INSTRUCTION MANUAL Microwave Smart Switch Series - Beam Blockage Detection - A higher level of performance
INTRODUCTION CONTENTS PROPRIETARY NOTICE The information contained in this publication is derived in part from proprietary and patent data. This information has been prepared for the express purpose of assisting operating and maintenance personnel in the efficient use of the instrument described herein. Publication of this information does not convey any rights to use or reproduce it, or to use for any purpose other than in connection with the installation, operation and maintenance of the equipment described herein. WARNING This instrument contains electronic components that are susceptible to damage by static electricity. Proper handling procedures must be observed during the removal, installation, or handling of internal circuit boards or devices: Handling Procedure: 1. Power to unit must be removed prior to commencement of any work. 2. Personnel must be grounded, via wrist strap or other safe, suitable means, before any printed circuit board or other internal devices are installed, removed or adjusted. 3. Printed circuit boards must be transported in a conductive bag or other conductive container. Boards must not be removed from protective container until the immediate time of installation. Removed boards must be placed immediately in a protective container for transport, storage, or return to factory. Comments: This instrument is not unique in its content of ESD (electrostatic discharge) sensitive components. Most modern electronic designs contain components that utilize metal oxide technology (NMOS, CMOS, etc.). Experience has proven that even small amounts of static electricity can damage or destroy these devices. Damaged components, even though they appear to function properly, exhibit early failure. General Description, Features 2 Typical Applications 3 Dimensions 5 Mounting 2 Wiring - Smart Integral Version 17 - Remote - Hawk Cable 18 - Remote - Customer Cable 19 - Junction Box / Cable extension 20 - Relay Functions 21 - Cross Talk Prevention - 2 Units 22 - More than 2 Units 23 - Multidrop Connections 24 - HawkLink GSM 25 - Test Terminal 27 Setup Procedure - Smart Integral Version 28 - Remote Version 32 Remote Software Menus 35 - Software Tree 36 - QuickSet Menu 37 - Advanced Menu 38 - Diagnostic Displays 40 Multidrop Communication 41 Remote Communication 42 Safety Information 43 Part Numbering 44 Specifications 47 Contact Information (back cover)
GENERAL DESCRIPTION FEATURES Principle of Operation Beam blockage A beam of microwave energy passes from a sender to a separate receiver in bursts approximately 200 times per second. If the path between the sender and receiver is blocked by any object or material which absorbs or reflects microwave energy, then the receiver will not be able to detect the signal. The presence or absence of the signal at the receiver is used to switch a relay for indication or control purposes. Wide beam pattern for easy alignment LCD setup/diagnostics on remote amplifier Ranges up to 200 meters (656 ft ) Simple 1-minute setup Remote sensor or Smart Integral all in one types Relay outputs: Smart Integral (1) Remote (2) Remote test function Adjustable ON and OFF delays (0-20 sec) Smart communication options: GosHawk, Modbus, HART, Profibus DP, DeviceNet Remote GSM Connection option Remote amplifier to sensor separation up to 500 m (1640 ft) Bright visual status indication on sensors Independent housing alignment after mounting sensors 2
TYPI APPLICATIONS Machine Protection Shiploader Luffing Control/Boom Protection Boom Protection Shiploader Protection Blocked Chute Protection 3
TYPI APPLICATIONS Coal Fired Power Station, Bulk Material Handling High/low and blocked Gladiator chute detection* Receivers Microwave Blocked Chute Detection Sender Gladiator Gladiator *For detection of product motion in applications such as product on conveyors, in transfer chutes or feeder pipes, see Gladiator Doppler Microwave product information. Blocked Chute Mount Microwave under pulley or out of main system flow Receiver Cement Plants Solid Level - Cyclone Bin High/low Level Sender High Gladiator Receiver Sender Low Gladiator 4
DIMENSIONS SMART INTEGRAL MICROWAVE SYSTEM Standard Sender or Receiver Ø85 mm (3.3 ) High Power Sender, Receiver or SRS Receiver Ø85 mm (3.3 ) 50 mm (2 ) 129.5 mm (5.1 ) 135.5 mm (5.3 ) 90 mm (3.5 ) 2 mm (0.078 ) 10 mm (0.4 ) 50 mm (2 ) 90 mm (3.5 ) 12 mm (0.5 ) Ø88 mm (3.5 ) Ø160 mm (6.3 ) 250 mm (9.8 ) Ø165 mm (6.5 ) Ø277 mm (10.9 ) Standard Sender or Receiver Flange High power Sender / Receiver or SRS Flange 160 mm (6.3 ) 135 mm (5.3 ) 8xØ22 mm Holes THRU 160 mm (6.3 ) Alignment marks 4x10 mm holes Ø238 mm(9.3 ) Ø88.5 mm (3.5 ) Ø165 mm (6.3 ) Ø277 mm (10.9 ) Note: Remote and Smart Integral types use the same flange dimensions 5
DIMENSIONS REMOTE MICROWAVE SYSTEM Amplifier Enclosure 192.5 mm (7.6 ) 174 mm (6.9 ) 111.5 mm (4.4 ) 78 mm (3.1 ) 14 mm (0.6 ) 30.7 mm (1.2 ) 7.5 mm (0.3 ) 192.5 mm (7.6 ) 147 mm (5.8 ) 108 mm (4.3 ) 190 mm (7.5 ) 107 mm (4.2 ) 190 mm (7.5 ) 167.5 mm (6.6 ) 141.5 mm (5.6 ) 131.5 mm (5.2 ) 182.5 mm (7.2 ) 50 mm (2 ) 74 mm (2.9 ) 4 mm (0.2 ) 147 mm (5.8 ) 158 mm (6.2 ) 182.5 mm (7.2 ) Standard Sender or Receiver Ø85 mm (3.3 ) High Power Sender, Receiver or SRS Receiver Ø85 mm (3.3 ) 50 mm (2 ) 90 mm (3.5 ) 2 mm (0.078 ) 10 mm (0.4 ) 129.5 mm (5.1 ) 135.5 mm (5.3 ) 50 mm (2 ) 90 mm (3.5 ) 12 mm (0.5 ) Ø88 mm (3.5 ) Ø160 mm (6.3 ) 250 mm (9.8 ) Ø165 mm (6.5 ) Note: For Flange dimensions see page 5 Ø277 mm (10.9 ) 6
