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INSTRUCTION MANUAL

Microwave Smart Switch Series


- Beam Blockage Detection -

A higher level of performance

Microwave Smart Switch Series

Manual

Rev 1.71, Sept 2013

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.

General Description, Features


Typical Applications

3
4-5

Dimensions 6-12
Mounting 13-17
Wiring
- Smart Integral Version
- Remote - Hawk Cable
- Remote - Customer Cable
- Cable extensions
- Relay Functions
- Cross Talk Prevention
2 Units
More than 2 Units
- Multidrop Connections
- HawkLink GSM
- Test Terminal

Setup Procedure
- Smart Integral Version
- Remote Version

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 ut ilize 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.

18
19
20
21
22
23
24
25
26
27
28
32

Remote Software Menus


- Software Tree
- Diagnostic Displays
- QuickSet Menu
- App Types
- Advanced Menu
- Relay 2 Actions

35
36
37
38
39
41

Troubleshooting / Error Codes

43

Safety Information

44

Part Numbering

45

Specifications

48

Contact Information (back cover)

Microwave Smart Switch Series

Manual

Rev 1.71, Sept 2013

GENERAL DESCRIPTION

FEATURES

Principle of Operation

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

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.

Note:
For wet, dusty environments where
build up issues of wet high dielectric material is prevalent Microwave
technology will have performance
problems. Hawk recommends the
Gladiator Acoustic Switch for these
applications.

Microwave Smart Switch Series

TYPICAL APPLICATIONS
Blocked Chute Detection / Machine Anti-Collision
Shiploader Luffing
Control/Boom Protection

Boom Protection

Shiploader Protection
Blocked Chute Protection

Manual

Rev 1.71, Sept 2013

Manual

Microwave Smart Switch Series

Rev 1.71, Sept 2013

TYPICAL APPLICATIONS
Bulk Material Handling

Receiver
Microwave
Blocked
Product Flow
Chute Detection

High/low and blocked


chute detection

Customer
Supplied
Mounting

Receiving Unit

Sender
Flange Mounted to a
Isolated Permanant S
Structure i.e.
I-Beam,and Rail, etc
High Vibration Applic
Microwave should be
from normal material
Brac

Process Plants

Solid Level - Cyclone Bin


High/low Level

Receiver

Gladiator

Note: Distance between


microwave face and window
should not exceed 75mm (3")
for all applications
HighWindows,
(UHMW/PTFE
Sight Glass, Ceramic Brick
and Firebrick assemblies).
Gladiator

Sender

Receiver

Sender

Low

Sending Unit

Blocked Chute
Mount Microwave under
pulley or out of main
Stable Supportsystem flow
Structure

Hopper/Feeder (Not to Scale)

Gladiator

Ceramic or Firebrick
W/Antenna Bracket

High Temp Area

High Temperature
Non Intrusive Switch
High/Low level
Blocked Chute

Wave Guides
GLADIATOR

Remote

Manual

Microwave Smart Switch Series

Rev 1.71, Sept 2013

DIMENSIONS
SMART INTEGRAL MICROWAVE SYSTEM
Standard Sender or Receiver

High Power Sender,


Receiver or SRS Receiver

250 mm (9.8)

129.5 mm (5.1)
135.5 mm (5.3)

12 mm (0.5)

50 mm (2)

10 mm (0.4)

90 mm (3.5)

50 mm (2)

2 mm (0.078)

90 mm (3.5)

85 mm (3.3)

85 mm (3.3)

88 mm (3.5)
160 mm (6.3)

165 mm (6.5)
277 mm (10.9)
Standard Sender or Receiver Flange

High power Sender / Receiver or SRS Flange


8x22 mm
Holes THRU

160 mm (6.3)
135 mm (5.3)

160 mm (6.3)

.3)

m(9

8m

23

Alignment
marks

4x10 mm holes

165 mm (6.3)
277 mm (10.9)

88.5 mm (3.5)

Note: Remote and Smart Integral types use the same flange dimensions
6

Manual

Microwave Smart Switch Series

Rev 1.71, Sept 2013

DIMENSIONS
REMOTE MICROWAVE SYSTEM
Amplifier Enclosure

30.7 mm (1.2)
7.5 mm (0.3)

111.5 mm (4.4)
78 mm (3.1)

192.5 mm (7.6)
147 mm (5.8)

131.5 mm (5.2)

190 mm (7.5)

107 mm (4.2)

108 mm (4.3)

190 mm (7.5)

182.5 mm (7.2)

167.5 mm (6.6)
141.5 mm (5.6)

14 mm (0.6)

192.5 mm (7.6)
174 mm (6.9)

147 mm (5.8)
158 mm (6.2)
182.5 mm (7.2)

50 mm (2)
74 mm (2.9)

High Power Sender,


Receiver or SRS Receiver

Standard Sender or Receiver

250 mm (9.8)

88 mm (3.5)
160 mm (6.3)

165 mm (6.5)
277 mm (10.9)
Note: For Flange dimensions see page 5
7

12 mm (0.5)

90 mm (3.5)

10 mm (0.4)

90 mm (3.5)
129.5 mm (5.1)
135.5 mm (5.3)

2 mm (0.078)

50 mm (2)

85 mm (3.3)

85 mm (3.3)

50 mm (2)

4 mm (0.2)

Manual

Microwave Smart Switch Series

Rev 1.71, Sept 2013

DIMENSIONS
ACCESSORIES
Weldments to suit UHMW/Teflon windows

D
H

6.5mm(0.25)
2 Places

100
(3.94)

3
NPT

22
(0.87)

5
(0.2)

92.5
(3.64)

118
(4.65)

4
(0.16)

125
(4.92)

4
NPT

24.4
(0.96)

5
(0.2)

120
(4.72)

148
(5.83)

4
(0.16)

190.4
(7.5)

6
NPT

40
(3.94)

5
(0.2)

175
(6.89)

223
(8.78)

11.2
(0.44)

3 steel weldment: MA-0


4 steel weldment: MA-18

C
UHMW/Teflon Windows

Size

Size

3
NPT

28.7
(1.13)

4
NPT

35
(1.38)

6
NPT

40
(1.57)

15mm (0.59")

75mm (2.95")

3 stainless steel weldment MA-19


4 stainless steel weldment MA-22

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

N OP Q

Size

100
(3.94)

3
NPT

22
(0.87)

5
(0.2)

65
(2.56)

75
(2.95)

92.5
(3.64)

118
(4.65)

4
(0.16)

125
(4.92)

4
NPT

24.4
(0.96)

5
(0.2)

90
(3.54)

101
(3.98)

120
(4.72)

148
(5.83)

4
(0.16)

L
M
Retainer for Ceramic Windows
(Bundled with matching Weldment)
6.3mm(0.25)
2 Places

Ceramic Windows
(Bundled with matching Weldment)

12.3mm (0.48)

11-12.7mm (0.43-0.5)

Size S

75
(2.95)

65
(2.56)

3
NPT

74.5
(2.93)

100
(3.94)

90
(3.54)

