Drums for moving the Gates. The operator’s controls are OPEN, STOP, Revision: A Date: 24 May 2018 Page 21

CLOSE with a 2-speed selector and an isolation switch (Maintenance switch) for each sector so that one sector can be operated at one time if needed.

The control circuit diagram is shown in Figure 6.

Figure 6.Canaveral Gate Control Circuit – West Gates

The OPEN, CLOSE, Stop controls are spring return pushbuttons. The diagram shows latch-in contacts for OPEN and CLOSE functions. The Stop switch breaks the AC-line source on the left and the circuit unlatches.

The bottom portion of Figure 6 shows the hydraulic speed control circuit.

Normally – the nearly closed (NC) and nearly open (NO) limit switches switch the speed to slow. The Gate Speed Slow/Fast is the SLOW speed over-ride that selects slow speed regardless of the limit switch positions.

The G2-1 and 2 contacts are controlled by the Gate 2 “Maintenance” switch.

The G4-1 and 2 contacts are controlled by the Gate 4 “Maintenance” switch.

Therefore, this circuit is a standard OPEN-CLOSE latch-in circuit with 2-speed control and Gate 2 and Gate 4 isolation for single gate operation.

Canaveral Ramp-Up and Ramp-Down Variable Speed

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Canaveral has received an upgrade to the original control system. Variable Flow valves were installed that provide a smooth speed change from slow to fast and from fast to slow. This hydraulic change was designed to reduce wear and tear on the gate mechanical systems.

This has been successful, but the implementation has had an impact on the Manatee Protection System. When the operator presses stop, the control vales will ramp down the speed of the gate and then stop. Then the Operator can choose to open or close to change direction. However, there is no feedback between the ramping system and the gate controls. This means that the operator must provide a time-delay between commanding a STOP and changing directions. For example, if the gates are closing and the operator commands a STOP, he must wait until the cycle time of the valves is complete. If he does not, then the Close valve will not have completely closed and when the ‘OPEN” command re-engages the hydraulic pressure, the gate can physically move in the close direction until the Ramp-Down cycle is complete. As the CLOSE Ramp- Down completes, the flow through the OPEN valve will take over and reverse the direction of the gate. The operators have been trained for this anomaly and perform their tasks effectively.

However, immediately after this upgrade was installed, the MPS System produced strange gate movements because the MPS had been programmed to PRESS the STOP for 2 seconds and then immediately press the OPEN to reverse the gate direction. To correct this, HBOI had to install a time delay between STOP and change-in-direction in order to match the requirements placed on the operator by the ramp/down valves.

HBOI had to install a delay timer between a “STOP” for Manatee Detection and the OPEN (in Crush Zone) to avoid the gate CLOSING a bit before opening. At all other locks, this “Detection Pause before Opening in Crush Zone” is set to 5 seconds, but at Canaveral, this delay is set to 8 seconds. This is just one of the reasons that the ADS System Touchscreen has been equipped with these easily adjusted Touchscreen parameters. See Figure 7.

Figure 7. Intervention Settings – Factory Default Screen Page 4.

4.1.1.3 W.P. Franklin Lock Layout

The Franklin Lock Layout is shown in Figure 8.

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Figure 8. MPS Site Layout – W.P. Franklin Lock – Not to Scale

4.1.1.4 W.P Franklin Lock Control and MPS Configuration

Two Control Houses Hydraulic/Cable Operation Gate Controls – Relay Logic with added feature of Proportional Valves for Ramp-Up Ramp-Down speed change (2 = Speeds: Fast, Slow).

MPS Configuration:

o Master PLC 1 with interface to Gate Position Sensor for Gate 1 o Master PLC 2 with interface to Gate Position Sensor for Gate 2 o Two RX Enclosures with Water Level Sensors – RX-1 Chamber Level, RX-2 Downstream Level – toward Gulf - Tidal.

o Two TX Enclosures – TX-3, TX-4 o Machinery House Enclosure MH3 with interface to Gate Position

Sensor for Gate 3 o Machinery House Enclosure MH3 with interface to Gate Position

Sensor for Gate 4 o Data Logger Panel-PC located in Control Central House.

o Ethernet – Copper connection between Central Control House.

o Gate Position Type: Incremental Encoder with spring loaded pick-up wheel on cable drum o Sensor Coverage Gates 1/3 (East) – Array of 4 Cartridges – 40 elements o Sensor Coverage Gates 2/4 (West) – Array of 4 Cartridges – 40 elements

4.1.1.4.1 W.P. Franklin Gate Controls

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Figure 9. W.P. Franklin Lock Controls – Gate 1 and 3 (East Gates)

The Franklin Lock Gates are almost identical to the Canaveral Gates -electrically controlled hydraulic drives with Cable Spools for moving the Gates. The operator’s controls are OPEN, STOP, CLOSE with a 2-speed selector (Slow Always ON or Slow Automatic), and an isolation switch (Maintenance switch) for each sector so that one sector can be operated at one time if needed.

At Franklin, either the OPEN Circuit is latched-in by a press of the OPEN Button or the CLOSE Circuit is latched in. The STOP Button unlatches both the CLOSE and the OPEN Circuits and is therefore a STOP ALL.

The OPEN or CLOSE Circuit stays latched-in until the STOP is pressed, or the Fully-Open or Fully Closed Limit Switches unlatch the function. However, once the OPEN or CLOSE is latched, the MAINTENANCE switched can still be switched from OFF to ON or ON to OFF and the selected gate will move or stop. These switches are renamed as “Isolation” switches when discussing the MPS System.

