e-Gladiator Gen 3 Microwave Switch Manual
Contents
1. 6 89 S a 0 44 lk 15mm _ 0 59 4 0 16 Part Size Window Weldment Number MAO 3 wv MA3 Ss Sf VA MA4 4 wi VA MA5 6 S YA MA6 3 S y MA7 4 Da SG MA8 6 y S MA18 4 S MA19 z wv MA20 4 S MA21 3 S MA22 4 S B Dimensions Gladiator Gen 3 Microwave Series Weldments and Windows Ceramic Weldment with Ceramic Windows Weldment is welded to the vessel Window is locked into Weldment with Locking Retainer Locking Window Weldment Weldment Window Parts Retainer Part Size Window Weldment Number MA16 ce wi Via MA17 4 Vf y z E te pe E E 3 i 2 5 65 925 118 4 65 God NPT 0 87 0 2 2 56 oe 3 64 4 65 0 16 i 2 56 NPT S A 244 15 90 101 120 148 100 90 4 100 5 NET 0 96 0 2 ps 3 98 4 72 5 83 nes Goin 3 54 NPT 3 96 Locking Retainer Ceramic Window 6 3mm 0 25 U A 2 Places A X Z 11 12 7mm 0 43 0 5 lt S gt 12 3mm 0 48 Dimensions Gladiator Gen 3 Microwave Series Weldments and Windows Ceramic Tile amp Firebrick Assemblies Weldment with Ceramic Windows Weldment is welded to the vessel Window is locked into Weldmen2. A Higher Level of Performance Manual Gladiator Gen 3 Microwave Switch Series S Beam Blockage Detection Circular Polarisation For more information please visit gt www hawkmeasure com Table of Contents Gladiator Gen 3 Microwave Series Contents Overview 3 Principle of Operation 3 Typical Uses 3 Function 3 Features 3 Dimensions 4 Remote Microwave System 4 Weldments and Windows UHMW PTFE 5 Weldments and Windows Ceramic 6 Weldments and Windows Ceramic Tile amp Firebrick Assemblies Us Mounting 9 General Guidelines 9 Mounting With Windowed Weldments 10 Installation With Adjustable Mounting 11 Correct Mounting Angle 12 Align Sender and Receiver 12 Wiring 13 Remote System Connection HAWK Supplied Cable 13 Remote System Connection Customer Supplied Cable 14 Alternate cable type between Amplifier and Sensors 14 Functionality Layout Remote System 15 Wiring 16 Integral System Connection 16 Functionality Layout Integral System 17 Wiring 18 Wiring Relay Functions 18 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 installati
3. r D i HAWK Use long nose pliers to extract terminals syvg9ungnny gl The AC earth i ground cable must be connected to the ground screw inside the housing when using AC power S Ground Ground the housing to vessel if vessel is metallic Ground xx Screw Ground the housing to plant ground if vessel is non metallic Screw 7 Integral Receiver Sender Status LED Status LED e Green LED Indicates received signal strength e Green when powered e High illumination strong signal e Blinks while working correctly e Low illumination weak signal e Solid while not transmitting e Red LED Indicates Relay status e Blue LED Flashes during calibration TEST Button Stays illuminated if calibration fails e Press and hold to test level relay action Signal Contact e Signal can be read with voltmeter across Signal contact point and earth screw SENDER TERMINAL LAYOUT or other ground reference DC IN AC IN e 2 4 2 5V is full signal OV is no signal DW W YW QW YW e YW Gs Gs Ge RECEIVER TERMINAL LAYOUT RELAY COMMS DC IN AC IN Ge ee ee ee AN ol Iw o N olo 2 30VDC 80 260VAC S Z gjg aajt 25 Terminals 1 2 3 4 5 6 not used O z a si go o X oslo Note RS 485 12 30VDC 80 260VAC 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 produc
4. Conductor size dependent on cable length Blue Green Black 2 e BELDEN 3120A DEKORON or equivalent Pair3 Brown Brown White 3 e Max BELDEN 3120A 500m 1640 ft White notused Black 3 not used 3 pairs 1 conductor not used Pair4 not used notused not used Functionality Layout Remote System Gladiator Gen 3 Microwave Series Functionality Layout Remote System 1 Calibrate button EWN DINIE Run button el Down button F7 4 Up button RELAY 1 nevave ea Vk O Relay LEDs 1 and 2 Display LCD with backlight Q 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 Receiver 4 HAWK OD e e ee ee ee e e e e e oe e oe o o D o 3 Signal contact 1 Sender status LED e Signal can be read with voltmeter across Signal contact point and earth screw or other ground e Blinks while working correctl reference 2 4 2 5V is full signal OV is no signal e Solid while not transmitting e Clear indicates no power 4 Receiver status LED 2 TEST button e High illumination for good signal Low illumination f ksional e Press and hold to test level relay action ow illumination for weak signa e Clear indicates no power Wiring Gladiator Gen 3 Microwave Series Integral System Connection Sender a Integral Receiver A uit sae JE
5. HAWK Supplied Cable e The black wire of HAWK supplied cable comes with one end GND and the other GND SHLD together e The GND SHLD end is a larger cable which has been heat shrunk The GND only end is the same size as the other cables e The GND SHLD end must be connected to the amplifier Remote Sender terminals N HAWKS o9999 dD D O e Add wire between terminal 8 and Ground screw ground screw Inputs model dependent kk at Use long nose pliers to extract Ki Gladiator Remote Amplifier Sender Receiver O CD GND only end Amplifier O CD GND SHLD end Remote Receiver gt lt af HAWK 9999990900 Add wire between terminal 8 and Ground screw ground screw MIC SENDER E RELAY 1 RELAY 2 gt O g Sin Remote Sender 23 2 5 2 Blo Bole Bg Remote Receiver Status LED OOOOO0OdGQOOO00OO000 Status LED 16 17 18 19 20 21 22 23 24 25 26 271 28 29 30 e Green when powered Sender e Green when powered e Blinks while working e High illumination strong signal correctly O g gg g o g go o gg g g e Low illumination weak signal e Solid while not transmitting a AB 5 E Elm a Flg s 5 jng 7 Signal Contact TEST Button _ oe EE e Signal can be read with voltmeter e Press and hold to test level rene across Signal contact point Blau aciion Ground the housing to vessel if vessel is and earth screw or other ground