DIMENSIONS ACCESSORIES Weldments to suit UHMW/Teflon windows Size A B C D E F G G 3 100 (3.94 ) 3 NPT 22 (0.87 ) 5 (0.2 ) 92.5 (3.64 ) 118 (4.65 ) 4 (0.16 ) A B E F 4 125 (4.92 ) 6 190.4 (7.5 ) 4 NPT 24.4 (0.96 ) 6 NPT 40 (3.94 ) 5 (0.2 ) 5 (0.2 ) 120 (4.72 ) 175 (6.89 ) 148 (5.83 ) 223 (8.78 ) 4 (0.16 ) 11.2 (0.44 ) UHMW/Teflon Windows 75mm (2.95") Ø6.5mm(0.25 ) 2 Places I C H D 15mm (0.59") 3 steel weldment: MA-0 3 stainless steel weldment MA-19 4 steel weldment: MA-18 4 stainless steel weldment MA-22 Size H I 3 3 NPT 4 4 NPT 6 6 NPT 28.7 (1.13 ) 35 (1.38 ) 40 (1.57 ) 3 UHMW window only MA-21 4 UHMW window only MA-20 3 UHMW window & weldment MA-3 4 UHMW window & weldment MA-4 6 UHMW window & weldment MA-5 3 teflon window & weldment MA-6 4 teflon window & weldment MA-7 6 teflon window & weldment MA-8 Weldments to suit Ceramic windows R J K Retainer for Ceramic Windows (Bundled with matching Weldment) U Ø6.3mm(0.25 ) 2 Places L M N O P Q Size J K L M N O P Q R 3 100 (3.94 ) 4 125 (4.92 ) 3 NPT 4 NPT Ceramic Windows (Bundled with matching Weldment) 22 (0.87 ) 24.4 (0.96 ) 5 (0.2 ) 5 (0.2 ) 65 (2.56 ) 90 (3.54 ) 75 (2.95 ) 101 (3.98 ) 92.5 (3.64 ) 120 (4.72 ) Size S T U V 3 75 (2.95 ) 65 (2.56 ) 3 NPT 118 (4.65 ) 148 (5.83 ) 74.5 (2.93 ) 4 (0.16 ) 4 (0.16 ) T V 4 100 (3.94 ) 90 (3.54 ) 4 NPT 100.5 (3.96 ) S 12.3mm (0.48 ) 11-12.7mm (0.43-0.5 ) 3 ceramic window & weldment MA-16 4 ceramic window & weldment MA-17 Unlisted parts not available separately 7
DIMENSIONS ACCESSORIES Ceramic Tile Window Assembly MA-10 Ceramic Time Mounting Assembly 152.4mm (6.0") 101.6mm (4.0") 317.5mm (12.5") Ceramic Tile (alumina) 101.6mm (4.0") 152.4mm (6.0") 25.4mm (1") 8
DIMENSIONS ACCESSORIES Firebrick Window Assembly MA-9 Firebrick Mounting Assembly 228.6mm (9.0") 114.3mm (4.5") 215.9mm (8.5") 419.1mm (16.5") 50.8mm (2.0") Firebrick 114.3mm (4.5") 228.6mm (9.0") 76.2mm (3.0") 9
DIMENSIONS ACCESSORIES Example High Temperature Waveguide Parts *All Waveguide Parts available on special order only Waveguide WR90 Cone 41mm (1.625") 33mm (1.283") 41mm (1.625") 32mm (1.275") 10mm (0.90") 23mm (0.890") Waveguide WR90 Straight FB GTAW 4mm Ø.172) ( Thru Typ 4 Pics 33mm (1.283") "A" Note: "A" = Per Application Finish Per Application 33mm (1.283") Waveguide WR90 Bend 4mm (Ø.172) Thru Type 8 Pics 33mm (1.283") FB 33mm (1.283") "A" GTAW FB Note: "A" = Per Application Finish Per Application 10
DIMENSIONS ACCESSORIES Adjustable Microwave Bracket MA-12 - With UHMW Window MA-13 - With PTFE Window 135mm (5.3") 4 x 10mm (3/8") Mounting holes Ø 225mm (8.85") 120mm (4.72") 148mm (5.83") 336mm (13.2") Glass Window MA-1 Flanged Pipe Mount MA-15 300mm (11.8") 2" N.P.T. 19.9mm (0.78") 6.3mm (0.25") 135mm (5.31") 140mm (5.51") 94mm (3.7") 4 mounting holes 10mm (3/8") 101mm (3.97") End closed with UHMW window 11
MOUNTING GENERAL GUIDELINES 1. The microwave beam is a polarized form of energy. As such, it is necessary to align the units in the same spatial plane. If the units do not have the same orientation, the amount of received energy is diminished. At 90 to each other, the detector is blind and cannot detect the beam. The actual angle of mounting is not relevant, so long as both the Sender & Receiver have the same angle and elevation. Flanges are marked with an alignment notch to assist in mounting correctly. 2. When looking for a mounting location, try to locate and mount the inside of the window for each unit flush with the vessel wall and where minimal build-up will occur. The system can penetrate through generous amounts of buildup of various products, however, the better the position, the more reliably it will operate. 3. Microwave energy cannot penetrate through steel linings or other conductive linings. You must cut a viewing hole and use an appropriate windowed weldment. 4. For high vibration applications, it is necessary to isolate the electronics to keep them from long term damage. This is most often accomplished using 4 UHMW or teflon windowed weldments in the vessel walls, and mounting the Microwave Sender and Receiver to a separate stable structure (I-beam, handrail) to isolate them from vibration. Isolation shock mounts can also be provided to help protect the electronics. 5. For applications which exceed 60 C/140 F (precipitators, cement cyclones, etc.), it is necessary to ensure that the sensors always remain below 60 C/140 F. This is normally achieved by installation of temperature resistant windows of ceramic or firebrick, and positioning of the Sender and Receiver in line with the windows, and set back far enough that their temperature remains below the given limit. Where this is impossible, it will be neccessary to use remote mounting microwaves with waveguide assemblies. This allows the electronics to be placed in an area where ambient temperatures do not exceed the maximum allowable for operation. It is necessary to contact the factory for this last type of waveguide application. 12
MOUNTING CORRECT MOUNTING ANGLE Correct Elevation Maximum Signal Strength to Receiver is indicated by maximum brightness of Green LED on Receiver. Sending Unit Microwave Beam Receiving Unit Incorrect Elevation Sending Unit Receiving Unit ALIGN SENDER AND RECEIVER Rotate so that Visual Alignment Guide is in the same position on both sender and receiver.! Correct rotational alignment is critical for correct performance 13
MOUNTING MOUNTING WITH WINDOWED WELDMENTS Metal Bin/Chute Walls 4 UHMW Windowed Weldment Sender Receiver Fabricated Bracket Attach fabricated brackets to separate structure if bin/chute walls are subject to high vibration BLOCKED CHUTE MOUNTING MAIN PRODUCT FLOW Receiving Unit Sending Unit Housing can be rotated within 200º after the mounting thread is tightened, to allow cable entries to face downwards or allow optimal cable clearance. Position blocked chute detectors to one side of main product flow 14
MOUNTING INSTALLATION WITH ADJUSTABLE MOUNTING Product Flow Hooper/Feeder X X X = 30 Maximum Sending Unit Receiving Unit Isolation Mount Adjustable microwave mounting bracket MA-12 or MA-13 welded to vessel wall. UHMW (MA-12) or Teflon (MA-13) Window. 15
