Hawk Gladiator User manual

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Gladiator
Gen 3 Microwave Switch Series
Beam Blockage Detection
Circular Polarisation
Manual

Table of Contents
Gladiator Gen 3 Microwave Series
2
Contents
PROPRIETARY NOTICE
The information contained in this publication is derived in
part from proprietary and patent data. This information has
been prepared for the express purpose of assisting operating
and maintenance personnel in the efficient use of the
instrument described herein. Publication of this information
does not convey any rights to use or reproduce it, or to use
for any purpose other than in connection with the installation,
operation and maintenance of the equipment described herein.
WARNING
This instrument contains electronic components that are
susceptible to damage by static electricity. Proper handling
procedures must be observed during the removal, installation,
or handling of internal circuit boards or devices:
Handling Procedure:
1. Power to unit must be removed prior to commencement of
any work.
2. Personnel must be grounded, via wrist strap or other safe,
suitable means, before any printed circuit board or other
internal devices are installed, removed or adjusted.
3. Printed circuit boards must be transported in a conductive
bag or other conductive container. Boards must not be
removed from protective container until the immediate time
of installation. Removed boards must be placed immediately
in a protective container for transport, storage, or return to
factory.
Overview 3
Principle of Operation 3
Typical Uses 3
Function 3
Features 3
Dimensions 4
Remote Microwave System 4
MA Series Weldments and Windows (UHMW / PTFE)
5
MA Series Weldments and Windows (Ceramic) 6
MD Series Weldments and Windows 7
Weldments and Windows
(Ceramic Tile & Firebrick Assemblies) 8
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
Integral System Connection 15
Wiring - Relay Functions 16
Functionality Layout - Remote System 17
Functionality Layout - Integral System 18
Setup Procedure 19
Setup Procedure - Remote System 19
Setup Procedure - Integral System 20
Remote Software 21
Operational Diagnostics 21
Main Menus & Interface 22
Quickset Menu - Parameters 23
App Types - Parameters 24
Advanced Menu - Parameters 25
Relay 2 Actions 26
Relay 2 Software Flow Chart 27
Cross-Talk Prevention 28
Cross-Talk Prevention - Remote 28
Cross-Talk Prevention - Integral Systems 29
Wiring 29
System Calibration 29
Integral Test Switch 30
Integral Receiver Test Switch Functions 30
Troubleshooting 31
Error Codes 32
Safety Information 33
FCC Regulations 33
Part Numbering 34
Remote Version 34
Integral Version 35
Accessories 35
MA Series Mounting Accessories 36
MD Series Mounting Accessories - Kit 36
MD Series Mounting Accessories - Parts 37
Specications 39

Overview
3
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.
• State of the art Circular transmission
• Backwards compatible with all Gladiator Microwave
generations
• IECEx ta tb IIIC T* Da Db
• LCD push button setup / diagnostics on
remoteamplier
• Simple sensitivity adjustment and calibration on
Integral system
• Ranges up to 1200 meters (3937ft)
• Simple ‘1-minute’ setup application pre-sets
• Remote sensor or Integral ‘all in one’ types
• Relay outputs: Integral (1 + failsafe) Remote (2)
• Remote test function
• Adjustable ON and OFF delays (0-20 sec)
• Remote 3G HAWKlink connection option
•Remoteampliertosensorseparationupto
500 meters (1640ft)
• Bright visual status indication on sensors
• Independent housing alignment after mounting
sensor.
Features
Gladiator Gen 3 Microwave Series
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.
Typical Uses
• Blocked chute detection
• Collision detection
• Stacker / Reclaimer protection
• Shiploader protection
• Nucleonic switch replacement
• High level alarm / Low level alarm
• Truck / machine detection.
*Consult Safety Instructions