6. Half Signal 2 0V to 2 5V is used for signal e 2 0V Sensor Value 0 Full Signal stability purposes e 2 0V to 2 5V Sensor Value 0 Full signal The programmed App Type Recover Gain applied Recover Gain is used retain the aed SE Recover e Ca will have pre defined amounts incoming signal during difficult conditions of Recover Gain available Gain Gain applied This is the total Gain Calibrated Gain plus Recover Gain applied by the system ERC Noise interference in V Noise from interfering received It is normal to see a small frequencies or along the communications wiring consistent amount of Noise e Remote e Remote default Standard remote system e Master e Master Unit mode is set as Master for cross talk prevention e Slave e Slave Unit mode is set as Slave for cross talk prevention Remote Main Menus amp Interface Gladiator Gen 3 Microwave Series Remote Main Menus amp Interface Remote System Note Parameters may vary depending on older software revisions Press Sensor Val By view Operation UnLock Default Unlock 0 code 0 RUN Run Return QuickSet Standard parameters D ress os LE Advanced Advanced parameters Select Edit Save DH x D n D A gt DH x D n D a gt Scroll up down Remote Setup Procedure Gladiator Gen 3 Microwave Series Quickset Menu Parameters Parameter Description Options App Type see next page for additional informati
7. the On Delay E E EE e This will trigger the water spray for 2 seconds when Gain goes above 80 The spray will repeat every e The unit will then count the Clean Time interval 5 minutes until Gain goes below 70 time before repeat the process until total Gain is below CleanGainLow point e You can view Gain while the unit is running by using the arrow key to locate the diagnostic display TimeOpt Cing e At every Clean Time interval the unit will switch on the relay for 1 2 of the On Delay time and then switch off Other Relay2 Actions e Relay 2 Sets the 2nd relay to mirror the first relay action e Failsafe Sets the relay to trigger for a failsafe condition such as sender receiver fail or voltage problem Eege HAWK Relay 2 Software Flow Chart Gladiator Gen 3 Microwave Series Relay 2 Software Flow Chart To set spray duration for Gain and Time options 1 2 of On Delay Sensor value gg Unlock 0 e Quickset App Type Cal Mount Switch Point On Delay Adj Off Delay Adj Relay Action To set Relay 2 action for one of Time Gain or Maintenance options Sensor valve gy Unlock 0 e Quickset D Advanced Switch Mode Relay2Action View Log Reset Log Comms Type ProbeAVG Initilize TX Clean Time LoadDefaults CAL Clean Time Edit CAL CAL to save Min 3 0 seconds CleanGainHi Edit CleanGainLo CleanGainLo Edit Clean Time Clean
8. 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 Select the required relay action The Relay can switch ON FSL or OFF FSH as the microwave beam is blocked Set the relay action selection switch position depending on your requirements FSH is recommended ordinarily on energised switches off DEN during blocked conditions 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 the primary sensitivity setting Select LO sensitivity for Blocked Chute detection and if build up is expected over sensors Select HI sensitivity for clean environments and lighter less absorptive material or targets LO recommended for most applications 6 2 The sensitivity dial Turning the pot fully counter clockwise factory recommended for blocked chute applications If operating in HI mode set the pot to 12 o clock In this mode you can turning the pot clockwise to reduce the amount of beam blockage required for switching and vice versa 7 Select the relay time delay Full anti clockwise is minimum 0 1 seconds Full clockwise is maximum 20 seconds Adjust as required allowing time to avoid possible nuisance trips The selected delay will be used for both an ON delay and an OFF delay 8 Perfor
9. y metallic Ground the housing to plant ground if vessel is non metallic reference e 2 4 2 5V is full signal OV is no signal Wiring Gladiator Gen 3 Microwave Series Remote System Connection Customer Supplied Cable Remote Sender a Remote Receiver Use long nose pliers to extract terminals CH REECH 9 ss sy99999g Shielding to grounarserey Shielding to ground screw Ground T 8 SSES Gladiator Remote Amplifier zs Inputs model dependent MIC SENDER RELAY 1 RELAY 2 Remote Receiver Remote Sender e S zb 2 ole Z Status LED Status LED oo Oloooloooiococ e Green when powered e Green when powered 19 20 22 24 2 2 2 28 29 30 e High illumination p F Sender e Blinks while working strong signal correctly O e Low illumination weak signal 8 e Solid while not transmitting z Signal Contact TEST Button SE ged can be rer e Press and hold to test level Remote Receiver Nice aes gna contact point and earth screw relay action Ground the housing to vessel if vessel is or other ground reference metallic Ground the housing to plant ground if vessel is non metallic e 2 4 2 5V is full signal OV is no signal Alternate cable type between l Alternate Cable Colour Equivalents Amplifier and Sensors Pairs HAWK Belden 3120A Dekoron e 6 or 8 conductor 5 used shielded twisted pair Pair1 Red Red White 1 p Black Black Black 1 instrument cable Pair 2 White Yellow White 2 e
10. 1 Mount the units according to Mounting Guidelines To protect from surges ensure that an external ground wire is connected between the outside ground screw on the Gladiator housing and the vessel or other ground source 2 Make sure that the material or target is not blocking the path between sender and receiver 3 Choose Application Type App Type Selecting the App Type sets the unit to pre sets specific for blocked plugged chute detection boom protection long range machinery collision detection and several others A Alignment For aligning the unit at long range Unit is set to 1 2V signal 48 switch value on display move the unit face to get the volt reading high 2 4V will be the maximum reading or 0 switch value Calibrate amp re select this mode and repeat till you cannot improve the alignment B Blocked Chute Configures the unit for blocked chute applications C Boom Protection Configures the unit for anti collision applications D Switch Allows selection of Sensitivity for typical level switch application The higher the programmed the more responsive the unit will be Use a lower if build up or dusty conditions are expected E Analog Density Special measurement mode See App Types for further information 4 Perform Cal Mount Some App Types require a Cal Mount This calibrates the system to ignore any interference caused by mounting etc There should be clear path between the sender and rece