MOUNTING SPECIFIC APPLICATIONS 1. When mounting to monitor the level of a flowing product such as coal, ore or wood chips, position the microwave path out of the direct product flow stream. If at all possible, go behind the flow stream or well in front of it. This will minimise any possibility of unwanted trips due to abnormal product flow blocking the beam. 2. When mounting to monitor for absence/ presence or plugged chute conditions, the Sender & Receiver must be mounted opposite each other observing correct elevation and orientation. The system should be mounted in such a way that as product reaches the level of the sensors, the beam will be broken. 3. When using the system as a proximity switch, the mounting arrangement is application dependent and must ensure proper operation even under worst case conditions. Please consult your representative or the factory for specific advice relating to mounting arrangements. 4. Mounting of a Microwave system on sloped vessel walls can be accomplished using the Microwave Adjustable Mount (MA- 12 or MA-13). This system allows the microwaves to be mounted to a sloped surface and then adjusted horizontally for optimum performance and operation. The adjustable mount has an integral 4 weldment with UHMW polyethylene or PTFE (teflon) window options. An option with the bracket is a vibration isolation kit (shock mounts) to help protect the electronics from damage. Each side wall of the vessel must not exceed 30 degrees from the vertical centerline. To mount the adjustable bracket, simply cut a hole and weld the 4 weldment directly to the vessel, install the window, mount the microwave and adjust horizontally. Similar performance can be obtained by fabrication of fixed brackets which mount the Sender and Receiver in direct line with one another and aimed through the centre of two MA-4 windowed weldments. 16
WIRING SMART INTEGRAL SYSTEM Receiver Green Power/Signal strength/alignment indicator LED Blue Calibration/Error LED Red Relay Status LED Sender Green Power ON LED Red Transmitter enabled LED SENSITIVITY HI FSH TEST DELAY Remove Plug-In terminal block for easier wiring. INT 1 MICROWAVE SENDER 2 3 PRESS PWR TX TO TEST 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 The AC earth/ground cable must be connected to the ground screw inside the housing when using AC power. Hole for securing of optional identification tag M4 grounding screw If only one cable is used for both power and output signal, then the second entry port must be plugged or blinded. Every Smart receiver is supplied with two M20 glands (or 3/4 NPT adaptors) mounted on the unit and one blind plug loose. **Ground the housing to vessel, if vessel is metallic. Ground the housing to plant ground, if vessel is non-metallic. ** RECEIVER TERMINAL LAYOUT RELAY COMMS DC-IN AC-IN SENDER TERMINAL LAYOUT DC-IN AC-IN 1. NC 2. COM 3. NO 4. Test 5. A 6. B 7. - N 8. 9. 10. L1 1. 2. 3. 4. 5. 6. 7. - N 8. 9. 10. L1 RS 485 7-30VDC 80-260VAC 7-30VDC Terminals 1, 2, 3, 4, 5, 6 not used 80-260VAC Note: AC power terminals may only be used when universal AC power supply option has been selected - see part numbers - AC terminals have no function in products without universial AC power option. 17
B A N Microwave Smart Switch Series WIRING REMOTE SYSTEM - HAWK SUPPLIED CABLE The black wire of Hawk supplied cable comes with one end GND and the other GND/SHLD together. The GND/SHLD end is a larger cable which has been heat shrunk. The GND only end is the same size as the other coloured cables. The GND/SHLD end must be connected to the amplifier and the GND end to the sender/receiver. Remote Receiver TERMINAL LAYOUT Remote Sender TERMINAL LAYOUT Green Power ON LED Red Transmitter enabled LED 1. 2. 3. 4. BROWN 5. WHITE 6. BLUE 7. RED 8. BLACK 9. 10. 1. 2. 3. 4. BROWN 5. 6. 7. RED 8. BLACK 9. 10. MICROWAVE SENDER INT 1 2 3 PRESS PWR TX TO TEST Terminals 1, 2, 3, 9, 10 not used Terminals 1, 2, 3, 5, 6, 9, 10 not used Green Power/ Signal strength/ alignment indicator LED 1 2 3 4 5 6 7 8 9 10 Signal Status 1 2 3 4 5 6 7 8 9 10 Remove Plug-In terminal block for easier wiring. Signal strength/ alignment test point for volt meter connection Hole for securing of optional identification tag M4 grounding screw Gladiator Remote Amplifier SLAVE IN MASTER OUT Test in NC COM NO NC COM NO STRIP INSULATION 9mm MIC-SENDER RELAY 1 RELAY 2 + Tx ** AWG 22-14 (0.5-1.5mm) **Ground the housing to vessel, if vessel is metallic. Ground the housing to plant ground, if vessel is non-metallic. CURRENT RED BLACK BROWN SENSOR COMMS DC-IN AC-IN Is + RED BLACK BLUE WHITE BROWN + 12-30VDC L1 90-260 VAC Relay 1 - Output Relay Relay 2 - FailSafe Relay Note: AC power terminals may only be used when universal AC power supply option has been selected - see part numbers - AC terminals have no function in products without universial AC power option. 18
B A N Microwave Smart Switch Series Is WIRING REMOTE SYSTEM - CUSTOMER SUPPLIED CABLE Remote Receiver TERMINAL LAYOUT Remote Sender TERMINAL LAYOUT Green Power ON LED Red Transmitter enabled LED 1. 2. 3. 4. BROWN 5. WHITE 6. BLUE 7. RED 8. BLACK 9. 10. 1. 2. 3. 4. BROWN 5. 6. 7. RED 8. BLACK 9. 10. MICROWAVE SENDER INT 1 2 3 PRESS PWR TX TO TEST Terminals 1, 2, 3, 9, 10 not used Terminals 1, 2, 3, 5, 6, 9, 10 not used Green Power/ Signal strength/ alignment indicator LED 1 2 3 4 5 6 7 8 9 10 Signal Status 1 2 3 4 5 6 7 8 9 10 Remove Plug-In terminal block for easier wiring. Signal strength/ alignment test point for volt meter connection SHIELD wire is NOT CONNECTED at Sender or Receiver Hole for securing of optional identification tag M4 grounding screw SHIELD wire is NOT CONNECTED at Sender or Receiver Gladiator Remote Amplifier MIC-SENDER RELAY 1 RELAY 2 + Tx ** SLAVE IN MASTER OUT Test in NC COM NO NC COM NO **Ground the housing to vessel, if vessel is metallic. Ground the housing to plant ground, if vessel is non-metallic. SHLD CURRENT RED SHLD BLACK BROWN SENSOR COMMS DC-IN AC-IN + RED BLACK BLUE WHITE BROWN + 12-30VDC L1 90-260 VAC Alternate cable type between Amplifier and Sensors 6 or 8 conductor (5 used) shielded twisted pair instrument cable. Conductor size dependent on cable length. BELDEN 3120A, DEKORON or equivalent. Max: BELDEN 3120A = 500m (1640 ft). 