4
NPT

100.5
(3.96)

3 ceramic window & weldment MA-16


4 ceramic window & weldment MA-17

Unlisted parts not available separately


8

Microwave Smart Switch Series

DIMENSIONS
ACCESSORIES
Ceramic Tile Window Assembly
MA-10

Ceramic Time Mounting Assembly

152.4mm (6.0")

101.6mm
(4.0")

317.5mm (12.5")

101.6mm (4.0")

Ceramic Tile (alumina)

152.4mm (6.0")

25.4mm (1")

Manual

Rev 1.71, Sept 2013

Manual

Microwave Smart Switch Series

Rev 1.71, Sept 2013

DIMENSIONS
ACCESSORIES
Firebrick Window Assembly
MA-9

Firebrick Mounting Assembly

228.6mm (9.0")

215.9mm
(8.5")

114.3mm
(4.5")

50.8mm
(2.0")

419.1mm (16.5")

Firebrick

114.3mm
(4.5")

76.2mm
(3.0")

228.6mm (9.0")

10

Manual

Microwave Smart Switch Series

Rev 1.71, Sept 2013

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")

10mm
(0.90")

32mm
(1.275")

23mm
(0.890")

Waveguide WR90 Straight


FB

GTAW

4mm.172)
(
Thru
Typ 4 Pics

33mm
(1.283")

"A"
33mm (1.283")
Note: "A" = Per Application
Finish Per Application

Waveguide WR90 Bend

4mm ( .172) Thru


Type 8 Pics

33mm (1.283")

FB
33mm
(1.283")

"A"
GTAW

FB
Note: "A" = Per Application
Finish Per Application

11

Manual

Microwave Smart Switch Series

Rev 1.71, Sept 2013

DIMENSIONS
ACCESSORIES
Adjustable Microwave Bracket

135mm (5.3")

MA-12 - With UHMW Window


MA-13 - With PTFE Window

4 x 10mm (3/8")
Mounting holes

225mm
(8.85")

120mm (4.72")
148mm (5.83")
336mm (13.2")

Glass Window MA-1

Flanged Pipe Mount MA-15

2" N.P.T.

140mm (5.51")

300mm (11.8")

101mm
(3.97")

4 mounting holes 10mm (3/8")

End closed
with UHMW
window

19.9mm (0.78")

135mm (5.31")

6.3mm (0.25")

12

94mm
(3.7")

Flanged pipe mount


recommended for
collision detection
applications

Microwave Smart Switch Series

Manual

Rev 1.71, Sept 2013

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 cut into one edge of the
flange to assist in mounting correctly.

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 high temperature applications which
exceed 65C/150F (precipitators, cement
cyclones, etc.), it is necessary to ensure
that the sensors always remain below
65C/150F. 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 necessary 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.

2. 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 result in a plug
forming in front of the beam path resulting in
unit performance issues.
3. Microwave energy cannot penetrate
through steel linings or other conductive
linings. You must cut a viewing hole and use
an appropriate windowed weldment.

13

Microwave Smart Switch Series

Manual

Rev 1.71, Sept 2013

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. Always use
the recommended setup for blocked chute
detection.

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.

2. 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.

6. For boom protection / anti collision


mounting the MA15 flange pipe should be
used to assist in the reduction of beam
spread over long distances. The units
should be mounted with a 2 meter exclusion
zone in mind for the beam path between
the sender and receiver. Do not use Integral
units for boom protection.

4. Mounting of a Microwave system on


sloped vessel walls can be accomplished
using the Microwave Adjustable Mount (MA12 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

See the dedicated Hawk Microwave alignment & setup procedure guide for further
information about anti collision / boom
protection application information
www.hawkmeasure.com

14

Manual

Microwave Smart Switch Series

Rev 1.71, Sept 2013

MOUNTING
CORRECT MOUNTING ANGLE
Correct Elevation

Maximum Signal Strength to Receiver is indicated by maximum brightness


of Green LED on Receiver.
Sending Unit

Receiving Unit

Microwave Beam

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
15

Manual

Microwave Smart Switch Series

Rev 1.71, Sept 2013

MOUNTING
MOUNTING WITH WINDOWED WELDMENTS
Metal Bin/Chute Walls

Sender

UHMW Windowed Weldment

Receiver

Fabricated Bracket

Attach fabricated brackets to separate structure


if bin/chute walls are subject to high vibration

BLOCKED CHUTE MOUNTING


MAIN PRODUCT FLOW

Housing can be rotated


within 200 after the
mounting thread is
tightened, to allow cable
entries to face downwards
or allow optimal cable
clearance.

Receiving Unit

Sending Unit
Position blocked
chute detectors
to one side of
main product flow

16

Manual

Microwave Smart Switch Series

Rev 1.71, Sept 2013

MOUNTING
INSTALLATION WITH ADJUSTABLE MOUNTING
Product Flow

Hopper/Feeder

X = 30 Maximum
Receiving Unit

Sending Unit

Isolation Mount

Adjustable microwave mounting bracket


MA-12 or MA-13 welded to vessel wall.
UHMW (MA-12) or Teflon (MA-13) Window.

17

Manual

Microwave Smart Switch Series

Rev 1.71, Sept 2013

WIRING
SMART INTEGRAL SYSTEM

HI

FSH

CAL

EN

Green Power ON LED


Red Transmitter enabled LED

Remove Plug-In
terminal block for
easier wiring.

TEST

Sender

Green Power/Signal
strength/alignment indicator LED
Blue Calibration/Error LED
Red Relay Status LED

DELAY

SITIVIT

Receiver

INT 1

9 10

MICROWAVE SENDER
3
PRESS
TO TEST
PWR TX

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 3/4NPT adaptors)
mounted on the unit and one
blind plug loose.

L1

8.

9.

10.

6.

5.

3.

4.

2.

AC-IN

7.

DC-IN

1.

L1

8.

10.

+
7.

5.

RS 485

SENDER TERMINAL LAYOUT


AC-IN

9.

6.

4. Test

NO
3.

1.

NC

RECEIVER TERMINAL LAYOUT


COMMS DC-IN
RELAY

2. COM

**

**Ground the housing to


vessel, if vessel is metallic.
Ground the housing to
plant ground, if vessel is
non-metallic.

12-30VDC 80-260VAC

12-30VDC 80-260VAC

Terminals 1, 2, 3, 4, 5, 6 not used

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 universal AC power option.

18

Manual

Microwave Smart Switch Series

Rev 1.71, Sept 2013

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 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.

The GND/SHLD end is a larger cable which


has been heat shrunk. The GND only end is

Remote Receiver

Remote Sender

Terminals 1, 2, 3, 9, 10 not used

9.

8. BLACK

INT 1

10.

5.

7. RED

4. BROWN

6.

3.

2.

1.

9.

8. BLACK

10.

5. WHITE

7. RED

4. BROWN

6. BLUE

3.

2.

1.