Dimensions
4
Remote Microwave System
RemoteAmplier
Gladiator Gen 3 Microwave Series
14 mm (0.6”)
74 mm (2.9”)
78 mm (3.1”)
107 mm (4.2”)
111.5 mm (4.4”)
4 mm (0.2”)
50 mm (2”)
131.5 mm (5.2”)
7.5 mm (0.3”)
192.5 mm (7.6”)
141.5 mm (5.6”)
190 mm (7.5”)
182.5 mm (7.2”)
147 mm (5.8”)
167.5 mm (6.6”)
147 mm (5.8”)
30.7 mm (1.2”)
158 mm (6.2”)
108 mm (4.3”)
190 mm (7.5”)
174 mm (6.9”)
192.5 mm (7.6”)
182.5 mm (7.2”)
30.0
20.2
33.029.029.033.0
1
6
.
2
Remote Sender / Receiver
129.5 mm (5.1”)
135.5 mm (5.3”)
Ø88 mm (3.5”)
Ø160 mm (6.3”)
90 mm (3.5”)
50 mm (2”)
Ø85 mm (3.3”)
2 mm (0.078”)
Ø165 mm (6.3”)
Ø277 mm (10.9”)
Ø238 mm (9.3”)
8xØ22 mm
Holes THRU
160 mm (6.3”)
160 mm (6.3”)
135 mm (5.3”)
Ø88.5 mm (3.5”)
4 x 10mm
(0.375”) holes
Alignment
marks
(A)
4 x 7mm
(0.28”) holes
129.5 mm (5.1”)
135.5 mm (5.3”)
Ø88 mm (3.5”)
Ø160 mm (6.3”)
90 mm (3.5”)
50 mm (2”)
Ø85 mm (3.3”)
2 mm (0.078”)
Mounting BracketIntegral Sender / Receiver
300mm (11.8")
4 x 10mm (0.375")
101mm
(3.97")
135mm (5.31")
160mm (5.51")
End closed
with UHMW
window
(A) 95mm
(3.75”)
(A)
(A)
4 x 7mm
(0.28")
MA15 / MA25 Focaliser Tube (extension pipe)
19.9mm (0.78")
6.3mm (0.25")
2" N.P.T.
135mm (5.3")
120mm (4.72")
148mm (5.83")
336mm (13.2")
225mm
(8.85")
Ø
4 x 10mm
(0.375")
MA12 / MA13 Adjustable Mounting Bracket
2 x
6.50mm
(0.25”)
75mm (2.95”)
4" NPT THD
67mm (2.6”)
100mm (3.94”)
35mm
(1.38”)
MA20-P1

5
MA Series Weldments and Windows (UHMW / PTFE)
Weldment with UHMW / PTFE Windows
Weldment is welded to the vessel. Window threads into Weldment
Dimensions
Gladiator Gen 3 Microwave Series
Ø 6.5mm (0.25”)
2 Places
75mm (2.95") 15mm (0.59")
H
I
V
T
U
12.3mm (0.48”) 11-12.7mm (0.43-0.5”)
R
P Q
K
M
J
L
N O
Ø6.3mm (0.25”)
2 Places
B
D
E
FA
C
S
G
Window Weldment
Weldment / Window Parts
Part
Number
Size Window Weldment
MA0 3”
MA3 3”
MA4 4”
MA5 6”
MA6 3”
MA7 4”
MA8 6”
MA18 4”
MA19 3”
MA20 4”
MA21 3”
MA22 4”
Size A B C D E F G
3” 100
(3.94”)
3”
NPT
22
(0.87”)
5
(0.2”)
92.5
(3.64”)
118
(4.65”)
4
(0.16”)
4” 125
(4.92”)
4”
NPT
24.4
(0.96”)
5
(0.2”)
120
(4.72”)
148
(5.83”)
4
(0.16”)
6” 190.4
(7.5”)
6”
NPT
40
(3.94”)
5
(0.2”)
175
(6.89”)
223
(8.78”)
11.2
(0.44”)
Size H I
3” 3”
NPT
28.7
(1.13”)
4” 4”
NPT
35
(1.38”)
6” 6”
NPT
40
(1.57”)
Ø 6.5mm (0.25”)
2 Places
75mm (2.95") 15mm (0.59")
H
I
V
T
U
12.3mm (0.48”) 11-12.7mm (0.43-0.5”)
R
P Q
K
M
J
L
N O
Ø6.3mm (0.25”)
2 Places
B
D
E
FA
C
S
G
UHMW / PTFE Window