3 pairs, 1 conductor not used. Max: DEKORON IED183AA004 = 350m (1150 ft). 4 pairs, 3 conductors not used. Relay 1 - Output Relay Relay 2 - FailSafe Relay Connect BOTH GND AND SHIELD to black terminal at Amplifier end only SHLD Alternate Cable Colour Equivalents Hawk Belden 3120A Dekoron (Pair 4 not used ) Pair 1 Red Black Red Black White 1 Black 1 Note: AC power terminals may only be used when universal AC power supply option has been selected - see part numbers - AC terminals have no function in products without universial AC power option. Pair 2 Pair 3 White Blue Brown --- Yellow Green Brown White (not used) White 2 Black 2 White 3 Black 3 (not used) 19
BLUE BLACK RED WHITE BROWN SHIELD RED BROWN BLACK SHIELD RED BLACK BLUE WHITE BROWN RED BLACK BROWN Microwave Smart Switch Series WIRING JUNCTION BOX / CABLE EXTENSION Cable shields connect to BLACK at AMPLIFIER end Gladiator Microwave Amplifier MIC-SENDER Re-connect Cable Shield to Black SENSOR Cable Shield Seperate Black/Shield Re-connect Cable Shield to Black CUSTOMER JUNCTION BOX. DO NOT GROUND SHIELD CABLE AT JUNCTION BOX Cable Shield Seperate Black/Shield SENDER TERMINAL CONNECTIONS RECEIVER TERMINAL CONNECTIONS 4. BROWN 7. RED 8. BLACK 4. BROWN 5. WHITE 6. BLUE 7. RED 8. BLACK SHIELD CABLE NOT CONNECTED TO SENDER/RECEIVER SENDER RECEIVER Alternate cable type between Amplifier and Sensors 6 or 8 conductor (5 used) shielded twisted pair instrument cable. Conductor size dependent on cable length. BELDEN 3120A, DEKORON or equivalent. Max: BELDEN 3120A = 500m (1640 ft). 3 pairs, 1 conductor not used. Max: DEKORON IED183AA004 = 350m (1150 ft). 4 pairs, 3 conductors not used. 20
WIRING RELAY FUNCTIONS Level Switch Contact Action Microwave Smart Switch Series Relay - for Smart Integral Probe Version (Set Relay Action selection switch pages 27 and 28) Relay 1 - for Remote Version (Set Relay Action parameter pages 32 and 35) FailSafe Low FSL Relay Action FailSafe High FSH (default) State 1 1 2 3 NC COM NO 1 2 3 NC COM NO Relay Status Smart Integral Receiver terminal numbers Remote Amplifier terminal function labels LED Status Material level rising State 2 1 2 3 NC COM NO 1 2 3 NC COM NO Material detected State 3 1 2 3 NC COM NO 1 2 3 NC COM NO Material level falling POWER FAILURE 1 2 3 NC COM NO 1 2 3 NC COM NO FailSafe Switch Contact Action Relay 2 - Remote version only. For Smart Integral units, the Test terminal can act as a solid state output with a similar function. (see page 25) POWER FAILURE OR INTERNAL FAILURE SYSTEM OPERATING NORMALLY NC COM NO NC COM NO NC COM NO NC COM NO 21
WIRING CROSS-TALK PREVENTION - FOR 2 UNITS (REMOTE ONLY) Within the menu for each unit, select Master for one system and select Slave for the second system. These settings are located in the Advanced menu then under Operation Mode. Operation Mode has 3 selections: 1. Remote 2. Master 3. Slave Receiver 1 MASTER* Sender 1 The wiring needs to be as indicated, with a shielded connection cable between the two units. The selected Master has a connection to Master Out and GND/DC- and the selected Slave has a connection to Slave In and GND/DC-. The shield is conncted to the Ground or 24Vdc (-ve) terminal on each unit. Receiver 2 SLAVE* Sender 2 GLADIATOR MICROWAVE REMOTE AMPLIFIER - MASTER GLADIATOR MICROWAVE REMOTE AMPLIFIER - SLAVE MIC-SENDER + Tx SLAVE IN MASTER OUT Test in RELAY 1 NC COM NO NC RELAY 2 COM NO MIC-SENDER + Tx SLAVE IN MASTER OUT Test in RELAY 1 NC COM NO NC RELAY 2 COM NO CURRENT SENSOR COMMS DC-IN AC-IN CURRENT SENSOR COMMS DC-IN AC-IN Is + RED BLACK BLUE WHITE BROWN B A + N L1 24 VDC 80-265 VAC Is + RED BLACK BLUE WHITE BROWN B A + N L1 24 VDC 80-265 VAC Ground Ground * Software selected MICROWAVE MASTER/SLAVE IBRATION Step 1: Place the Master unit into mode by pressing the button. Step 2: Ensure that the Slave system, which you intend to Calibrate, has been set to Slave mode. Step 3: To calibrate the Slave system select the CalMounting option, which can be found in the Quickset menu and select YES. Step 5: To calibrate the Master system select the CalMounting option, which can be found in the Quickset menu and select YES. Step 6: Press the RUN button to resume operation. The calibration process is now complete for a Master/Slave system. Step 4: Press the RUN button to resume operation. 22
B B A N Is A N Microwave Smart Switch Series WIRING CROSS-TALK PREVENTION - FOR MORE THAN 2 UNITS (REMOTE ONLY) Operation is similar to cross-talk prevention for 2 units except that the GMSEQ Microwave sequencer will operate as the Master and each individual Microwave unit will operate as a Slave. The sequencer will control and step from CH1 to CH2 to CH3 to CH4 then return to CH1. The maximum time between scans if 4 units are connected is approx. 