Green Power ON LED


Red Transmitter
enabled LED

TERMINAL LAYOUT

TERMINAL LAYOUT

MICROWAVE SENDER
3
PRESS
TO TEST
PWR TX

Terminals 1, 2, 3, 5, 6, 9, 10 not used

Green Power/
Signal strength/
alignment indicator LED

Signal

9 10

Remove Plug-In
terminal block for
easier wiring.

Status

Add wire
between
terminal 8
and ground
screw

9 10

Signal strength/
alignment test
point for volt
meter connection

Hole for securing of


optional identification tag
M4 grounding screw

Add wire between


terminal 8 and
ground screw

**

4-20mA (N/A)

SENSOR

26

27

28

29

30

10

11

12

13

14

15

+
DC-In

AC-In*

NO

COM

25

L1

NC

24

NO

COM

TEST IN

23

NC

22

COMMS

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 universal AC power option.

19

AWG 22 -14
(0.5 -1.5mm)

RELAY 2

MASTER OUT

21

BROWN

SLAVE IN

20

WHITE

BROWN

19

BLUE

BLACK

18

RED

17

BLACK

16

Is

**Ground the housing to


vessel, if vessel is metallic.
Ground the housing to
plant ground, if vessel is
non-metallic.

RELAY 1

RED

MIC-SENDER

STRIP INSULATION
9mm

Gladiator Remote Amplifier

User pliers to extract


terminal blocks

Manual

Microwave Smart Switch Series

Rev 1.71, Sept 2013

WIRING
REMOTE SYSTEM - CUSTOMER SUPPLIED CABLE
Remote Receiver

Remote Sender

Terminals 1, 2, 3, 9, 10 not used

9.

8. BLACK

INT 1

10.

7. RED

6.

3.

5.

2.

4. BROWN

1.

9.

8. BLACK

10.

7. RED

6. BLUE

3.

5. WHITE

2.

4. BROWN

1.

Green Power ON LED


Red Transmitter
enabled LED

TERMINAL LAYOUT

TERMINAL LAYOUT

MICROWAVE SENDER
3
PRESS
TO TEST
PWR TX

Terminals 1, 2, 3, 5, 6, 9, 10 not used

Green Power/
Signal strength/
alignment indicator LED

Signal

9 10

Remove Plug-In
terminal block for
easier wiring.

Status

9 10

Signal strength/
alignment test
point for volt
meter connection

Hole for securing of


optional identification tag

SHIELD wire is
NOT CONNECTED
at terminal block SHIELD is
connected to
grounding screw

M4 grounding screw

SHIELD wire is
NOT CONNECTED
at terminal block SHIELD is
connected to
grounding screw

**

Gladiator Remote Amplifier

4-20mA (N/A)

SENSOR

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.

NO

COM

26

27

28

29

30

10

11

12

13

14

15

L1

NC

25

NO

COM

24

NC

TEST IN

23

RELAY 2

MASTER OUT

22

SLAVE IN

21

WHITE

20

BROWN

BROWN

19

BLUE

BLACK

18

RED

17

BLACK

16

Is

**Ground the housing to


vessel, if vessel is metallic.
Ground the housing to
plant ground, if vessel is
non-metallic.

RELAY 1

RED

MIC-SENDER

DC-In

AC-In*

COMMS

Relay 1 - Output Relay


Relay 2 - FailSafe Relay

User pliers to extract


terminal blocks

Connect BOTH GND


AND SHIELD to black
terminal at Amplifier
end only

Alternate Cable Colour Equivalents

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 universal AC power option.

Hawk

Belden 3120A

Dekoron (Pair 4 not used )

Pair 1

Red
Black

Red
Black

White 1
Black 1

Pair 2

White
Blue

Yellow
Green

White 2
Black 2

Pair 3

Brown
---

Brown
White (not used)

White 3
Black 3 (not used)

20

Manual

Microwave Smart Switch Series

Rev 1.71, Sept 2013

WIRING
JUNCTION BOX / CABLE EXTENSION
Gladiator Microwave
Amplifier

Cable shields
connect to

BLACK

BROWN

WHITE
BROWN

RED
BLACK
BLUE

Seperate
Black/Shield

8. BLACK

7. RED

5. WHITE

4. BROWN

8. BLACK

6. BLUE

RECEIVER TERMINAL CONNECTIONS

SENDER TERMINAL CONNECTIONS

7. RED

SHIELD

BLUE

WHITE

CUSTOMER
JUNCTION BOX.
DO NOT GROUND
SHIELD CABLE AT
JUNCTION BOX

Seperate
Black/Shield

4. BROWN

Cable
Shield

Re-connect
Cable Shield
to Black

BLACK
BROWN
SHIELD

RED

Cable
Shield

BROWN

RED
RED

SENSOR

BLACK

Re-connect
Cable Shield
to Black

BLACK

MIC-SENDER

at AMPLIFIER end

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.

21

Manual

Microwave Smart Switch Series

Rev 1.71, Sept 2013

WIRING

RELAY FUNCTIONS
Level Switch Contact Action
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)

Relay Action

State 1

FailSafe Low
FSL

FailSafe High
FSH (default)

Relay Status

1
2
3
NC COM NO

1
2
3
NC COM NO

Smart Integral
Receiver terminal
numbers
Remote Amplifier
terminal function
labels
LED Status

State 2

Material level rising

NC COM NO

1
2
3
NC COM NO

1
2
3
NC COM NO

1
2
3
NC COM NO

1
2
3
NC COM NO

1
2
3
NC COM NO

NC COM NO

NC COM NO

NC COM NO

NC COM NO

State 3

Material detected

Material level falling

POWER FAILURE

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

22

Manual

Microwave Smart Switch Series

Rev 1.71, Sept 2013

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.

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-.

Operation Mode has 3 selections:


1. Remote
2. Master
3. Slave

MASTER*

The shield is conncted to the Ground or


24Vdc (-ve) terminal on each unit.

SLAVE*

Sender 1

Sender 2

Receiver 1

Receiver 2

GLADIATOR MICROWAVE REMOTE AMPLIFIER - MASTER

4-20mA (N/A)

SENSOR

NO

COM

NC

24

25

26

27

28

29

30

10

11

12

13

14

15

L1

23

NO

22

L1

21

TEST IN

AC-In*

20

COM

DC-In

COMMS

MASTER OUT

19

DC-In

AC-In*

15

SLAVE IN

14

BROWN

13

18

BROWN

12

BLACK

11

17

WHITE

10

RED
16

RED

30

Is

29

28

RELAY 2

NC

SENSOR

27

RELAY 1

4-20mA (N/A)

26

BLUE

25

BLACK

NO

COM

NC

NO

24

TEST IN

COM

MASTER OUT
23

MIC-SENDER

NC

SLAVE IN
22

GLADIATOR MICROWAVE REMOTE AMPLIFIER - SLAVE

RELAY 2

BROWN
21

BROWN

BLACK
20

WHITE

19

RED

18

BLUE

Is

17

BLACK

16

RELAY 1

RED

MIC-SENDER

COMMS

Ground

* Software selected

MICROWAVE MASTER/SLAVE CALIBRATION


Step 1: Place the Master unit into CAL mode by
pressing the CAL button.