11. 7 DI SENSOR COMMS DC In 4 20mA N A GMSEQ MICROWAVE SEQUENCER CH1 CH2 CH3 CH4 EE EE EE EE EE EE x lt H TO TO SLAVE3 SLAVE4 Integral Test Switch Gladiator Gen 3 Microwave Series Integral Receiver Test Switch Functions The test terminal has two potential modes of operation for 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 ON 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 Test Input from PLC SCADA DCS Digital Output Receiver Terminal Block PLC SCADA DCS Output CONNECT BACK TO GLADIATOR GROUND OR DC TERMINALS D 1 PLC SCADA DCS GROUND MUST Receiver Terminal Block Operator Controlled Press To Test Externally provided test button T EXTERNAL PUSH BUTTON GROUND MUST CONNECT BACK TO GLADIATOR GROUND OR DC TERMINALS Failsafe Output Mode Test Switch OFF 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 inte
12. KORON IED183AA004 350m 1150 ft 4 pairs 3 conductors not used Maximum Operating Pressure e 2 BAR Display Remote version only e 2 line x 12 character alphanumeric LCD e Backlight standard Memory Remote e Non Volatile No backup battery required e gt 10 years data retention Enclosure Sealing e Integral Sensors IP67 e Remote Electronics IP65 NEMA 4x e Remote Sensors IP67 Cable Entries e Remote Sensors 1xM20 Gland 3 4 NPTF threaded adaptor e Remote Amplifier 4x20mm 0 8 1x16mm 0 6 knock outs e Integral Units 2xM20 Glands 3 4 NPTF threaded adaptors Mounting e 3 male NPT thread or four 10mm 0 4 holes in flange e MA12 MA13 adjustable mounting bracket Environment Seal e 3 4 and 6 weldments for standard mounting on vessel wall with PTFE and UHMW windows e Flange for mounting separate from vessel wall isolation shock mounts are available e Ceramic window assemblies e Firebrick window assemblies available on custom basis e Waveguides custom assemblies available for high temperature and limited access applications Weight e GSA 1kg GMS5kg GMR 5kg TE gg HAWK A Higher Level of Performance Gladiator Gen 3 Microwave Series HAWK Since 1988 Hawk Measurement Systems Pty Ltd HAWK was established in 1988 It s founding members saw the universal requirement of various industries requiring improved process control and efficiency in their opera
13. Receiver units mild steel Approval Standard 16 3 Ceramic Window amp Weldment each X Not Required 17 4 Ceramic Window amp 4 Weldment each A22 ATEX Grp ll Cat 3 GD 18 4 Microwave Weldment only each T85 C IP67 Tamb 19 3 Stainless steel Weldment only for 40 C to 70 C KE 20 4 UHMW Window only each GMSR B101SX 21 3 UHMW Window only each 22 4 Stainless steel Weldment only for UHMW each HAWKLink Modem 25 Flanged Focaliser tube extension pipe Model 316L HL HAWKLink 20 P1 4 UHMW Window with 40mm Type insertion depth fits 4 Weldment R Remote stand alone system MA 4 Power Supply B 12 30VDC E GMSEQ Gladiator Microwave Sequencer Network Type Power Supply G3 3G Simcard B 12 30VDC S3 A e e C 30 48VDC and 48 90VAC ustralian Simcard expires after 3 month U 12 30VDC and 90 260VAC 12 Australian Simcard expires GMSEQ U after 12 month X Not Required customer supplied data enabled simcard HAWkKlink USB HAWKlink USB PC HL R U G3 5S3 connector for GosHawkIll Oa aM HAWKO Specifications Gladiator Gen 3 Microwave Series Operating Voltage e Integral 12 30VDC Remote 12 30VDC residual ripple no greater than 100mV e Integral 80 260VAC Remote 90 260VAC 50 60Hz Power Consumption e lt 0 8W 24VDC e lt 5VA 240VAC Communications e lt 3VA 115VAC e GosHawk Modbus e 4 20mA e Multidrop mode can address 1 250 units over 4 wires Relay Output 1 SMART 2 Remote e Form C SPD
14. T contacts rated 5A at 240VAC resistive e Remote fail safe test facility for one relay Operating Temperature e Remote electronics 40 C 40 F to 80 C 176 F e Integral Units 30 C 20 F to 65 C 150 F e Remote Sensors 30 C 20 F to 65 C 150 F F or higher temperature applications remote mounting with refractory windows is necessary Power Density e Rated from emitter to receiver at approximately 20 uW cm e Complies with FCC Title Rules Part 15 Beam Blockage e Caution sign posting not required Transmitted Signal e Circular transmission polarity e Frequency 10 525GHz e Power 20dBm 100mW Fail Safe e Sensitivity 95dBm e Beam width 25 e Selectable presence or absence of material e High level fail safe relay is activated when material is present e Low level fail safe relay is activated when no material is present Range e Maximum range under ideal conditions 1200m 656ft e Minimum range under ideal conditions 10cm 4 inches Note Minimum ranges are dependent on application conductivity Sender Receiver to Amplifier Separation e Up to 500m 1640ft using specified extension cable Alternate cable type between Amplifier and Sensors e 6 or 8 conductor 5 used shielded twisted pair instrument cable e Conductor size dependent on cable length e BELDEN 3120A DEKORON or equivalent e Max BELDEN 3120A 500m 1640 ft 3 pairs 1 conductor not used e Max DE
15. Time Edit to save Wd to Save CleanGainHi D Edit CleanGainLo CleanGainLo D Edit D to save Cross Talk Prevention Sequencer Wiring Gladiator Gen 3 Microwave Switch Series Cross Talk Prevention Sequencer Wiring e Up to four remote Microwave systems can be set up for anti crosstalk e For two systems one can be set to operating mode Master and the other to operating mode Slave e For up to four systems a dedicated Sequencing control unit must be used with the four systems set to operating mode Slave e See user manual for further information Master Slave Wiring GLADIATOR MICROWAVE REMOTE AMPLIFIER GLADIATOR MICROWAVE REMOTE AMPLIFIER MASTER SLAVE MIC SENDER RELAY 1 RELAY 2 MIC SENDER RELAY 1 RELAY 2 e m 2 x SIS z w i z O gt E F Zza E D 4 OO ae D om lt Kd E a gja H as 4 2 8 2 OOOOOOO0O0 D UU OOO 20 2 22 24 16 17 18 23 24 28 29 30 13 14 15 SENSOR Sequencer Slave Wiring GLADIATOR MICROWAVE REMOTE AMPLIFIER GLADIATOR MICROWAVE REMOTE AMPLIFIER SLAVE SLAVE MIC SENDER MIC SENDER RELAY 1 RELAY 2 RELAY 1 RELAY 2 ad ad gt gt F S RE ju BE zo E a 4 OJ a o d SC 26 2 SZ d Sid s H 2 8 2 2 8 2 OOO OOO OOOOOQOOOQOUOUOO0O 0 22 23 24 28 29 30 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 O