3ms. Within the menu of each individual Microwave unit, select Slave mode in the Advanced Menu under Operating Mode. Is B A N Receiver 1 SLAVE 1 Sender 1 Receiver 2 SLAVE 2 Sender 2 GLADIATOR MICROWAVE REMOTE AMPLIFIER - SLAVE GLADIATOR MICROWAVE REMOTE AMPLIFIER - SLAVE GLADIATOR MICROWAVE REMOTE AMPLIFIER - SLAVE MIC-SENDER Is Receiver 3 SLAVE 3 Sender 3 + Tx SLAVE IN MASTER OUT Test in RELAY 1 NC COM NO NC RELAY 2 COM NO MIC-SENDER + Tx SLAVE IN MASTER OUT Test in RELAY 1 NC COM NO NC RELAY 2 COM NO MIC-SENDER + Tx SLAVE IN MASTER OUT Test in RELAY 1 NC COM NO NC RELAY 2 COM NO CURRENT SENSOR COMMS DC-IN AC-IN CURRENT SENSOR COMMS DC-IN AC-IN CURRENT SENSOR COMMS DC-IN AC-IN + RED BLACK BLUE WHITE BROWN + L1 24 VDC 80-265 VAC + RED BLACK BLUE WHITE BROWN + L1 24 VDC 80-265 VAC + RED BLACK BLUE WHITE BROWN + L1 24 VDC 80-265 VAC GMSEQ Microwave Sequencer Terminal CH1 CH2 CH3 CH4 com Tx com Tx com Tx com Tx MICROWAVE MASTER/SLAVE IBRATION Step 1: Place the sequencer unit into mode by pressing the button on the sequencer unit. Step 2: Ensure that the system that you intend to calibrate is set to operate as a slave. The sequencer unit will operate as the Master to control the pulsing sequence in normal operation. Step 3: Remove the cable connection to the Slave In terminal, which connects between the slave system and the sequencer unit. Step 4: To calibrate the Slave system select the CalMounting option, which can be found in the Quickset menu and select YES. Step 5: After calibration is done, re-connect the Slave In cable between the slave system and the sequencer unit. Step 6: Repeat steps 1 to 5 for each of the slave systems connected to the sequencer. Step 7: Press the RUN button on the sequencer and all of the slave units. The process is now complete. * Note for best performance the sequencer setting is shown below. Do not adjust these settings. On time 240μs Off time 700μs 23
HI FSH ON HI FSH ON TEST ON 1 2 1 2 LO FSL OFF OFF 1 2 3 4 5 6 7 8 9 10 HI FSH ON 1 2 3 4 5 6 7 8 9 10 TEST ON 1 2 1 2 LO FSL OFF OFF 1 2 1 2 LO FSL OFF OFF 1 2 3 4 5 6 7 8 9 10 TEST ON HI FSH ON TEST ON 1 2 1 2 LO FSL OFF OFF 1 2 3 4 5 6 7 8 9 10 HI FSH ON HI FSH ON TEST ON 1 2 1 2 LO FSL OFF OFF 1 2 3 4 5 6 7 8 9 10 TEST ON 1 2 1 2 LO FSL OFF OFF 1 2 3 4 5 6 7 8 9 10 Microwave Smart Switch Series WIRING MULTIDROP CONNECTIONS Multidrop GSM/CDMA Connection* HawkLink GSM/CDMA unit SENSITIVITY DELAY SENSITIVITY DELAY A B Gnd A B Gnd A B Gnd Laptop or PC Communications using PCMCIA card or wired (PSTN) modem and remote GSM/CDMA connection with GosHawk software. Multidrop Connection Using HawkLink USB* SENSITIVITY DELAY SENSITIVITY DELAY A B Gnd A B Gnd A B Gnd White Blue Black Hawklink USB Laptop or PC Communications using Hawklink USB or RS485 / 232 converter with GosHawk software. Multidrop Connection to PLC/DCS/SCADA* SENSITIVITY DELAY SENSITIVITY DELAY A B Gnd A B Gnd A B Gnd PLC / DCS / SCADA for Remote Communication with Modbus. * Wiring installation should follow RS-485 standards for layout and termination. 24
WIRING HAWKLINK GSM - CONNECTING POWER AND COMMS (1) USING DC POWER DERIVED FROM AC POWERED REMOTE GLADIATOR NOT POSSIBLE WITH GLADIATOR SMART IN- GSM REMOTE AMP COMMS DC-IN AC-IN COMMS DC-IN AC-IN! TEGRAL UNIT. INTERNAL POWER SUPPLY HAS IN- SUFFICIENT CAPACITY. B A RS 485 12-30VDC N L1 80-265VAC 1 2 3 4 1 2 3 4 B A RS 485 12-30VDC Connect shield to DC - only at this end. N L1 80-265VAC Existing AC power supply (GSM will be powered by DC generated by the Gladiator) (2) USING DC POWER FROM DC REMOTE GLADIATOR GSM COMMS DC-IN AC-IN REMOTE AMP COMMS DC-IN AC-IN RS 485 B A 12-30VDC N L1 80-265VAC RS 485 B A 12-30VDC N L1 80-265VAC 1 2 3 4 1 2 3 4 Existing DC power supply -! GSM COMMS DC-IN AC-IN Connect shield to DC - only at this end. TERMINAL ORDER VARIES BETWEEN GLADIATOR SMART INTEGRAL UNIT AND REMOTE AMPLIFIER. ENSURE CORRECT LAYOUT IS USED. (3) USING DC POWER FROM DC POWERED GLADIATOR SMART INTEGRAL UNIT SMART PROBE COMMS DC-IN B A RS 485 12-30VDC 1 2 3 4 N L1 80-265VAC - RS 485 12-30VDC A B 2 1 4 3 - Existing DC power supply Connect shield to DC - only at this end. 25
WIRING HAWKLINK GSM - CONNECTING POWER AND COMMS (4) USING SEPARATE AC OR DC POWER WITH SMART INTEGRAL UNIT GSM COMMS DC-IN AC-IN SMART PROBE COMMS DC-IN AC-IN B A RS 485 12-30VDC N L1 80-265VAC Separate AC power supply for the GSM module or DC power supply 1 2 2 1 - RS 485 12-30VDC 80-265VAC A B N L1 Existing AC or DC power supply * Connect shield to DC - only at this end.! TERMINAL ORDER VARIES BETWEEN GLADIATOR SMART INTEGRAL UNIT AND REMOTE AMPLIFIER. ENSURE CORRECT LAYOUT IS USED. (5) USING SEPARATE AC OR DC POWER WITH REMOTE GLADIATOR GSM COMMS DC-IN AC-IN REMOTE AMP COMMS DC-IN AC-IN B A RS 485 12-30VDC N L1 80-265VAC Separate AC power supply for the GSM module or DC power supply 1 2 1 2 B A RS 485-12-30VDC N L1 80-265VAC Existing AC or DC power supply * Connect shield to DC - only at this end. * Ensure separate DC supplies have the same ground potential 26
WIRING TEST TERMINAL FUNCTION SELECTION The test terminal has two potential modes of operation for Smart Integral units and always operates in the test input mode for Remote units. Remote units have a separate, failsafe relay contact, which is always functional. TEST INPUT MODE (Test switch must be in TEST (ON) position on Smart Integral Units - function always enabled on Remote Units) Test terminal acts as an input for remote testing of the instrument s switching function. Used to check for malfunction of unit from a remote position, PLC, SCADA etc. For more information see page 29. TEST INPUT FROM PLC/SCADA/DCS DIGITAL OUTPUT Terminal Block PLC / SCADA / DCS Output Test OPERATOR CONTROLLED PRESS TO TEST! PLC/SCADA/DCS GROUND MUST CONNECT BACK TO GLADIATOR GROUND OR DC - TERMINALS Terminal Block Externally provided test button Test FAILSAFE OUTPUT MODE (Test switch must be in the OFF position - default setting)! EXTERNAL PUSH BUTTON GROUND MUST CONNECT BACK TO GLADIATOR GROUND OR DC - TERMINALS Test terminal will provide an output which is able to switch an external failsafe relay or PLC/SCADA/DCS input. During normal system operation this terminal will internally switch a solid state (transistor) output to ground (or DC - ). If power fails or an internal system failure occurs, the terminal will act as an open circuit. To switch an external relay To a PLC input Test +12-24Vdc Coil rating 500mW max or 50mA max Relay will turn on during normal system operation or off in failed or unpowered conditions. Test 27 max 50mA 12-24Vdc Pull up PLC SCADA DCS Input Input will detect 0 state during normal system operation, or 1 in failed or unpowered conditions.