Step 5: To calibrate the Master system select the


CalMounting option, which can be found in the
Quickset menu and select YES.

Step 2: Ensure that the Slave system, which you


intend to Calibrate, has been set to Slave mode.

Step 6: Press the RUN button to resume operation. The calibration process is now complete for
a Master/Slave system.

Step 3: To calibrate the Slave system select the


CalMounting option, which can be found in the
Quickset menu and select YES.
Step 4: Press the RUN button to resume operation.
23

Manual

Microwave Smart Switch Series

Rev 1.71, Sept 2013

WIRING

CROSS-TALK PREVENTION - FOR MORE THAN 2 UNITS


(REMOTE ONLY)
are connected is approx. 3ms. More than one
unit can be connected to each channel, note that
each unit connected to the same channel will be
part of the same slave sequence in the pulsing

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 channels
Sender 1

Receiver 2

DC-IN

+
24 VDC

NC

NO

COM

AC-IN

L1

NC

NO

COM

Tx

MASTER OUT

Test in

SLAVE IN

RELAY 2

COMMS

Is

80-265 VAC

SENSOR

RELAY 1

CURRENT

BLUE

AC-IN

BROWN

NO

NC

BLACK

24 VDC

MIC-SENDER

L1

COM

NO

DC-IN

GLADIATOR MICROWAVE REMOTE AMPLIFIER - SLAVE

RELAY 2

COM

Tx

NC
A

WHITE

COMMS

BROWN

RED

BLUE

SENSOR

BLACK

Is

CURRENT

RELAY 1
Test in

MASTER OUT

MIC-SENDER

SLAVE IN

GLADIATOR MICROWAVE REMOTE AMPLIFIER - SLAVE

Sender 2

SLAVE 2

WHITE

SLAVE 1

RED

Receiver 1

Within the menu of each individual Microwave


unit, select Slave mode in the Advanced Menu
under Operating Mode.

80-265 VAC

com
Tx

com
Tx

com
Tx

com
Tx

GMSEQ Microwave Sequencer Terminal


CH1
CH2
CH3
CH4

TO
SLAVE 3

TO
SLAVE 4

MICROWAVE MASTER/SLAVE CALIBRATION


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.

Step 1: Place the Sequencer unit into CAL unlock


1 mode by pressing the CAL button on the sequencer unit.
Step 2: Ensure that the systems that you intend
to calibrate is set Operation Mode as Slave.
The Sequencer unit will operate as the Master to
control the pulsing sequence.
Step 3: Remove the wire 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.

On time 240s
Off time 700s
24

Manual

Microwave Smart Switch Series

Rev 1.71, Sept 2013

WIRING
MULTIDROP CONNECTIONS
Multidrop GPRS Connection*
Y

ON

1 2
OFF OFF

HI

SITIVIT
EN

CAL TEST

FSH

ON

10

A B Gnd

CAL TEST

FSH

ON

ON

1 2
LO FSL

DELAY

DELAY

SITIVIT
EN

HI

1 2
LO FSL

HawkLink
HLRUG6
GPRS modem

1 2
OFF OFF

10

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*


CAL TEST

ON

1 2
OFF OFF

HI

CAL TEST

FSH

ON

ON

1 2
LO FSL

10

A B Gnd

White
Blue
Black

SITIVIT
EN

FSH

ON

DELAY

DELAY

SITIVIT
EN

HI

1 2
LO FSL

1 2
OFF OFF

10

A B Gnd

A B Gnd

Hawklink
USB
Laptop or PC Communications using
Hawklink USB or RS485 / 232 converter
with GosHawk software.

Multidrop Connection to PLC/DCS/SCADA*

CAL TEST

ON

1 2
OFF OFF

HI

SITIVIT
EN

FSH

ON

10

A B Gnd

A B Gnd

CAL TEST

FSH

ON

ON

1 2
LO FSL

DELAY

DELAY

SITIVIT
EN

HI

1 2
LO FSL

1 2
OFF OFF

10

A B Gnd

* Wiring installation should follow


RS-485 standards for layout and
termination.

PLC / DCS / SCADA for Remote


Communication with Modbus.

25

12-30VDC

RS 485

80-265VAC

Separate AC power supply


for the GSM module
or
DC power
supply

Microwave Smart Switch Series


TO

WIRING

Manual

HAWK UNIT

Rev 1.71, Sept 2013

Connect shield to
DC - only at this end.

HAWKLINK GSM - CONNECTING POWER AND COMMS


HAWKLINK MODEM TERMINAL BLOCK

TOP

GND

ID 5

GND

ID 4

GND

ID 3

GND

ID 2

GND

2 WIRE LOOP POWERED DEVICES

ID 1

SHIELDED
TWISTED-PAIR

GND
GND

ID 5

GND

ID 4

GND

ID 3

GND

GND

ID 2

TOP

HAWK
UNIT
2
GND

ID 1

26

MASTER

PC

90-265 VAC

POWER

NETWORK 12-30VDC

L1

BOTTOM

NETWORK 12-30VDC

HAWK
UNIT
GND Nx
A

POWER

PC

IN

MASTER

B
HAWK
A
UNIT
Nx
GND

HAWK
UNIT
1
GND
A

HAWK
A
UNIT
2
GND

GND

NETWORK
B
HAWK
A
UNIT
1
GND

LOOP
UNIT 5

Each terminal block


ID 1 to 5 wired to
individual loop
powered units

OUT

B A

A
GND

LOOP POWER CONNECTION


LOOP
UNIT 1

NETWORK

Connect shield to
DC - only at this end.

MASTER
B A GND

PVC
Jacket

PLC

STANDARD CONNECTION

12-30VDC

Shield
Copper
Wire Foil

90-265 VAC

GND

COMMS

L1

NETWORK 12-30VDC

PLC CONNECTION

Hawk Unit

90-265 VAC
BOTTOM

POWER

IN

OUT

GND

NETWORK 12-30VDC

GND

PC

POWER

MASTER

PC

GND

MASTER

90-265 VAC

Manual

Microwave Smart Switch Series

Rev 1.71, Sept 2013

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 instruments 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

Test

PLC / SCADA / DCS Output

PLC/SCADA/DCS GROUND MUST


CONNECT BACK TO GLADIATOR
GROUND OR DC - TERMINALS

OPERATOR CONTROLLED PRESS TO TEST

Terminal Block

Test

Externally provided
test button

FAILSAFE OUTPUT MODE

EXTERNAL PUSH BUTTON GROUND


MUST CONNECT BACK TO GLADIATOR
GROUND OR DC - TERMINALS

(Test switch must be in the OFF position - default setting)


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

+12-24Vdc
12-24Vdc

max 50mA

Test

Test

Coil rating
500mW max
or 50mA max

Relay will turn on during


normal system operation
or off in failed or unpowered
conditions.

Pull up

PLC
SCADA
DCS Input

Input will detect 0 state during normal system


operation, or 1 in failed or unpowered conditions.