6
Dimensions
Gladiator Gen 3 Microwave Series
MA Series Weldments and Windows (Ceramic)
Weldment with Ceramic Windows
Weldment is welded to the vessel. Window is locked into Weldment with Locking Retainer.
Weldment / Window Parts
Part
Number
Size Window Weldment
MA16 3”
MA17 4”
Size J K L M N O P Q R S T U V
3”
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”)
75
(2.95”)
65
(2.56”)
3”
NPT
74.5
(2.93”)
4”
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”)
100
(3.94”)
90
(3.54”)
4”
NPT
100.5
(3.96”)
Ø 6.5mm (0.25”)
2 Places
75mm (2.95") 15mm (0.59")
H
I
V
T
U
12.3mm (0.48”) 11-12.7mm (0.43-0.5”)
R
P Q
K
M
J
L
N O
Ø6.3mm (0.25”)
2 Places
B
D
E
FA
C
S
G
Window WeldmentLocking
Retainer
Ø 6.5mm (0.25”)
2 Places
75mm (2.95") 15mm (0.59")
H
I
V
T
U
12.3mm (0.48”)
11-12.7mm (0.43-0.5”)
R
P Q
K
M
J
L
N O
Ø6.3mm (0.25”)
2 Places
B
D
E
FA
C
S
G
Locking Retainer
Ø 6.5mm (0.25”)
2 Places
75mm (2.95") 15mm (0.59")
H
I
V
T
U
12.3mm (0.48”)
11-12.7mm (0.43-0.5”)
R
P Q
K
M
J
L
N O
Ø6.3mm (0.25”)
2 Places
B
D
E
FA
C
S
G
Ceramic Window

7
Dimensions
Gladiator Gen 3 Microwave Series
MD Series Weldments and Windows
Weldment with UHMW or PTFE Windows
The Weldment is welded to the vessel. The Window locks into the weldment using a locking ring.
For Approval Option 2D Installations. Consult Safety Instructions for critical details.
WeldmentUHMW / PTFE Window Assembled Piece
A
B
C
D
E
P.C.D.
10°
N x M5 x 6.5mm (0.25”)
22mm (0.87”)
5mm
(0.2”)
19mm (0.75”)
F
H
G
Part No1. Window
Material
A B C D E P.C.D No.
Holes
mm in mm in mm in mm in mm in mm in
MD3-X UHMW 122 4.8 93 3.7 77 3.0 115 4.5 90 3.5 99 3.9 4
MD4-X UHMW 148 5.8 120 4.7 102 4.0 141 5.6 116 4.6 125 4.9 6
MD5-X UHMW 203 8.0 175 6.9 153 6.0 196 7.7 171 6.7 180 7.1 6
MD6-X PTFE 122 4.8 93 3.7 77 3.0 115 4.5 90 3.5 99 3.9 4
MD7-X PTFE 148 5.8 120 4.7 102 4.0 141 5.6 116 4.6 125 4.9 6
MD8-X PTFE 203 8.0 175 6.9 153 6.0 196 7.7 171 6.7 180 7.1 6
1X = Weldment Material Selection
Part No1. Window
Material
F G H P.C. D No.
Holes
mm in mm in mm in mm in
MD3-X UHMW 89 3.5 76 3.0 41.6 99 3.9 4
MD4-X UHMW 115 4.5 102 4.0 41.6 125 4.9 6
MD5-X UHMW 170 6.7 153 6.0 4.5 1.8 180 7.1 6
MD6-X PTFE 89 3.5 76 3.0 41.6 99 3.9 4
MD7-X PTFE 115 4.5 102 4.0 41.6 125 4.9 6
MD8-X PTFE 170 6.7 153 6.0 4.5 1.8 180 7.1 6
1X = Weldment Material Selection