SETUP PROCEDURE FUNCTIONALITY LAYOUT - SMART INTEGRAL SENDER 3 1 4 INT 1 MICROWAVE SENDER 2 3 PRESS TO TEST PWR TX 5 REM 0 0 0 1 2 3 4 5 6 7 8 9 10 2 REMOVABLE SENDER TERMINAL BLOCK DC-IN AC-IN - N L1 6 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 7-30VDC 80-260VAC Terminals 1, 2, 3, 4, 5, 6 not used 1 Smart Integral / Remote mode selection switch (INT/REM) 2 Green LED - power status, continuously on when power supply is OK 3 Red LED - transmitter enabled 4 Pulse rate setting switches (see table below) Press to test button - interupts signal transmission for system testing. 5 Simulates the effects of breaking of microwave beam. 6 Removable terminal block - plug in type Switch Settings INT/REM 1, 2, 3 Sender pulse rate selection 0 = OFF 1 = ON Set to INT for Smart Integral types 1 2 3 0 0 0 45 Pulses per sec 0 0 1 44 0 1 0 42 0 1 1 41 1 0 0 40 1 0 1 39 1 1 0 38 1 1 1 37 - Default for INT The pulse rate may be changed to minimize the potential for cross-talk if multiple units are in the same operational area. If cross-talk is likely to occur, it is strongly recommended to use Remote type units and employ the cross-talk prevention schemes for 2 units or the multi sequence connection for more than 2 units using a separate GMSEQ sequencing unit. Cross-talk prevention and sequencing for Remote units are detailed on pages 20 & 21. 28
SETUP PROCEDURE FUNCTIONALITY LAYOUT - SMART INTEGRAL RECEIVER 9 3 6 12 4 SENSITIVITY signal HI FSH TEST ON ON 1 2 1 2 LO FSL OFF OFF 1 2 3 4 5 6 7 8 9 10 DELAY 1 5 2 8 REMOVABLE RECEIVER TERMINAL BLOCK RELAY COMMS DC-IN AC-IN 10 7 11 1. NC 2. COM 3. NO 4. Test A B 5. 6. 7. 8. 9. N 10. L1 RS 485 7-30VDC 80-260VAC - Functionality Description (bold is default) 1 Mounting Calibration switch /OFF 7 RED LED: Relay status ON when relay coil is energised 2 3 4 5 6 Test input function select TEST/OFF Relay action selection switch FSH - FailSafe High FSL - FailSafe Low HI / LO sensitivity switch Delay Potentiometer (0-20 sec) (Default 0 sec. at minimum position) Sensitivity Potentiometer Default 50% = 12 o clock 8 9 10 11 GREEN LED: Power / Received signal strength. Brightness varies with strength of received signal. BLUE LED: Blinking indicates calibration function is on. Continuously ON indicates failed calibration. AC Ground - must be used for AC powered installations Removable terminal block - plug in type 12 Signal voltage test point 29
SETUP PROCEDURE SMART INTEGRAL VERSION! 1. Mount the units in their actual position (See mounting procedure - pages 12-16) Make sure that external ground wire on both the sender and receiver is connected between the outside ground screw on the Gladiator housing and the roof/wall/side of the silo/tank/vessel/ chute. (For non metallic tanks make sure that external ground wire is connected between the same outside ground screw on the housing and the general plant ground potential). 2. Check where the actual level or target is located relative to the sensors Make sure that the material or target is not blocking the path between sender and receiver. 3. Turn the power on The green LED on the sender and receiver will stay on permanently to indicate that power is on. Green LED on receiver varies in brightness with strength of received signal. 4. Ensure that the REM/INT DIP switch on the Sender unit is selected to the INT (ON) position and the remaining switches (1, 2, 3) are all selected to OFF initially. See point 1 page 26. 5. Select the required relay action The Relay can switch ON or OFF as the microwave beam is blocked and switch ON or OFF in response to an instrument failure (for details see page 19). Set the relay action selection switch position (FSL or FSH) depending on your requirements. 6. Cancel influence of mounting Do not proceed with this step unless the material or target position is well beneth the line between the sender and receiver. Switch the Mounting Calibration switch on the Receiver unit to (ON) position. The Blue LED will blink to indicate that mounting calibration is now in progress. Wait for at least 10 sec, then switch the mounting calibration switch to OFF position. The blue LED should turn off after a short time. The blue LED will stay on if there was a calibration error. If this is the case please check that the path between sender and receiver is clear, then try the calibration again. If mounting calibration was successful the blue LED should be off and the Green LED should be ON. Unit is now able to cancel influence of mounting and measurement history has been cleared. 6. Select the sensitivity There are two adjustments controlling the sensitivity of the switch point: 6.1 The HI/LO sensitivity switch is used as a coarse adjustment of the sensitivity of the unit. Select HI sensitivity if build-up is expected over sensors or with strongly absorptive materials or targets. Select LO sensitivity for cleaner environments and less absorptive material or targets. 6.2 The sensitivity potentiometer Set the potentiometer according to your requirements. A 12 o clock setting (50%) - default, will cover the majority of instances - for the remaining instances, turning the potentiometer clockwise will increase sensitivity. Increasing sensitivity may be necessary if the green signal LED does not illuminate brightly with no blocking of the signal path, or if there is build-up of material over the sensor. 7. Select the time delay Set the required delay using the Delay potentiometer. (Default is 0 sec. at minimum position) Turn the potentiometer clockwise if any delay is required. Maximum rotation is ¾ of a revolution. Max delay is 20 sec. The selected delay will be used for both an ON delay and an OFF delay.* * Setting of different time ranges for the delay potentiometer for ON delay and OFF delay is possible using a PC connected via GosHawk2 software. By default, both will have the same time adjustment range (20 sec max) and adjustment will result in equal ON delay and OFF delay. 30
SETUP PROCEDURE SMART INTEGRAL VERSION 8. Test function (used to check for malfunction of unit from remote position, PLC, SCADA etc) Select the desired Test function by switching the Test switch (Default = OFF ). TEST (ON) Position: Test function is selected. Test terminal (terminal number 4 of Smart integral unit) is used as an input to the unit. The test function allows you to check the functionality of the unit. Applying a ground wire to the Test terminal will change the state of the relay. It will hold this state until the ground is removed, then it will change back to the standard running mode. If the unit was in a Fail mode then the relay will not change states. OFF (Default) Position: Fail safe output function is selected. Test terminal (terminal number 4 of Smart probe) will function as an open drain drive. This can be used to drive a relay or an active low PLC input to detect a Fail condition. In normal operation mode the Test terminal will output Zero Volts (Short to GND). In Fail or unpowered mode the Test terminal will be open circuit. See page 25. 31