27

Manual

Microwave Smart Switch Series

Rev 1.71, Sept 2013

SETUP PROCEDURE
FUNCTIONALITY LAYOUT - SMART INTEGRAL SENDER
3
4
1

MICROWAVE SENDER
INT 1

REM 0

PRESS
TO TEST

PWR TX
0

10

L1

8.

9.

10.

5.

6.

3.

4.

2.

1.

7.

REMOVABLE SENDER TERMINAL BLOCK


DC-IN
AC-IN

7-30VDC

Terminals 1, 2, 3, 4, 5, 6 not used

Smart Integral / Remote mode selection switch (INT/REM)

Green LED - power status, continuously on when power supply is OK

3
4

Red LED - transmitter enabled

Press to test button - interupts signal transmission for system testing.


Simulates the effects of breaking of microwave beam.

Removable terminal block - plug in type

80-260VAC

Pulse rate setting switches (see table below)

Switch Settings
INT/REM
1, 2, 3
Sender pulse
rate selection
0 = OFF
1 = ON

Set to INT for Smart Integral types


1

45 Pulses per sec

44

42

41

40

39

38

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

Manual

Microwave Smart Switch Series

Rev 1.71, Sept 2013

SETUP PROCEDURE
FUNCTIONALITY LAYOUT - SMART INTEGRAL RECEIVER

9
4

ON

1 2
LO FSL

1 2
OFF OFF

signal

10

8.

L1

+
7.

9.

5.

RS 485

10.

6.

NO
3.

10

11

4. Test

REMOVABLE RECEIVER TERMINAL BLOCK


COMMS DC-IN
AC-IN
RELAY

NC

12

1.

2. COM

CAL TEST

FSH

ON

DELAY

SITIVIT
EN

HI

7-30VDC 80-260VAC

Functionality Description (bold is default)


1

Mounting Calibration switch CAL/OFF

Test input function select TEST/OFF

Relay action selection


switch
FSH - FailSafe High
FSL - FailSafe Low

HI / LO sensitivity switch
LO default. LO = less sensitivty.
Lo for blocked chute detection

Delay Potentiometer (0-20 sec)


(0.1 sec. at minimum position)

Sensitivity Potentiometer
Anti-clockwise (low) for blocked chute detection

RED LED: Relay status


ON when relay coil is energised

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.

10

AC Ground - must be used for


AC powered installations

11

Removable terminal block - plug in type

12

Signal voltage test point

29

Microwave Smart Switch Series

Manual

Rev 1.71, Sept 2013

SETUP PROCEDURE
SMART INTEGRAL VERSION
1. Mount the units in their actual position

6.2 The sensitivity potentiometer


Turning the pot fully counter-clockwise factory recommended for blocked chute applications. If operating
in HI mode set the pot to 12 oclock. In this mode you
can turning the pot clockwise to reduce the amount of
beam blockage required for switching and vice versa.

1.1 If units are AC powered ensure proper grounding is


connnected to ground screw.
2. Make sure that the material or target is not blocking
the path between sender and receiver.

7. Select the 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.

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. Sender (GMRS): Ensure the REM/INT DIP switch


is selected to the INT position and the remaining
switches (1, 2, 3) are all selected to OFF.

8. Perform a CAL mount


Do not proceed with this step unless the material or
target position is well beneth the line between the
sender and receiver.

5. 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).

Switch the Mounting Calibration switch on the Receiver


unit to CAL (ON) position. The Blue LED will blink to
indicate that mounting calibration is now in progress.
Wait 5-10 sec, then switch the mounting calibration
switch to OFF position. The blue LED will switch off
after successfull 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 then try the calibration
again. If mounting calibration was successful the blue
LED should be off and the Green LED should be ON.

6. Select the sensitivity


There are two adjustments controlling the sensitivity of
the switch point:
6.1 The HI/LO sensitivity DIP switch is used as
the primary sensitivity setting. Select LO sensitivity
for Blocked Chute detection. Select LO If build-up
is expected over sensors or with strongly absorptive
materials or targets. Select HI sensitivity for clean
environments and lighter/less absorptive material or
targets. LO recommended for most applications.

9. Switch check
If required block the Sender with a steel plate to check
relay action & time delay. The green LED will dim when
the Microwave beam begins to be blocked.

Recommended Settings for


Blocked Chute applications

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.
Contact Hawk for information about the remote type
systems.
30

Manual

Microwave Smart Switch Series

Rev 1.71, Sept 2013

SETUP PROCEDURE - REMOTE VERSION


FUNCTIONALITY LAYOUT
REMOTE AMPLIFIER
1

RELAY 1

RELAY 2

STATUS A

STATUS B

Calibrate button

Run button

Down button

Up button

Relay LEDs 1 and 2

Display (LCD with backlight)

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

10

4.

5.

6.

7.

8.

RED

3.

BLACK

2.

BLUE

1.

WHITE

STATUS

BROWN

REMOTE

Terminals 1, 2, 3, 9, 10 not used.

GREEN LED: Power / Received signal strength.


Brightness varies with strength of received signal.

Removable terminal block - plug in type

31

9. 10.

Manual

Microwave Smart Switch Series

Rev 1.71, Sept 2013

SETUP PROCEDURE
FUNCTIONALITY LAYOUT - REMOTE SENDER
3
4
1

MICROWAVE SENDER
INT 1

REM 0

PRESS
TO TEST

PWR TX
0

REMOVABLE SENDER TERMINAL BLOCK

2
6

Terminals 1, 2, 3, 5, 6, 9, 10 not used

Smart Integral / Remote mode selection switch (INT/REM)

Green LED - power status, continuously on when power supply is OK

Red LED - transmitter enabled

Pulse rate setting switches (settings have no function for Remote units)

Press to test button - interupts signal transmission for system testing.


Simulates the effects of breaking of microwave beam.

Removable terminal block - plug in type

Switch Settings
INT/REM

Set to REM for Remote types

1, 2, 3
Sender pulse
rate selection

Settings has no function for


remote types.

32

9.

10

10.

8. BLACK

7. RED

5.

6.

3.

4. BROWN

2.

1.

Microwave Smart Switch Series

Manual

Rev 1.71, Sept 2013

SETUP PROCEDURE
REMOTE VERSION
1. Mount the unit in its actual position
(see mounting procedure - pages 12-16)
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.

Press

UnLock
0
CAL

QuickSet
Press

CAL

App Type
Press

CAL

Press

CAL

Cal Mounting
Yes / No

Press

CAL

Press

CAL

Yes
Switch Point
75%
Press

CAL

Press

CAL

Delay Adjust
2.0S
Press

CAL

Press

CAL

0.1S
Relay Action
FailSafe Hi

Press

Press
Twice

CAL

RUN

FailSafe Hi
FailSafe Low

Ensure that the mode selection switch on the


! 3.
transmitter is set to REM (OFF). See point 1 page 31.
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

Choose Application Type


Alignment - For Aligning the unit at long range. Unit is set to 1.2V signal (~48% switch
value), move the unit face to get the volt reading high (2.4V will be the maximum
reading or 0% switch value). Calibrate & re-select this mode and repeat till you cannot
improve the alignment.
Blocked Chute - Configures the unit for blocked chute applications
Boom Protection - Configures the unit for anti collision applications
Switch - Allows selection of Sensitivity% for standard switch application.
Density - Special Density measurement mode. See App Types for further information
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.
Always calibrate the unit after changing Application type.
Select the Switch point
The output relay will switch at 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).
Select the Time Delay
Set the time to be used for both switch on and switch off delays
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 (see below). Set the parameter
to FailSafe Low or FailSafe Hi depending on your requirements.