317.5mm (12.5")
152.4mm (6.0")
101.6mm
(4.0")
152.4mm (6.0")
101.6mm (4.0")
25.4mm (1")
50.8mm
(2.0")
215.9mm
(8.5")
76.2mm
(3.0")
228.6mm (9.0")
114.3mm
(4.5")
94mm
(3.7")
135mm (5.31")
300mm (11.8")
4 mounting holes 10mm (3/8")
101mm
(3.97")
140mm (5.51")
End closed
with UHMW
window
8
Weldments and Windows (Ceramic Tile & Firebrick Assemblies)
Weldment with Ceramic Windows
Weldment is welded to the vessel. Window is locked into Weldment with Locking Retainer
Dimensions
Gladiator Gen 3 Microwave Series
Weldment / Window Parts
Part Number Size Window Weldment
MA9 Special
MA10 Special
MA16 3”
MA17 4”
Mounting Assemblies
FirebrickCeramic Tile
Flanged Pipe Mount MA-15
Flanged pipe mount
recommended for long
range applications

Mounting
9
General Guidelines
Gladiator Gen 3 Microwave Series
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 result 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
(I-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.
XX
Product Flow
Sending Unit Receiving Unit
Isolation Mount
Adjustable microwave mounting bracket
MA-12 or MA-13 welded to vessel wall.
UHMW (MA-12) or Teflon (MA-13) Window.
X = 30° Maximum
Hopper/Feeder
XX
Product Flow
Sending Unit Receiving Unit
Isolation Mount
Adjustable microwave mounting bracket
MA-12 or MA-13 welded to vessel wall.
UHMW (MA-12) or Teflon (MA-13) Window.
X = 30° Maximum
Hopper/Feeder
XX
Product Flow
Sending Unit Receiving Unit
Isolation Mount
Adjustable microwave mounting bracket
MA-12 or MA-13 welded to vessel wall.
UHMW (MA-12) or Teflon (MA-13) Window.
X = 30° Maximum
Hopper/Feeder
Do not mount
with cavity
Do not mount
where sensor can
be damaged by
material
Mount flush
with wall in safe
location
XX
Product Flow
Sending Unit Receiving Unit
Isolation Mount
Adjustable microwave mounting bracket
MA-12 or MA-13 welded to vessel wall.
UHMW (MA-12) or Teflon (MA-13) Window.
X = 30° Maximum
Hopper/Feeder
Mount behind
flush Window/
Weldments

Mounting
10
General Guidelines
Gladiator Gen 3 Microwave Series
5. 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.
6. 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. Mount away
from main
product flow
Mounting With Windowed Weldments
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.
4” UHMW Windowed Weldment
Metal Bin/Chute Walls
ReceiverSender

11
Mounting
Gladiator Gen 3 Microwave Series
Installation With Adjustable Mounting
XX
Product Flow
Sending Unit Receiving Unit
Isolation Mount
Adjustable microwave mounting bracket
MA-12 or MA-13 welded to vessel wall.
UHMW (MA-12) or Teflon (MA-13) Window.
X = 30° Maximum
Hopper/Feeder
Mounting of a Microwave system on sloped vessel
walls can be accomplished using the Microwave
Adjustable Mount (MA-12 or MA-13). This system
allows the microwaves to be mounted to a sloped
surface and then adjusted horizontally for optimum
performance and operation. The adjustable mount
has an integral 4” weldment with UHMW polyethylene
or PTFE (Teflon) window options. An option with the
bracket is a vibration isolation kit (shock mounts)
to help protect the electronics from damage. Each
side wall of the vessel must not exceed 30 degrees
from the vertical centerline. To mount the adjustable
bracket, simply cut a hole and weld the 4” weldment
directly to the vessel, install the window, mount the
microwave and adjust horizontally.