16. cable 1 10 525 GHz 20 20m cable Transducer Facing Material Selection 30 30m cable 0 UHMW Polyethylene 50 50m cable 1 PTEE Tele 100 100m cable Transducer Housing Material CA GMR ap Lengths above 1 Aluminium Mild Steel 100m available via special order 2 316L Stainless Steel Output Option X Not Required Outputs generated from GSA amplifier Approval Standard X Not Required A22 ATEX Grp II Cat 3 GD T85 C IP67 Tamb 40 C to 70 C GMSB 1 0 1 X X O gg HAWKO Part Numbering Gladiator Gen 3 Microwave Series Integral Version GMS Gladiator Microwave Sender MA Mounting Accessory GMSR_ Gladiator Microwave Smart Integral Receiver Type Power Supply 0 3 Weldment each ee 4 4 UHMW Window amp Weldment each indow eldment eac Se eee en eae 5 6 UHMW Window amp Weldment each Frequency 6 3 PTFE Window amp Weldment each KAO DES RZ 7 4 PTFE Window amp Weldment each Transducer Facing Material Selection 8 6 PTFE Window amp Weldment each 0 UHMW Polyethylene 9 9 x 4 5 fire brick assembly each 1 PTFE Teflon 10 6 x 4 ceramic brick assembly each Transducer Housing Material 11 Shock vibration insulation mounts pack of 4 1 Aluminium Mild Steel 12 Adjustable mounting bracket gt 2 Full stainless steel UHMW window each Output Option 13 Adjustable mounting bracket lt X Not Required for Sender units PTFE window each S Switch 1 output relay with 15 Flanged Focaliser tube extension pipe Modbus for
17. ds this should be done with Clear Path between Sender and Receiver Press RUN several times to restart the unit This will be the 4mA reference point for the analogue Note You must RUN the unit before proceeding with To set the 20mA reference point you can either 4 Enter a specific HighSpan 10 100 or 5 Start the process you wish to measure When the desired density of product is between the Sender amp Receiver you can enter the Quickset menu and run Autoset This sets the measured condition between Sender and Receiver to the 20mA 100 reference If Autoset returns Failed you either did not press RUN after the Cal Mount to set the 4mA point or the Microwave pulses are not blocked by a high enough density which the unit can detect Remote Setup Procedure Gladiator Gen 3 Microwave Series Advanced Menu Parameters Parameter Description Sub Menu e Auto Switch On set in Quickset Switch On Switch Off automatically configured Switch Mode e Switch Off e Manual Manually adjust Switch On and Switch Off TE SC e Off Switch mode disabled in Analog Density mode Set Relay2Action as one of the below e Failsafe Relay2 triggers on failsafe conditions e Relay2 Mirrors Relay1 action to act as a second backup relay for the system EE ti S or further information abou e Maintnce Chk Triggers Relay2 at a pre defined Gain value Relay2Action the Maintenance and Cl
18. e extension pipe 4 x 10mm 0 375 4x7mm oO er OF 0 28 Se Z A 95mm 3 75 O Ei Ka O 135mm 5 31 160mm 5 51 300mm 11 8 101mm 3 97 1A MA12 MA13 Adjustable Mounting Bracket 4x 10mm 0 375 135mm 5 3 336mm 13 2 225mm 8 85 End closed with UHMW window 147 mm 5 8 a 158 mm 6 2 182 5 mm 7 2 2j Mounting Bracket 160 mm 6 3 135 mm 5 3 4x 7mm 0 28 holes ane SE A Alignment marks TR Shis E O EJE EIE Si 4x 10mm S 0 375 holes O LY e Bi 88 5 mm 3 5 MA20 P1 75mm 2 95 PD 100mm 3 94 L 4 NPT THD 2 x 6 50mm 0 25 J Dimensions Gladiator Gen 3 Microwave Series Weldments and Windows UHMW PTFE Weldment with UHMW PTFE Windows Weldment is welded to the vessel Window threads into Weldment Window G Si 5 92 5 118 4 ne NPT m 0 2 3 64 4 65 0 16 Weldment UHMW PTFE Window 6 5mm 0 25 e 2 Places gt gt 75mm 2 95 CN 125 244 5 120 148 4 92 0 96 0 2 4 72 5 83 190 4 5 175 11 2 7 5 S S 94 0 2
19. e 20mA reference point This can be Viewed Autoset or set to a Custom value This value will always be a 10 100 with 10 the most sensitive 100 below Density application is selected suited to measure the indicate the widest variation Sensitivity A high value will make the unit more Switch Sets the unit to a standard switch mode with adjustable sensitive to switching and responding to sensitivity lighter materials A low value will make the unit more resilient and ignore dust build up Boom Sets the unit to Boom Protection mode This can also be used for machinery truck or object Protection WW detection amp collision avoidance Sets the unit for blocked chute mode Blocked i l l Note This mode may be unsuitable for very low dielectric Chute materials A mode to assist aligning units over long range Select this mode and perform a Cal Mount RUN the unit and it will indicate half signal approximately 48 Switch on the display Improving the alignment will reduce the Alignment with the goal to reduce as low possible Re Cal Mount if the reaches 0 and continue to adjust the alignment until it cannot be improved further After using this mode you must set the unit back to a normal app type as function is purely for alignment Analog Density Setup Guide 2 the next step Select Analog Density App Type To set the 4mA condition reference Perform a Cal Mount HAWK recommen
20. e amplifier to sensor separation up to e Simple sensitivity adjustment and calibration on 500 meters 1640ft Integral system e Ranges up to 1200 meters 3937ft e Bright visual status indication on sensors e Independent housing alignment after mounting e Simple 1 minute setup application pre sets sensor e Remote sensor or Integral all in one types Dimensions Gladiator Gen 3 Microwave Series Remote Microwave System Remote Amplifier 192 5 mm 7 6 174 mm 6 9 182 5 mm 7 2 Remote Sender Receiver 985 mm 3 3 90 mm 3 5 1 2 mm 0 078 D D 129 5 mm 5 1 135 5 mm 5 3 160 mm 6 3 111 5 mm 4 4 50 mm 2 74 mm 2 9 4 mm 0 2 j OOOO 78 mm 3 1 a 3 14 mm Wer TEn 192 5 mm 7 6 m gE 147 mm 5 8 le i O bag TT ot GH lt N T_T BI Je oy l i Mind 2 e ve EI Ele El Selfie EI ElHKlo ge 2 7 EIS Se 2 g Integral Sender Receiver 85 mm 3 3 160 m 3 6 3 MA15 MA25 Focaliser Tub