33

Microwave Smart Switch Series

Manual

Rev 1.71, Sept 2013

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.
34

Manual

Microwave Smart Switch Series

Rev 1.71, Sept 2013

FLOW CHART
SOFTWARE TREE

Sensor Value
0.0%
Press

On first start up there is


no security code protection.

CAL

Normal Running Display


Press
to view unit
operation diagnostics

To Calibrate

UnLock
0

Press

CAL

Press
Press

Press

To QuickSet
CAL
flow chart
See page 37

Advanced

QuickSet

CAL

Advanced Menu
covers less commonly
used or advanced
parameters.

QuickSet Menu
covers all parameters
required for standard
setups.

Press RUN to return to normal operation

35

To Advanced
flow chart
See page 38

Microwave Smart Switch Series

Manual

Rev 1.71, Sept 2013

FLOW CHART
DIAGNOSTIC DISPLAYS (Remote type only)
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.

Sensor Value
0.0%
SW On 75.0%
0.0%

Percentage above
which the Relay
will be in State 2*.

SW Off 50.0%
0.0%

Percentage below
which the Relay
will be in State 1*.

Max 99.8%
0.0%
Min 0.0%
0.0%
Delay 0.1s
0.0%

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.

Max/Min captured
Sensor Value % since
Last history log reset,
or last Cal Mounting
operation

Pressing RUN several times returns the unit


into normal operation.
Current switch
delay time

Temp: 22.4C
0.0%

Current temperature
inside housing
(Celsius)

Normal
0.0%

Status
Normal / CommRetry

Signal 2.40V
0.0%

The diagnostics provide the user with


valuable performance feedback on how the
instrument is performing whilst in operation.

*Switch points are refered to as On and


Off to reflect the most simply understood
performance in F
 ailSafe Low mode. Actual
relay state may be different a
 ccording to
setting of relay action (see page 19).
CommErr 1 -> unit has lost communications
with the receiver.

Received Signal strength

Fail 1 - No comms available.

Gain 10.2%
0.0%

Current Gain% value.


In Blocked Chute mode this will increase
when product passes in front of the sensor.
The unit has a maximum possible gain% of ~94%

Noise 0.04V
0.0%

Background Noise received

Remote
0.0%

Device operating mode


Remote/Master/Slave

36

Manual

Microwave Smart Switch Series

Rev 1.71, Sept 2013

QUICKSET MENU
Parameter

Description

App Type (see next page for Select application pre-set.


full App Type descriptions)
This automatically configures the unit to the recommended settings for each
specificapplication.

Options
Density
Switch
Boom Protect
Blocked Chute
Alignment

Note you must perform a


Cal Mount after changing or
selecting App Type
Cal Mounting

Performs a Cal Mount in


which the unit automatically
configures itself based on
the selected App Type and
the mounting environment.

Yes / No

Switch Point

This is the switch on / off


sensor value % for relay
actions

Auto - 75% (on) 50% (off)


Manual (set in Advanced)

On Delay Adj

Set on delay time for the


first relay. If using the 2nd
relay in cleaner / maintenance mode 1/2 of this
value will be the duration of
the relay timer

Adjustable in seconds

Relay1Action

Adjust the Relay action


to be energised or de-energised during normal
operation

FailSafe Hi
FailSafe Low

Lock Code

Set a lock code to prevent


unauthorised access

Default 0

37

Manual

Microwave Smart Switch Series

Rev 1.71, Sept 2013

APP TYPES
Software Rev 740 and higher
App Type

Description

Sub Menu

Density (see Density Setup Guide


below)

Density is the new App Type which allows


customers to measure variation in the amount
of Microwave energy blocked and absorbed
by in application. The variance is represented
by a 4-20mA analog output. Note: Relay1 as
a switch function is disabled while the Density
application is selected.

HiSpan%
This is the 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% suited to measure the indicate the
widest variation

Switch

Sets the unit to a standard switch mode with


adjustable sensitivity

Sensitivity%
A high value will make the unit more
sensitive to switching and responding to
lighter materials. A low value will make
the unit more resilliant and ignore dust
/ build up.

Boom Protection

Sets the unit to Boom Protection mode. This


can also be used for machinery or object
detection

Blocked Chute

Sets the unit for blocked chute mode. Note


that this mode may be unsuitable for very low
dieletric materials.

Alignment

A special mode for aligning units over long


range. After performing a Cal Mount and
running the unit it will indicate half signal /
approximately 50%. Improving the alignment
will reduce the %. Re-calibrate if the %
reaches 0. After using this mode you must
select a normal app type.

Density Setup Guide


1. Select Density App Type
2. Perform a CAL MOUNT
3. 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 the next step

5. Start the process you wish to measure.


When the desired density of product is between the sender & receiver you can enter
the Quickset menu and run Autoset. This
sets the condition to 20mA / 100%.
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 measure.

To set the 20mA reference point you can


either:
4. Enter a specific HighSpan% (10-100%)
or;
38

Microwave Smart Switch Series

Manual

Rev 1.71, Sept 2013

FLOW CHART
ADVANCED MENU
Default values/settings
in bold and underlined

Advanced
Switch Mode
Auto

CAL

Auto - Factory default values. Switch On 75%, Switch Off 50%


Manual - Switch On and Switch Off values can be edited in Manual
mode.
Manual
(editable) *Only possible if manual selected

CAL

Auto
(view only)

Switch On

76%

Switch Off

71%

Relay2Action

CAL

View Log

CAL

CAL

CAL

Relay switch point On (Default 75%)


*Output relay in State 2 above this value.

CAL

CAL

Relay switch point Off (Default 50%)


*Output relay in State 1 below this value.

See Relay 2

CAL

View history log of instrument


% and temperature Yes / No

Yes

Min Sensor %

Minimum Sensor % since last


Reset Log (not adjustable).

Max Sensor %

Maximum Sensor % since last


Reset Log (not adjustable).

0.0%

No

99.4%

Continued next
page (Reset Log)

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).

*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).

39

Manual

Microwave Smart Switch Series

Rev 1.71, Sept 2013

FLOW CHART
ADVANCED MENU (CONT)
From previous page

Reset Log
No

CAL

Comms Type
Modbus

CAL

CAL

CAL

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

Device ID
1

Baud Rate
19200

Selection should not be changed


unless required hardware is
present.