12
Mounting
Gladiator Gen 3 Microwave Series
Correct Mounting Angle
Microwave Beam
Correct Elevation
Maximum Signal Strength to Receiver is indicated by maximum brightness of
Green LED on Receiver.
Incorrect Elevation
Receiving UnitSending Unit
Receiving UnitSending Unit
Align Sender and Receiver
Rotate so that Visual Alignment Guide is in the same position on both sender and receiver.
Housing can be rotated
within 200º after the
mounting thread is
tightened, to allow cable
entries to face downwards
or allow optimal cable
clearance.

Wiring
13
Remote System Connection - HAWK Supplied Cable
• The black wire of HAWK supplied cable comes with one end GND and the other GND / SHLD together.
• The GND / SHLD end is a larger cable which has been heat shrunk. The GND only end is the same size as
the other cables.
• The GND / SHLD end must be connected to the amplifier.
Gladiator Gen 3 Microwave Series
**
**
microwave sender
STATUS
remote
Signal
STATUS
Gladiator Remote Amplifier
+–
A
1L
+
–
N
B
RED
BLACK
BLUE
WHITE
BROWN
Is
SENSOR DC-In AC-In*4-20mA
COMMS
MIC-SENDER
RED
BLACK
BROWN
SLAVE IN
MASTER OUT
TEST IN
RELAY 1
NC
COM
NO
RELAY 2
NC
COM
NO
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
Remote Receiver
Sender
Inputs model dependent
Add wire between
terminal 8 and
ground screw
Add wire between
terminal 8 and
ground screw
1 2 3 4 5 6 7 8 9 10
BRN
RED
BLK
1 2 3 4 5 6 7 8 9 10
BRN
RED
BLK
WHT
BLU
Ground screw Ground screw
Remote Sender Remote Receiver
Amplifier
(GND / SHLD end)
Sender / Receiver
(GND only end)
**
**
microwave sender
STATUS
remote
Signal
STATUS
Gladiator Remote Amplifier
+–
A
1L
+
–
N
B
RED
BLACK
BLUE
WHITE
BROWN
Is
SENSOR DC-In AC-In*4-20mA
COMMS
MIC-SENDER
RED
BLACK
BROWN
SLAVE IN
MASTER OUT
TEST IN
RELAY 1
NC
COM
NO
RELAY 2
NC
COM
NO
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
Remote Receiver
Sender
Inputs model dependent
Add wire between
terminal 8 and
ground screw
Add wire between
terminal 8 and
ground screw
1 2 3 4 5 6 7 8 9 10
BRN
RED
BLK
1 2 3 4 5 6 7 8 9 10
BRN
RED
BLK
WHT
BLU
Ground screw Ground screw
Remote Sender
Status LED
• Green when powered
• Blinks while working
correctly
• Solid while not transmitting
TEST Button
• Press and hold to test level
relay action
Remote Receiver
Status LED
• Green when powered
• High illumination = strong signal
• Low illumination = weak signal
Signal Contact
• Signal can be read with voltmeter
across Signal contact point
and earth screw (or other ground
reference)
• 2.4-2.5V is full signal.
0V is no signal
Use long nose
pliers to extract
terminals
*AC-In is replaced by 36-60VDC with Power Input
Option ‘C’.
**Ground the housing to vessel if vessel is metallic.
Ground the housing to plant ground if vessel is
non-metallic.