SETUP PROCEDURE - REMOTE VERSION FUNCTIONALITY LAYOUT REMOTE AMPLIFIER 4 1 1 Calibrate button 2 Run button 3 Down button 4 Up button 5 Relay LEDs 1 and 2 3 RELAY 1 RELAY 2 STATUS A STATUS B 6 Display (LCD with backlight) 5 6 7 2 7 Status LEDs A and B - Status A flashes with signal transmission of a unit in Remote or Master mode. - Status B flashes with signal transmission of a unit in Master or Slave mode. REMOTE RECEIVER REMOTE RECEIVER TERMINAL BLOCK TRANSDUCER 8 REMOTE STATUS 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 1 2 3 4 5 6 7 8 9 10 9 BROWN WHITE BLUE RED BLACK Terminals 1, 2, 3, 9, 10 not used. 8 GREEN LED: Power / Received signal strength. Brightness varies with strength of received signal. 9 Removable terminal block - plug in type 32
SETUP PROCEDURE FUNCTIONALITY LAYOUT - REMOTE SENDER 3 1 4 INT 1 MICROWAVE SENDER 2 3 PRESS TO TEST PWR TX 5 REM 0 0 0 REMOVABLE SENDER TERMINAL BLOCK 1 2 3 4 5 6 7 8 9 10 2 1. 2. 3. 4. BROWN 5. 6. 7. RED 8. BLACK 9. 10. 6 Terminals 1, 2, 3, 5, 6, 9, 10 not used 1 Smart Integral / Remote mode selection switch (INT/REM) 2 Green LED - power status, continuously on when power supply is OK 3 Red LED - transmitter enabled 4 Pulse rate setting switches (settings have no function for Remote units) 5 Press to test button - interupts signal transmission for system testing. Simulates the effects of breaking of microwave beam. 6 Removable terminal block - plug in type Switch Settings INT/REM 1, 2, 3 Sender pulse rate selection Set to REM for Remote types Settings has no function for remote types. 33
SETUP PROCEDURE REMOTE VERSION 1. Mount the unit in its actual position (see mounting procedure - pages 12-16)! 3. Ensure that the mode selection switch on the transmitter is set to REM (OFF). See point 1 page 31. Make sure that external ground wire is connected between the outside ground screw on the Gladiator housing and the roof/wall/side of the silo/tank/vessel/chute. (For non metallic tanks make sure that external ground wire is connected between the same outside ground screw on the housing and the general plant ground potential.) 2. Check where the actual level or target is relative to the sensors Make sure that the material or target is not blocking the path between sender and receiver. 4. Turn the power on The display will turn on and the fail-safe relay will switch. The display will scroll through the following messages: Hawk, Amp SerialNo, Type, Amp Soft Ver, Device ID, SensorSerial, SensorModel, Sens SoftVer, Sensor Addrs, Gladiator System Amp. The unit will then go into operational mode displaying Switch with a % value. This % value represents the changing amount of signal loss between sender and receiver. 5. Simple 1-minute Setup - Follow the flow chart Press Press Sensor Value 0.0% UnLock 0 QuickSet Press Cal Mounting Yes / No Press Yes Press Switch Point 50% Press 50% Press Delay Adjust 0.1S Press 0.1S Press Relay Action FailSafe Hi Press Press Twice RUN FailSafe Hi FailSafe Low Cancel Influence of Mounting Do not proceed with this step unless the material or target position is well beneth the line between the sender and receiver. Select Yes to start the mounting calibration. Wait will be displayed during the calibration for up to 30 seconds. Unit is now able to cancel the influence of the mounting. The % reading on the back lit display has been zeroed with the existing process conditions and the measurement history log has been cleared. Select the Switch point (sensitivity) The output relay will switch at the entered % value. The default value of 50% will be suitable for detecting most media. For detection of products which are less absorbent of Microwave energy, select a lower % value and vice versa. For highly absorbent materials, almost any setting will work, but higher % settings will be more immune to build up. When the level or target falls below the sensors the relay will switch back at half of the entered switch point % value (when the beam is no longer broken). Select the Time Delay Set the time to be used for both switch on and switch off delays (default: 0.1 seconds). Maximum Delay is 40 seconds. Select the required relay action The Relay can switch ON or OFF as the microwave beam is blocked and switch ON or OFF in response to an instrument failure (for details see page 19). Set the parameter to FailSafe Low or FailSafe Hi depending on your requirements. 34
SOFTWARE MENU REMOTE AMPLIFIER ENTERING DATA All software adjustments are achieved via the four PUSHBUTTONS on the front panel. In Run Mode (A) Press and hold - interrupts normal operations and allows access to software menu headings. In Calibrate Mode (B) Steps into a menu selection to allow editing (down one level) (C) Saves selected value and moves onto the next menu item. In Run Mode (A) Scrolls up through operating diagnostics on display LCD. In Calibrate Mode (B) Scrolls up through software parameters when browsing the menus. (C) Increases display value when editing a parameter. In Run Mode (A) Scrolls down through operating diagnostics on LCD display. In Calibrate Mode (B) Scrolls down through software parameters when browsing the menus. (C) Decreases display value when editing a parameter. In Run Mode (A) Hides diagnostics if they are in view and returns to the standard running display. In Calibrate Mode (B) Steps out of a menu or selection (up one level). Parameter value will be stored automatically when stepping up. (C) Returns to running mode from the top level menu. 35
FLOW CHART SOFTWARE TREE Sensor Value 0.0% Normal Running Display Press To Calibrate On first start up there is no security code protection. Press UnLock 0 Press Press Press To QuickSet QuickSet Advanced flow chart To Advanced flow chart See page 35 See page 36 QuickSet Menu Advanced Menu covers all parameters covers less commonly required for standard used or advanced setups. parameters. Press RUN to return to normal operation 36
FLOW CHART QUICKSET MENU Microwave Smart Switch Series QuickSet *When is pressed edit will flash on the bottom line of the display for a short time to indicate that the parameter is being opened for editing. Cal Mounting No Calibrate mount will cancel the mounting influence and zero the % reading with the existing process conditions. History log will be cleared. Path between Sender and Receiver must be clear before calibration. Yes / No Switch Point 50% Delay Adjust 0.1S Relay 1 will switch at the entered Switch Point value (default 50%) and switch back at half of this value. will be displayed if you have set the parameter Switch Mode to in Advanced menu. The setting can only be removed or adjusted from the Advanced menu. Set switch delay time 0.1-72.8sec. Delay used for both Switch On and Switch Off conditions. (default 0.1 sec). Relay Action FailSafe Hi Relay Action (FailSafe Hi or FailSafe Low) See page 19 Lock Code 0 Security code lock Adjustable 0-200 Default 0 Default values/settings in bold and underlined 37