The Isolation switches enable the MPS execute Gate Alignment by isolating (Stopping) the leading gate until the trailing gate catches up.

The MPS MASTER PLC enclosures for the W.P. Franklin Locks are located right beside the Operators Control Station and the enclosures have clear door panels. This enables the service technician to observe the marked relays with built in LEDs to indicate exactly what the MPS is trying to execute Open, Close, Stop. See Figure 10.

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Figure 10. Franklin MPLC and MPS Control relays

4.1.1.5 Port Mayaca Lock Layout

The Port Mayaca Lock Layout is shown in Figure 11.

Figure 11. MPS Site Layout – Port Mayaca Lock – Not to Scale

4.1.1.6 Port Mayaca Lock Control and MPS Configuration

Two Control Houses Hydraulic/Cable Operation

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Gate Controls – Relay Logic, 2-speed Hydraulic Valves. Speeds: Fast, Slow.

MPS Configuration:

o Master PLC 1 with interface to Gate Position Sensor for Gate 1 o Master PLC 2 with interface to Gate Position Sensor for Gate 2 o Two RX Enclosures with Water Level Sensors – RX-1 Chamber Level, RX-2 Canal (East) Water Level o Two TX Enclosures – TX-3, TX-4 o Machinery House Enclosure MH3 with interface to Gate Position

Sensor for Gate 3 o Machinery House Enclosure MH3 with interface to Gate Position

Sensor for Gate 4 o Data Logger Panel-PC located in Control House #1.

o Fiber Optic link - Serial Link for Data Logger between Control

House 1 and Control House 2.

o Sensor Coverage Gates 1/3 (West, or Lake Side) – Vertical Array of 5 Cartridges – 50 elements on Skin and Timber Sides of each sector – total 200 sensor elements -100 transmitters, 100 receivers o Sensor Coverage Gates 2/4 (East, or Canal Side) – Vertical Array of 5 Cartridges – 50 elements on Skin and Timber Sides of each Sector – total 200 sensor elements – 100 transmitters and 100 receivers.

4.1.1.6.1 Port Mayaca Gate Controls

The Port Mayaca typical control panel is shown in Figure XX.

Figure 12. Port Mayaca Gate Control Panel with MPS Auto-Shutdown

The Port Mayaca controls are standard Latch-in Open/Close/Stop circuits with a FAST/SLOW Speed Control switch. The only MPS interface that is different at Port Mayaca is a MPS Assisted Shutdown control. This feature ensures that the Hydraulic Motors are turned off after the Gate Closure is complete. This is especially helpful at the Lower Gates. In MANUAL, the MPS has no effect on the Motor Shutdown Controls. In AUTO, the MPS has a (series) normally-closed contact for the Motor latch-in circuit that can open and turn-off the hydraulic motors.

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At Gates 1/3 the Master PLC is below the floor in the machinery pit and is not easily observed for diagnostics. At the Lowers, however, there is a MPLC2 enclosure next to the control panel and a single door can be opened to observe the MPLC Control Relays. See Figures 13 and 14.

Figure 13. Port Mayaca MPLC 2

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Figure 14. Port Mayaca MPS Control Relays

4.1.1.7 Ortona Lock Layout

The Ortona Lock Layout is shown in Figure 15.

Figure 15. MPS Site Layout – Ortona Lock – Not to Scale

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4.1.1.8 Ortona Lock Control and MPS Configuration

Two Control Houses Variable Frequency Drive with direct Rack/Pinion Gear Drive.

Gate Controls – Contractor installed PLC.

MPS Configuration:

o Master PLC 1 with interface to Gate Position Sensor for Gate 1 o Master PLC 2 with interface to Gate Position Sensor for Gate 2 o Two RX Enclosures with Water Level Sensors – RX-1 Chamber Water

Level, RX-2 Downstream (West) Level o Two TX Enclosures – TX-3, TX-4 o Machinery House Enclosure MH3 with interface to Gate Position

Sensor for Gate 3 o Machinery House Enclosure MH3 with interface to Gate Position

Sensor for Gate 4 o Data Logger Panel-PC located in Office Building, Copper Ethernet

Link to MH #1.

o Fiber Optic link - Ethernet Link for Data Logger between Control

House 1 and Control House 2.

o Gate Position Type: Single Turn Encoder, analog output with

Clamped pick-up gear segment on Gear-Reduction shaft – Machinery House 1,2,3,4.

o Sensor Coverage Gates 1/3 (East) – Vertical Array of 4 Cartridges

– 40 elements on Skin and Timber Sides of each sector – total 160 sensor elements -80 transmitters, 80 receivers o Sensor Coverage Gates 2/4 (West) – Vertical Array of 4 Cartridges

– 40 elements on Skin and Timber Sides of each Sector – total 160 sensor elements – 80 transmitters and 80 receivers.

4.1.1.8.1 Ortona Gate Controls

The Ortona Lock has been equipped with PLC Control of Variable Frequency Drives for the electric motors and direct gear drives for the gates. When this occurred, a new control panel was installed. A set of Gate Controls is shown in Figure 16.

Figure 16. Ortona Gate Controls

The Gate controls were designed for optimum gate control but are not optimized for auxiliary control by the external MPS System. The Gate controls are sprint return to center toggle switches. The operator independently selects OPEN function or CLOSE function with the switches. If he uses two hands, the gates are reasonably aligned during a 2-gate opening/closing. If he uses one hand, the Gates will not be well aligned in the MPS Zone and this

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