Wiring
14
Remote System Connection - Customer Supplied Cable
Gladiator Gen 3 Microwave Series
Remote Sender Remote Receiver
Alternate Cable Colour Equivalents
Pairs HAWK Belden 3120A Dekoron
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)
Pair 4 not used not used not used
Alternate Cable Type Between
AmplierandSensors
• 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.
Remote Sender
Status LED
• Green when powered
• Blinks while working
correctly
• Solid while not transmitting
TEST Button
• Press and hold to test level
relay action
Remote Receiver
Status LED
• Green when powered
• High illumination =
strong signal
• Low illumination = weak signal
Signal Contact
• Signal can be read with
voltmeter across Signal
contact point and earth screw
(or other ground reference)
• 2.4-2.5V is full signal.
0V is no signal
Use long nose
pliers to extract
terminals
**
**
microwave sender
STATUS
remote
Signal
STATUS
Gladiator Remote Amplifier
+–
A
1L
+
–
N
B
RED
BLACK
BLUE
WHITE
BROWN
Is
SENSOR DC-In AC-In*4-20mA
COMMS
MIC-SENDER
RED
BLACK
BROWN
SLAVE IN
MASTER OUT
TEST IN
RELAY 1
NC
COM
NO
RELAY 2
NC
COM
NO
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
Remote Receiver
Sender
Inputs model dependent
Add wire between
terminal 8 and
ground screw
Add wire between
terminal 8 and
ground screw
1 2 3 4 5 6 7 8 9 10
BRN
RED
BLK
1 2 3 4 5 6 7 8 9 10
BRN
RED
BLK
WHT
BLU
Ground screw Ground screw
*AC-In is replaced by 36-60VDC with Power Input
Option ‘C’.
**Ground the housing to vessel if vessel is metallic.
Ground the housing to plant ground if vessel is
non-metallic.

Wiring
15
Integral System Connection
Gladiator Gen 3 Microwave Series
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.
**
**
D
e
l
a
y
FSHHI
LO FSL
CAL TEST
OFF OFF
Signal
S
e
n
s
i
t
i
v
i
t
y
microwave sender
STATUS
ON
1 2
ON
1 2
D
e
l
a
y
FSHHI
LO FSL
CAL TEST
OFF OFF
Signal
S
e
n
s
i
t
i
v
i
t
y
1 2 3 4 5 6 7 8 9 10
ON
1 2
ON
1 2
3
4
567
9
microwave sender
STATUS
1
2
10
8
remote
Signal
STATUS
3
4
1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10
1 2 3 4 5 6 7 8 9 10
1 2 3 4 5 6 7 8 9 10
RELAY
1. N
C
2. CO
M
3. N
O
COMMS DC-IN AC-IN
4. Test
+
7.
8.
N
9.
L1
10.
5.
B
6.
A
-
RECEIVER TERMINAL LAYOUT
12-30VDC 80-260VAC
RS 485
1.
2.
3.
DC-IN
+
7.
8.
N
9.
L1
10.
5.
6.
-
SENDER TERMINAL LAYOUT
4.
AC-IN
12-30VDC 80-260VAC
Terminals 1, 2, 3, 4, 5, 6 not used
Sender Integral Receiver
Ground
Screw
Integral Receiver
Status LED
• Green LED: Indicates received signal strength
• High illumination = strong signal
• Low illumination = weak signal
• Red LED: Indicates Relay status
• Blue LED: Flashes during calibration.
Stays illuminated if calibration fails.
Signal Contact
• Signal can be read with voltmeter across Signal
contact point and earth screw
(or other ground reference)
• 2.4-2.5V is full signal. 0V is no signal.
Sender
Status LED
• Green when powered
• Blinks while working correctly
• Solid while not transmitting.
TEST Button
• Press and hold to test level relay action.
Use long nose
pliers to extract
terminals
**Ground the housing to vessel if vessel is metallic.
Ground the housing to plant ground if vessel is non-metallic.
The AC earth /
ground-cable must
be connected to the
ground screw inside
the housing when
using AC power.
Ground
Screw