FLOW CHART ADVANCED MENU Advanced Default values/settings in bold and underlined Switch Mode Auto Auto (view only) Auto - Switch point is set in QuickSet by the Switch Point parameter. Switch On = Switch Point, Switch Off = Half of Switch Point value (by default). Switch On and Switch Off can not be changed (view only) in Auto. - Switch On and Switch Off values can be edited in mode. editing over-rides the QuickSet selected values. (editable) *Only possible if manual selected Switch On 50% Relay switch point On (Default 50%) *Output relay in State 2 above this value. Switch Off 25% Relay switch point Off (Default 25%) *Output relay in State 1 below this value. View Log Yes View history log of instrument % and temperature Yes / No No Min Sensor % 0.0% Minimum Sensor % since last Reset Log (not adjustable). Max Sensor % 288.4% Maximum Sensor % since last Reset Log (not adjustable). Min Temp 20.0C Minimum temperature value since last Reset Log (not adjustable). Max Temp 26.9C Maximum temperature value since last Reset Log (not adjustable). Continued next page (Reset Log) *Switch points are refered to as On and Off to reflect the most simply understood performance in FailSafe Low mode. Actual relay state may be different according to setting of relay contact action (see page 19). 38
FLOW CHART ADVANCED MENU (CON T) From previous page Reset Log No Comms Type Modbus Reset history log (Yes / No) Log will automatically reset when Cal Mounting is used in QuickSet to cancel mounting influences and re-zero the % reading. Modbus HART Profibus DP DeviceNet Selection should not be changed unless required hardware is present. (see part numbers - page 42-44) Device ID 1 1-255 Baud Rate 19200 1200 4800 9600 19200 38400 57600 Default values/settings in bold and underlined Back Light On Display Backlight On/Off Display Span 3 Display Span: 0-100% change in displayed value will occur with the selected change of raw internal units. Changing of this parameter will change the value of the Switch Point (Switch On and Switch Off) values. 0. 0-3500 2. 0-2482 4. 0-1241 1. 0-3103 3. 0-1862 5. 0-621 Theshold 2.27 V Signal size to be achieved during mounting calibration 0.3V - 2.5V Default 2.27V Opertng Mode Remote Selection of device operating mode when used in installations requiring cross-talk prevention. Remote, Master, Slave Average 20 Averaging* of measurement samples. A smaller number gives faster response and a larger number is more stable. Default 20 *Function may not be available in some units - contact factory for assistance if required 39
FLOW CHART DIAGNOSTIC DISPLAYS (Remote type only) Sensor Value 0.0% SW On 41.7% 0.0% SW Off 31.3% 0.0% Max 99.8% 0.0% Min 0.0% 0.0% Delay 0.1s 0.0% Temp: 22.4C 0.0% Normal 0.0% Signal 1.86V 0.0% Percentage above which the Relay will be in State 2*. Percentage below which the Relay will be in State 1*. } Max/Min captured Sensor Value % since Last history log reset, or last Cal Mounting operation Current switch delay time Current temperature inside housing (ºCelsius) Status Normal / CommRetry Received Signal strength The diagnostic displays appear on the top line of the LCD, after pressing the Up or Down push button when the Gladiator Microwave switch is in its normal running mode. The diagnostics provide the user with valuable performance feedback on how the instrument is performing whilst in operation. The measured reading Sensor Value (%) continues to be displayed on the second line of the LCD during diagnostic viewing on the top line. Ouput relays will continue to operate during diagnostic viewing. Pressing twice at any time returns the unit into normal operation. *Switch points are refered to as On and Off to reflect the most simply understood performance in FailSafe Low mode. Actual relay state may be different according to setting of relay action (see page 19). CommErr 1 -> unit has lost communications with the receiver. Fail 1 - No comms available. Gain 10.2% 0.0% Gain result of mounting calibration Noise 0.04V 0.0% Background Noise received Remote 0.0% Device operating mode Remote/Master/Slave 40
SULTAN 234 SULTAN 234 Microwave Smart Switch Series MULTIDROP CONNECTIONS Gladiator Admittance Switch Gladiator Admittance Switch Gladiator Admittance Switch Gladiator Admittance Switch Sultan Acoustic Wave Transmitter Slurries Sultan Acoustic Wave Transmitter Floatation Cells GLadiator Microwave Low Level Sultan Acoustic Wave Transmitter Silo, bin levels, coal, plastic powder, woodchip, sawdust, cement, clinker, iron ore, lime etc. Gladiator Microwave Low Level Gladiator Vibration Switch Gladiator Conductivity Switch Sultan Smart Transducer Farm Tanks, Grain Terminals Gladiator Conductivity Switch Orca Sonar Interface Thickener, CCD Sultan Acoustic Wave Switch Blocked Chute Detection Orca Sonar Interface Clarifier GSM Network or CDMA Network Sultan Master/Slave Positioning System Sultan Acoustic Wave Transmitter Stockpiles, Stackers, Reclaimers 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. Laptop or PC Communications or PLC / DCS with MODBUS RTU Port GosHawk Software for inventory monitoring on PC (Limited Modbus query rate for Switches only) 41
ADVANCED REMOTE COMMUNICATION GSM/CDMA HawkLink GSM/CDMA communication device allows any authorized computer with a standard modem and GosHawkII software to dial in and calibrate, test or check in on the performance of the connected Hawk product. The HawkLink device can be wired to the standard communication terminals of the Hawk products. Remote technical support and complete commissioning of equipment in applications is possible via our GSM/CDMA module and allows monitoring and adjustment of settings no matter what corner of the world. Remote connection worldwide! 42
SAFETY INFORMATION FCC REGULATIONS Qualifications The Federal Communications Commission imposes strict requirements on radiating sources such as the GSA, GMSB, GMSHB, GMRR, GMRRH, GMRRS, GMS, GMSH, GMSR, GMSRH Microwave Systems. This unit is tested to, and meets these requirements, which include operating frequency and stability, harmonic and spurious generations and power output. The Hawk Gladiator Microwave System complies with FCC Rules Part 15 for industrial controls. No licenses or approvals are required to use the system. Requirements (A) OSHA - 10mW/cm2of radiated power. (B) ANSI - 5mW/cm2 of radiated power. The Hawk Gladiator Microwave Systems have approximately 20µW/cm2 of radiated power. Note: The Hawk Microwave Pulse Systems are well below the stringent safety standards required by both the above governing bodies. It is regarded as a SAFE level control and may be used with no special precautions. 43