21. eaner for a maintenance build up alarm e GainOPpt Cln Triggers Relay2 to activate a cleaner system EE RR SE based on total Gain used EE E Pee e TimeOpt Cln Triggers Relay to activate a cleaner system based on a programmed time delay Ke Sets the unit to Boom Protection mode This can also be used iew i for machinery truck or object detection amp collision avoidance Sets the unit for blocked chute mode Note that this mode may Reset Log be unsuitable for very low dielectric materials e DeviceNet not functional Adjust amp select additional communications baud rate and e Profibus not functional Comms Type device ID All GSA units by default include Modbus e HART not functional e Modbus Back Light Turn on off LCD backlight k r e Remote Default setting for standard remote system For further information see eratin E J e Master Set system to Master mode for 2 system anti crosstalk Cross Talk Prevention e Slave Set system to Slave mode for 2 system anti crosstalk Sequencer Wiring section Display Span Probe Avg is a output damping parameter Probe Avg Increase to smooth out unwanted fluctuations or instability LoadDefaults Reset system to defaults amplifier and or sensor InputVolChk Used for power related failsafe When active the unit will switch to failsafe mode if input voltage drops below required power When not active unit will display Input Voltage too low on the dis
22. iver 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 will be zeroed with the existing process conditions and the measurement history log has been cleared Always calibrate the unit after adjusting the App Type 5 Select Switch Point The output relay will switch when the Switch exceeds the entered value The default value of 76 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 6 Set Delay Set the time delay to be used for both switch on and switch off action 7 Choose Relay Action Sensor Value Press iS gt FM UnLock 0 Press CAL Switch Point 76 Press CAL AL o0 Press Ss CAL Delay Adjust 2 0S Press Ss CAL AO 1 Press CAL Relay Action FailSafe Hi Press 3s CAL Press Twice o gt RUN The Relay can switch ON or OFF as the microwave beam is blocked and switch ON or OFF in response to an instrument failure Failsafe Hi for no
23. m a CAL mount Do not proceed with this step unless the material or target position is well beneath the line between the sender and receiver Switch CAL switch on the Receiver unit to ON position The Blue LED will blink to indicate that mounting calibration is now in progress Wait 5 seconds then switch the mounting calibration switch to OFF position The blue LED will switch off after successful calibration If it stays on this indicates there was a calibration error If this is the case please check that the path between sender and receiver is clear and alignment is correct You may need to lower the Sensitivity setting Try the calibration again If mounting calibration was successful the blue LED should be off and the Green LED should be ON 9 Switch check If required block the Sender with a sample of the application material note the units are capable of penetrating significant amounts build up The green LED will dim when the Microwave beam begins to be blocked You can also press the TEST button on the Sender to simulate a blocked chute condition and thus trigger the relay action Note Integral type Microwave systems should not be used for anti collision detection boom protection applications where there is limited access to the electronics Contact Hawk for information about the remote type systems Setup Procedure Remote System Gladiator Gen 3 Microwave Series Setup Procedure Remote System
24. nes 4 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 Always use the recommended setup for blocked chute detection 5 When using the system as a proximity switch such as truck detection the mounting arrangement is application dependent and must ensure proper operation even under worst case conditions Mounting With Windowed Weldments Mount away VA from main product flow Windowed Weldments are designed to protect the Microwave from the hazards of the application The weldment is welded to the chute application wall and then the window is threaded or locked into position The Microwave pulse will pass through plastics and ceramics However it will not pass through metallic type lining Sender iann UD I Metal Bin Chute Walls 4 UHMW Windowed Weldment ern Receiver UU Wey hatt i iii AU hum UU HUOT NIT Mounting Gladiator Gen 3 Microwave Series Installation With Adjustable Mounting Mounting of a Microwave system on sloped vessel to help protect the electronics from damage Each walls can be accomplished using the Microwave side wall of the vessel must not exceed 30 degrees Adju
25. not enough Gain is available Check for build up obstructions or choose a new App Type perform new Cal Mount e Check incoming voltage with a multimeter in line Confirm it is as per Specification e If the unit is AC powered put a multimeter over the If the system does not respond to pressing the DC terminals The unit generates a diagnostic Test button DC voltage in these terminals If powered by AC There may be a potential hardware fault This should read at least 8V consistently e First confirm wiring runs are correct see Error 01 H this is unstable and dropping below 7V while codes for further information on wiring checks your incoming AC is stable there is likely a problem with the internal power supply Contact your local e Change the Receiver Sender Amplifier in this order disiibutoror HAWK If this does not resolve the issue remove hardware and perform isolated bench test on the units Switch Testing e If the Sensor reads 0 this means full signal is present and the system is operating correctly Use the Test button on the Sender to test the relay action Troubleshooting Gladiator Gen 3 Microwave Series Error Codes Error 01 e Amplifier Transmitter can not communicate with sender receiver e Error No 01 is displayed on power up with a reset loop or after unit has successfully operated and subsequently failed e Check wiring terminals for a loose or incorrect connection including juncti