(see part numbers - page 43-45)

CAL 1-255

CAL

CAL

CAL

1200
4800
9600
19200
38400
57600

Default values/settings
in bold and underlined

Back Light
On

CAL

Opertng Mode
Remote

CAL

CAL

Selection of device operating mode when used in installations requiring


cross-talk prevention.
Remote, Master, Slave

Display Span
Span 0

CAL

CAL

Not Adjustable

Display
ProbeAVG
Span
23

CAL

CAL

Averaging of measurement samples. A smaller number gives faster


response and a larger number is more stable.
Default 2

LoadDefaults
Yes / No

CAL

Reset to factory defaults


CAL You will be prompted Yes / No for both the amplifier and sensors seperately

InputVoltChk
Yes / No

CAL

Turns on voltage failsafe check


CAL If connected power is below minimum specification the unit can trigger its
failsafe relay. When off unit will display V in fail.

CAL

Display Backlight
On/Off

40

Microwave Smart Switch Series

Manual

Rev 1.71, Sept 2013

RELAY 2 ACTIONS
Concept

Setup Example - Time Based

The Gladiator Amplifier has received a


firmware update to utilise the Relay 2 as
a trigger mechanism to notify the user or
activate a cleaning system based on time
or conditions within the application which
require cleaning.

In Quickset Set On Delay to 4.0 seconds this will provide a 2.0 second water blast.
In Advanced set Relay2Action to TimeOptCln with a Clean Timer of 30min.
Every 30 minutes the sensors will be
sprayed for 2 seconds.

There are three software options using


two diffferent concepts. The first concept is
based on total Gain used and the second is
based on a Time interval.

Setup Example - Gain Based


In Quickset Set On Delay to 4.0 seconds this will provide a 2.0 second water blast.

The options are located in the Advanced


menu as a sub menu for Relay2Action.

In Advanced set Relay2Action to GainOptCln with a CleanGainHi of 80%, CleanGainLo of 70% and Clean Timer to 5.0min

The selectable software options are as


follows:
[Maintnce Chk] - 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 %.

This will trigger the water spray for 2


seconds when Gain goes above 80%. The
spray will repeat every 5 minutes until Gain
goes below 70%. You can view Gain while
the unit is running by using the arrow key to
locate the diagnostic display

[GainOpt Clng] - When total Gain exceeds


the CleanGainHigh point the unit activates
the relay for 1/2 of the On Delay time and
then switches off. The unit will then count
the Clean Time interval time before repeat
the process until total Gain is below CleanGainLow point.
[TimeOpt Clng] - At every Clean Time interval the unit will switch on the relay for 1/2 of
the On Delay time and then switch off.

41

Manual

Microwave Smart Switch Series

Rev 1.71, Sept 2013

RELAY 2 ACTIONS

Note: Requires GSA unit with software revision 7.40 or later

To set spray duration for Gain and Time options (1/2 of On Delay).
Sensor Value

CAL

Unlock 0

CAL

Quickset

CAL

App Type
Cal Mount
Switch Point

On Delay Adj
Off Delay Adj
Relay Action

CAL

On Delay Adj

CAL

On Delay Adj

*Edit*

CAL

to save

Min 3.0 seconds

To set Relay 2 action for one of Time, Gain or Maintenance options.


Sensor Value

CAL

Unlock 0

CAL

Quickset

Advanced

CAL

Switch Mode

Relay2Action

CAL

View Log
Reset Log
Comms Type
ProbeAVG
Initilize TX
LoadDefaults

TimeOpt Cln

GainOpt Cln

CAL

Clean Time

CAL

CAL

CleanGainHi

CleanGainHi

CAL

CAL

CleanGainHi

CleanGainHi

CAL

Clean Time
*Edit*

*Edit*

CAL

to save

Maintnce Chk

Relay2
Failsafe

*Edit*
CAL

CAL

CleanGainLo

CleanGainLo

CAL

CAL

CleanGainLo

CleanGainLo

*Edit*

*Edit*
CAL

Clean Time

CAL

to save

CAL

Clean Time
*Edit*
CAL

to save

Other Relay2 Actions


Relay 2 - Sets the 2nd relay to mirror the first relay action
Failsafe - Sets the relay to trigger for a failsafe condition such as sender/reciever fail or
voltage problem

42

Microwave Smart Switch Series

Manual

Rev 1.71, Sept 2013

TROUBLESHOOTING
Error 01: Amplifier/Transmitter can not
communicate with sender/receiver.

Error 02: Communication data corruption


between Transmitter and Transducer.

Error No 01 is displayed on power up with


a reset loop or after unit has successfully
operated and subsequently failed.

It can be a result of noise in data lines or


one of data lines (white or blue wires) being
open circuit.

Check wiring terminals for a loose or


incorrect connection (including junction
box/cable extensions). Check the cables for
any signs of damage. Ensure any customer
supplied cable meets Hawk specifications.

1. Make sure wiring is correct especially


look to the screen (earth).
Error 03: Incorrect comms module selected
(eg Profitbus, FF)

Ensure correct power is applied to the


correct terminals. DC only version units will
not support AC.

Error 04: Amplifier is programmed with


incorrect software. Contact your local
support.

Use a multimeter to check voltage supply for


the Remote Sender & Receiver on the red/
black labeled terminals of the Amplifier. You
should get approximately as below:

Relays & LCD intermittently dimming


and dropping out.

Sender

Check incoming voltage with a multimeter. If


unstable and dropping below 8V the unit is
not getting enough power.

+/- 24.0V
Receiver:
+/- 9.4V

If AC powered put a multimeter over the


DC +/- terminals. The unit generates a DC
voltage in these terminals if powered by AC.
This should read at least 8V consistently. If
this is unstable and dropping below 7V while
your incoming AC is stable there is likely
a problem with the internal power supply.
Contact your local distributor or Hawk.

Ensure the Sender is set to the correct


mode (integral or remote). This is set by the
INT / REM switch on the Sender facia.

Note:
For wet, dusty environments where
build up issues of wet high dielectric material is prevalent Microwave
technology will have performance
problems. Hawk recommends the
Gladiator Acoustic Switch for these
applications.
43

Microwave Smart Switch Series

Manual

Rev 1.71, Sept 2013

SAFETY INFORMATION
FCC REGULATIONS
Qualifications

Requirements

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.

(A) OSHA - 10mW/cm2of radiated power.


(B) ANSI - 5mW/cm2 of radiated power.
The Hawk Gladiator Microwave Systems
have approximately 20W/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.