26. on 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 Setup Procedure Integral System 19 Setup Procedure Remote System 20 Operational Diagnostics 21 Remote Main Menus amp Interface 22 Remote Main Menus amp Interface Remote System 22 Remote Setup Procedure 23 SE ES i ER e EE T App Type Parameters 24 Advanced Menu Parameters 25 Relay 2 Actions 26 Relay 2 Software Flow Chart 27 Cross Talk Prevention Sequencer Wiring 28 Integral Test Switch 29 Integral Receiver Test Switch Functions 29 Troubleshooting 30 Se ee ag re eeee ann Safety Information 32 CS Ge SC EE E Part Numbering 33 GES ge Gen EE S Integral Version 34 Specifications 35 Ce 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 st
27. on about Application Types Select application pre set This automatically configures the unit to the recommended settings for each specific application Note you must perform a Cal Mount after changing or selecting App Type e 4 20mA Density e Switch e Boom Protect e Blocked Chute e Alignment Performs a Cal Mount in which the unit Cal Mounting automatically configures itself based on the e Yes No selected App Type and the mounting environment This is the switch on off sensor value for relay Auto 75 on 50 off Switch Point actions e Manual set in Advanced Set on delay time for the first relay If using the On Delay Adj 2nd relay in cleaner maintenance mode 1 2 of e Adjustable in seconds this value will be the duration of the relay timer Adjust the Relay action to be energised or e FailSafe Hi Relay1Action J e de energised during normal operation e FailSafe Low Lock Code Set a lock code to prevent unauthorised access e Default 0 Remote Setup Procedure Gladiator Gen 3 Microwave Series App Type Parameters App Type Analog Density see Density Setup Guide Description Analog is the new App Type which allows customers to measure variation in the amount of Microwave energy blocked and absorbed by on application The variance is represented by a 4 20mA analog output Note Relayl as a switch function is disabled while the Sub Menu HiSpan This is th
28. on box cable extensions e Check the cables for any signs of damage e Ensure any customer supplied cable meets HAWK specifications e Ensure correct power is applied to the correct terminals DC only version units will not support AC e Use a multimeter to check voltage supply for the Remote Sender amp Receiver on the red black labeled terminals of the Amplifier You should get approximately as below Sender 24 0VDC Receiver 9 10VDC e Disconnect Sender and Receiver from amplifier and use a multimeter to check kohm resistance values approximate across the following wires Sender e Brown Black 200 230kohm Receiver e White Blue 27 32kohm e Black White or Blue 13 16kohm e Brown Blue or White 70 80kohm e Brown Black 60 70kohm Error 02 e Error Codes can also indicate communication data failures or corruption between Amplifier and Sender Receiver e Ensure any junction box wiring extensions are as per Hawk wiring guide Make sure wiring is correct especially look to the screen earth Error 03 e Incorrect comms module selected W eg Profibus FF Check part number to confirm lt communications options All units are Modbus as default Error 04 e Amplifier is programmed with incorrect software Contact your local support Safety Information Gladiator Gen 3 Microwave Series FCC Regulations Qualifications The Federal Communications Commission imposes strict requirements
29. on radiating sources such as the GSA GMS GMRR GMSR 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 20UW 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 Part Numbering Gladiator Gen 3 Microwave Series Remote Version Remote Amplifier GSA Gladiator Amplifier compatible with all Gladiator products Modbus Housing S Polycarbonate Power Supply B 12 30 VDC C 30 48VDC and 48 90VAC U 12 30VDC and 90 260VAC Output Options S 2 Relays relay 1 primary switch relay 2 secondary switch OR Failsafe Cleaner Maintenance alarm X Option S plus 4 20mA output Approval A22 ATEX Grp Il Cat 3 GD T85 C IP67 Tamb 40 C to 70 C GSA S U S Remote Sender Receiver Connection Cable GMSB Gladiator Microwave Sender CA GMR Pre cut cable for remote GMRR Gladiator Microwave Remote Receiver sender or receiver Frequency 10 10m
30. orage or return to factory Overview Gladiator Gen 3 Microwave Series 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 Microwaves are small Micro radio waves transmitted from point to point hence the system setup of sender and receiver units Typical Uses e Blocked chute detection e Nucleonic switch replacement e Collision detection e High level alarm Low level alarm e Stacker Reclaimer protection e Truck machine detection e Shiploader protection Function The Gladiator Microwave Switch can be used for blockage detection barrier detection machine detection collision detection for protection point level measurement and detection of objects or material between two points Features e State of the art Circular transmission e Relay outputs Integral 1 failsafe Remote 2 e Backwards compatible with all Gladiator Microwave Remote test function generations e Adjustable ON and OFF delays 0 20 sec e LCD push button setup diagnostics on e Remote 3G HAWKlink connection option remote amplifier e Remot
31. ovative system allows our Global Support Team to assist with commissioning and after sales service of HAWK equipment worldwide Measurement problems are addressed as they happen not days or weeks later Knowledge Sharing HAWK believes that knowledge sharing is key to creating long term relationships Empowering our customers and our worldwide distribution network whilst being available at all times to lend a helping hand is the perfect recipe for long term solutions and relationships HAWK openly extends an invitation to share our 25 plus years of level measurement experience and ensure that your day to day processes are efficient understood and always working All company or product names are registered trademarks or trademarks of their respective owners Hawk Measurement 96 Glenn Street z Lawrence MA 01843 USA Z Phone 1 888 HAWKLEVEL 1 888 429 5538 S Phone 1 978 304 3000 Fax 1 978 304 1462 e info hawkmeasure com 2 S E HONk
32. play if input voltage drops below required power Relay 2 Actions Gladiator Gen 3 Microwave Series Relay 2 Actions Maintenance amp Auto cleaner functions Setup Example Time Based e The Gladiator Amplifier can use Relay 2 as a trigger In Quickset Set On Delay to 4 0 seconds this mechanism to notify the user or activate a cleaning will provide a 2 0 second water blast system based on time or conditions within the application which require cleaning maintenance e Iin Advanced set Relay2Action to TimeOptClin with a Clean Timer of 30min e There are three software options using two different concepts The first concept is based on total Gain e Every 30 minutes the sensors will be sprayed for 2 seconds used and the second is based on a Time interval The selectable software options are as follows Setup Example Gain Based Maintnce Chk See next page for Software flow chart e The unit will switch on the relay when total Gain is greater than the CleanGainHigh the relay will switch off when Gain falls below CleanGainLow e In Quickset Set On Delay to 4 0 seconds this will provide a 2 0 second water blast e In Advanced set Relay2Action to GainOptCln GainOpt Cing with a CleanGainHi of 80 CleanGainLo of e When total Gain exceeds the CleanGainHigh point 70 and Clean Timer to 5 0min the unit activates the relay for 1 2 of
33. rmally closed relay failsafe Low for normally open relay Note Older software revisions may have different parameters or menu Structure CAA HAWK FailSafe Hi FailSafe Low Operational Diagnostics Gladiator Gen 3 Microwave Series Operational Diagnostics Diagnostic Description Sensor Sensor value indicates the amount of signal blocked from Value 0 100 0 is full signal 100 is complete blockage For the level relay to switch to state 2 the Sensor value SW On must exceed this SW On for the duration of the on delay time For the level relay to switch to state 1 the Sensor value Switch mode Auto will SW Off must drop below this SW Off for the duration of the off automatically set the SW Off delay time to 2 3rds of SW On Max The maximum recorded Sensor value since last log reset Min The minimum recorded Sensor value since last log reset Delay Dynamic switch delay time indication Temp Measured temperature inside Receiver unit e Normal e Unit in normal operation RER EE commonly for blocked e Recover e Unit applying Recover Gain to retain or enhance signal Y SE chute and other switching e Failed e Unit is in failsafe condition e applications Signal strength measured at the Receiver This value is proportionate to the Sensor Value In most modes the unit will be Sane e OV Sensor Value 100 No Signal looking to hold a 2 5V signal igna 9 1V Sensor Value 50
34. rnal system failure occurs the terminal will act as an open circuit To switch an external relay To a PLC input 12 24Vdc Receiver Terminal EE Ee DCS Input Coil rating 500mW max or 50mA max es Die Input will detect 0 state during normal system Pelay Een E operation or 1 in failed or unpowered conditions normal system operation Receiver or off in failed or unpowered Terminal conditions Block Troubleshooting Gladiator Gen 3 Microwave Series Troubleshooting Erratic non responsive Sensor value Manual blockage switch testing e For older hardware ensure the Sender is set to the e In some modes the Hawk Microwave system will be correct mode via switch on facia INT for Integral difficult to switch test using small objects You REM for remote must completely cover the Sender and Receiver e Press and hold the Test button on the Sender unit with solid materials such as bags of process This will force the Sensor to read 99 100 If this material functions correctly the system is operating correctly e You can also view the Recover Gain Diagnostic which will respond while the signal begins to be blocked by objects e If the system is operating correctly increase Probe Avg to create a smoother displayed value e There may be build up or signal loss if the unit is Relays amp LCD intermittently dimming and not able to hold a 0 value this indicates signal loss dropping out or
35. stable Mount MA 12 or MA 13 This system from the vertical centerline To mount the adjustable allows the microwaves to be mounted to a sloped bracket simply cut a hole and weld the 4 weldment surface and then adjusted horizontally for optimum directly to the vessel install the window mount the performance and operation The adjustable mount microwave and adjust horizontally 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 Product Flow Hopper Feeder se rr X EN X 30 Maximum Sending Unit Receiving Unit QT Isolation Mount Adjustable microwave mounting bracket MA 12 or MA 13 welded to vessel wall UHMW MA 12 or Teflon MA 13 Window Mounting Gladiator Gen 3 Microwave Series Correct Mounting Angle Correct Elevation Maximum Signal Strength to Receiver is indicated by maximum brightness of Green LED on Receiver Sending Unit wv Receiving Unit Microwave Beam REES Housing can be rotated within 200 after the mounting thread is tightened to allow cable entries to face downwards or allow optimal cable clearance Incorrect Elevation ae eg Sending Unit as Receiving Unit Align Sender and Receiver Rotate so that Visual Alignment Guide is in the same position on both sender and receiver Wiring Gladiator Gen 3 Microwave Series Remote System Connection