44

Microwave Smart Switch Series

Manual

Rev 1.71, Sept 2013

PART NUMBERING
REMOTE VERSION
Remote Amplifier
GSA Remote Gladiator System Amplifier

Housing


S Polycarbonate

Power Supply

B 12-30VDC

C 30-48VDC and 48-90VAC (30-48VDC)

U 12-30VDC and 90-260VAC
Output Options
S 2 relays with Modbus

X 2 relays with Modbus plus 4-20mA Analogue for Density measurement

GSA S U S

Remote Sender/Receiver
GMSB
Gladiator Microwave Sender
GMSHB Gladiator Microwave Sender High Power
GMRR
Gladiator Microwave Remote Receiver
GMRRH Gladiator Microwave Remote Receiver High Power

Frequency

1 10 GHz

Facing Material

0 UHMW Polyethylene

W Wave guide connector
Housing Material
1 Aluminium / Mild Steel

2 Full stainless steel GMSB/GMRR

3 Full stainless steel GMSHB/GMRRH
Output Option
X Not required
Approval Standard
X Not Required

A22 ATEX Gas/Dust (Grp II Cat 3 GD T65C IP67)

GMSB 1 0

1 X X

45

Microwave Smart Switch Series

Manual

Rev 1.71, Sept 2013

PART NUMBERING
SMART INTEGRAL VERSION
GMS
Gladiator Microwave Sender
GMSH
Gladiator Microwave Sender High Power
GMSR
Gladiator Microwave Smart (Integral) Receiver
GMSRH Gladiator Microwave Smart (Integral) Receiver High Power

Power Supply

B 12-30VDC

C 30-48VDC and 48-90VAC (30-48VDC)

U 12-30VDC and 90-260VAC

Frequency

1 10 GHz
Facing Material

UHMW Polyethylene

W Wave guide connector
Housing Material
1 Aluminium / Mild Steel

2 Full stainless steel GMS/GMSR

3 Full stainless steel GMSH/GMSRH or GMSRS
Output Option

X Not required (Sender units)
S Switch, 1 output relay with Modbus (Receiver units)
Approval Standard
X Standard CE approved

A22 ATEX Gas/Dust (Grp II Cat 3 GD T65C IP67)




GMSR
B 1 0 1 S X

46

Microwave Smart Switch Series

Manual

Rev 1.71, Sept 2013

PART NUMBERING
ACCESSORIES

CA-GMR Pre-cut cable for remote sender or receiver unit

10 10m cable each


20 20m cable each
30 30m cable each
50 50m cable each
100 100m cable each (contact factory)

CA-GMR 10M
MA Mounting Accessory

Type
0
3
4
5
6
7
8
9
10
12
13
14
15
16
17
18
19
20
21
22
25

3 Steel Weldment only each


3 UHMW Window & Weldment each
4 UHMW Window & Weldment each
6 UHMW Window & Weldment each
3 PTFE Window & Weldment each
4 PTFE Window & Weldment each
6 PTFE Window & Weldment each
9 x 4.5 Firebrick Window Assembly each
6 x 4 Ceramic Tile Window Assembly each
Adjustable mounting (UHMW window) each
Adjustable mounting (PTFE window) each
Remote wave guide Assembly
Focaliser Tube / Flanged Pipe Mount
3 Ceramic window & weldment each
4 Ceramic window & weldment each
4 Steel Weldment only each
3 Stainless steel Weldment only each
4 UHMW Window only each
3 UHMW Window only each
4 Stainless steel Weldment only each
Stainless Steel Focaliser Tube / Flanged Pipe Mount

MA 3

GMSEQ Gladiator Microwave Sequencer

Power Supply
HL HawkLink 3G modem

B 12-30VDC

Type

C 30-48VDC and 48-90VAC (30-48VDC)

R Remote stand alone system mounted in a remote enclosure

U 12-30VDC and 90-260VAC

c/w antenna.
Power Supply
GMSEQ U

B 12-30VDC

U 12-30VDC and 90-260VAC
Network Type
G3 3G Multiband
Network Type

S3 Australian Sim Card expires after 3 month

S12 Australian Sim Card expires after 12 month

X Sim Card not required

HL R U G3 X

47

Microwave Smart Switch Series

Manual

Rev 1.71, Sept 2013

SPECIFICATIONS
Operating Voltage
Smart Integral 12-30VDC / Remote 12-30 VDC (residual ripple no greater than 100mV)
Smart Integral 80-260Vac / Remote 90-260Vac
50/60Hz

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.

Power Consumption
<0.8W @ 24Vdc
<5VA @ 240Vac
<3VA @ 115Vac

Maximum Operating Pressure


2 BAR (absolute)

Communications
GosHawk, Modbus
Remote version also with HART,
Profibus DP and DeviceNet (options)
Multidrop mode can address 1-250 units
over 4 wires

Display (Remote version only)


2 line x 12 character alphanumeric LCD
Backlight standard
Memory - Remote
Non-Volatile (No backup battery required)
>10 years data retention

Relay Output: (1) SMART (2) Remote


Form C (SPDT) contacts, rated 5A at
240Vac resistive
Remote failsafe test facility for one relay (Remote).

Enclosure Sealing
Smart Sensors IP67
Remote Amplifier IP65 (Nema 4x)
Remote Sensors IP67

Operating Temperature
Remote electronics -40C (-40F) to 80C (176F)
Smart Units -30C (-20F) to 65C (150F)*
Remote Sensors -30C (-20F) to 65C (150F)*
*For higher temperature applications, remote mounting
with refractory windows is necessary
Power Density
Rated from emitter to receiver at approximately 20W/cm
Complies with FCC Title Rules Part 15
Caution sign posting not required
Transmitted Signal
Frequency: 10.525GHz
Average Power Density: 20W/cm typical
Linearly Polarised Field
Beam angle (3db) approximately 30 (10GHz)
Fail-Safe
Selectable - presence or absence of material blocking
the path between Sender and Receiver
High level fail-safe: relay is activated when no material
is present.
Low level fail safe: relay is activated when
material is present.

Cable Entries
Remote Sensors
1 x M20 Gland/3/4 NPTF threaded adaptor
Remote Amplifier
4 x 20mm (0.8), 1 x 16mm (0.6) knock outs.
Smart Integral Units
2 x M20 Glands/ 3/4 NPTF threaded adaptors
Mounting
3 male NPT thread or four 10mm (0.4) holes in flange
on standard units or 6 ANSI flange on high power/SRS
units
3 weldments for direct mounting on vessel wall
Flange for mounting separate from vessel wall - isolation shock mounts are available
3, 4 or 6 Weldments with UHMW or PTFE (teflon)
windows
Ceramic tile window assemblies
Firebrick window assemblies
2 NPT sight glass window
Waveguides - custom assemblies available for high
temperature and limited access applications.
Remote Test Input
Press to test (used to check for malfunction of unit from
remote position, PLC, SCADA etc)

Range
Maximum range under ideal conditions: 200m (656ft),
Minimum range under ideal conditions: 10cm (4 inches)

Weight
GSA 1kg
GMS 5kg
GMR 5kg

Sender/Receiver to Amplifier Separation


up to 500m (1640ft) using specified extension cable

48

Rev 1.71 Sept 2013

Contacts
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

Hawk Measurement
7 River Street
Middleton, MA 01949
USA
Phone: +1 888 HAWKLEVEL (1-888-429-5538)
Phone: +1 978 304 3000
Fax: +1 978 304 1462
info@hawkmeasure.com

For more information and global


representatives:

Represented by:

www.hawkmeasure.com

Part no. DOC-MICROWAVE-MAN