36. t with Locking Retainer 152 4mm_ 6 0 i EM 317 5mm 12 5 Ceramic Tile 101 6mm 4 0 152 4mm 6 0 25 4mm 1 Weldment Part Size Window Number MAQ Special VA wi MA10 Special VY wv MA16 3 Da Sf MA17 4 Ka y 215 9mm Gen Y k 50 8mm 2 0 Firebrick 114 3mm 4 5 762mm 228 6mm 9 0 3 0 Dimensions Gladiator Gen 3 Microwave Series MA 12 With UHMW Window MA 13 With PTFE Window Adjustable Microwave Bracket 135mm 5 3 4x 10mm 3 8 Mounting holes 225mm 8 85 336mm 13 2 Flanged Pipe Mount MA 15 300mm 11 8 T vi 101mm 3 97 E CH t End closed with UHMW 4 mounting holes 10mm 3 8 window Flanged pipe mount recommended for long range applications Mounting Gladiator Gen 3 Microwave Series General Guidelines 1 When looking for a mounting location it is important to locate and mount the interior of the window sensor face 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 A cavity in the vessel mount position where build up is possible will res
37. tions We Can Help HAWK understands the difficulties customers face when seeking accurate level measurement Every application is different involving a multitude of environmental factors This is where HAWK excels Our aim is to ensure that customers not only feel comfortable with our technology but also to ensure a consistent and reliable solution is in place for the long term We believe that a combination of application and product expertise as well as forward thinking and proactive support policies are the foundation of successful customer supplier relationships Progressive Technical Support HAWK believes that the future of the Level Measurement Industry revolves around the quality of pre and post sales support Our aim is for all sales amp support staff to be product experts and more importantly application experts making our customers applications as efficient and consistent as possible Hawk Measurement Systems Head Office 15 17 Maurice Court Nunawading VIC 3131 AUSTRALIA Phone 61 3 9873 4750 Fax 61 3 9873 4538 info hawk com au For more information and global representatives www hawkmeasure com Remote Innovation HAWK understands the need for immediate technical assistance The HAWKLink 3G communication device allows any computer with internet access and our free GosHawk diagnostic amp calibration software to dial in calibrate test and check the performance of HAWK products This inn
38. ts without universal AC power option TTT ege HAWK Functionality Layout Integral System Gladiator Gen 3 Microwave Series Functionality Layout Integral System Sender A m HAWK FS gsy9Nugyu9unve S 1 Sender status LED e Blinks while working correctly e Solid while not transmitting 2 TEST button e Press and hold to test level relay action 3 Sensitivity dial e Turn clockwise for switching in clean environments and object detection e Turn counter clockwise for difficult applications dusty wet environments 4 Hi Lo switch e Hi mode for clean environments and object detection e Lo mode for difficult applications dusty wet environments 5 FSH FSL switch e FSH relay normally closed e FSL relay normally open 6 Receiver status LEDs e Green High illumination for good signal Low illumination for weak signal e Red Relay indication Illuminated when closed e Blue Cal mount indication flashes during Cal mount will stay illuminated if Cal mount fails Receiver GECKEGE 7 Cal Mount switch e Cal mount conducts the automatic setup routine for the system Perform Cal mount for all new installations and after adjusting either Sensitivity pot or Hi Lo switch e Switch up to initiate Cal mount wait several seconds then switch back down Unit will automatically complete Cal mount routine 8 Test switch e Can be used for a failsafe test relay See f
39. ull manual for further information 9 Delay pot e Rotate clockwise to increase Relay on off delay time 15 Sec 2 5 Sec 0 5 Sec 10 Signal contact e Signal can be read with voltmeter across Signal contact point and earth screw or other ground reference 2 4 2 5V is full signal OV is no signal Wiring Gladiator Gen 3 Microwave Series Wiring Relay Functions Switch contact actions Relay for Smart Integral Probe Version Relay 1 for Remote Version Relay Action FailSafe Low FailSafe High FSL FSH default Relay Status Smart Integral Receiver terminal E j NC COM NO numbers Remote Amplifier terminal function O labels gt LED Status Material level risin S lt Material detected E NC COM NO O Material level falling NC COM NO O POWER FAILURE FailSafe Switch Contact Action POWERTAILURE L Relay 2 Remote version only For Smart Integral OR NC COM NO el NC COM NO units the Test terminal can act as a solid state INTERNAL FAILURE output with a similar function SYSTEM OPERATING NORMALLY Setup Procedure Integral System Gladiator Gen 3 Microwave Series Setup Procedure Integral System 1 Mount the units according to Mounting Guidelines 1 1 If units are AC powered ensure proper grounding is connected to ground screw 2 Make sure that the material or target is not blocking the path between sender and receiver 3 Turn
40. ult in a plug forming in front of the beam path resulting in unit performance issues 2 Microwave energy cannot penetrate through steel linings or other conductive linings You must cut a viewing hole and use an appropriate windowed weldment 3 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 l beam handrail to isolate them from vibration Isolation shock mounts can also be provided to help protect the electronics 4 For high temperature applications which exceed 65 C 150 F precipitators cement cyclones etc it is necessary to ensure that the sensors always remain below 65 C 150 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 Ww v Tir II Ii Ill Ill I l v Do not mount with cavity Do not mount here sensor can be damaged by material Mount flush with wall in safe location Mount behind flush Window Weldments Mounting Gladiator Gen 3 Microwave Series General Guideli
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