Wiring
Gladiator Gen 3 Microwave Series
16
HI
OFF
TEST
LOW
EN
DEN
CALOFF
DELAY
SENSITIVITY
123
123
123
123
123
123
1 2 3
123
Material level rising
Material detected
NC NO
NC NO
NC NO
NC NO
NC NO
NC NO
NC NO
NC NO
COMMS DC-IN
AC GND to metal case
12-30VDC
+
7.
8.
RS 485
5.
B
6.
A
1 2 3 4 5 6 7 8 9 10
+–
4-20mA
AC-IN
A
1L
+
–
DC-IN
4-20mA COMMSTRANSDUCER
N
B
RELAY 1
NC
COM
NO
RELAY 2
NC
COM
NO
RELAY 3
NC
COM
NO
RELAY 4
NC
COM
NO
RELAY 5
NC
COM
NO
Test in
Is
RED
BLACK
BLUE
WHITE
REMOTE AMPLIFIER
GLADIATOR TERMINAL
COM COM
COM COM
COM COM
COM COM
POWER FAILURE
NC NO NC NOCOM COM
INTERNAL FAILURE
POWER FAILURE
OR
SYSTEM OPERATING
NORMALLY
NC NOCOM NC NOCOM
State 1State 2State 3
Smart Integral
Receiver terminal
numbers
Remote Amplifier
terminal function
labels
FailSafe Low
FSL
FailSafe High
FSH (default)
Relay Status
LED Status
Relay Action
Material level falling
Relay - for Smart Integral Probe Version
Relay 1 - for Remote Version
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.
Wiring - Relay Functions
Switch contact actions.

Functionality Layout - Remote System
Gladiator Gen 3 Microwave Series
17
remote
STATUS
1 2 3 4 5 6 7 8 9 10
BRN
RED
BLK
WHT
BLU
CAL
RUN
RELAY 1 RELAY 2 STATUS A STATUS B
8
9
1
2
3
4
5
8
9
Calibrate button
Down button
Up button
Relay LEDs 1 and 2
Run button
Removable terminal block - plug in type
1
2
3
4
5
REMOTE RECEIVER TERMINAL BLOCK
7.1. 2. 3. 4. 5. 6. 8. 9. 10.
TRANSDUCER
RED
WHITE
BLUE
BLACK
6
6Display (LCD with backlight)
Terminals 1, 2, 3, 9, 10 not used.
7Status 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.
7
GREEN LED: Power / Received signal strength.
Brightness varies with strength of received signal.
BROWN
Functionality Layout - Remote System
**
**
D
e
l
a
y
FSHHI
LO FSL
CAL TEST
OFF OFF
Signal
S
e
n
s
i
t
i
v
i
t
y
microwave sender
STATUS
ON
1 2
ON
1 2
D
e
l
a
y
FSHHI
LO FSL
CAL TEST
OFF OFF
Signal
S
e
n
s
i
t
i
v
i
t
y
1 2 3 4 5 6 7 8 9 10
ON
1 2
ON
1 2
3
4
567
9
microwave sender
STATUS
1
2
10
8
remote
Signal
STATUS
3
4
1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10
1 2 3 4 5 6 7 8 9 10
1 2 3 4 5 6 7 8 9 10
(1) Sender status LED
• Blinks while working correctly
• Solid while not transmitting
• Clear indicates no power
(2) TEST button
• Press and hold to test level relay action
**
**
D
e
l
a
y
FSHHI
LO FSL
CAL TEST
OFF OFF
Signal
S
e
n
s
i
t
i
v
i
t
y
microwave sender
STATUS
ON
1 2
ON
1 2
D
e
l
a
y
FSHHI
LO FSL
CAL TEST
OFF OFF
Signal
S
e
n
s
i
t
i
v
i
t
y
1 2 3 4 5 6 7 8 9 10
ON
1 2
ON
1 2
3
4
567
9
microwave sender
STATUS
1
2
10
8
remote
Signal
STATUS
3
4
1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10
1 2 3 4 5 6 7 8 9 10
1 2 3 4 5 6 7 8 9 10
Sender Receiver
(3) Signal contact
• Signal can be read with voltmeter across Signal
contact point and earth screw (or other ground
reference). 2.4-2.5V is full signal. 0V is no signal.
(4) Receiver status LED
• High illumination for good signal
• Low illumination for weak signal
• Clear indicates no power

Functionality Layout - Integral System
Gladiator Gen 3 Microwave Series
18
Sender Receiver
(1) Sender status LED
• Blinks while working correctly.
• Solid while not transmitting.
(2) TEST button
• Press and hold to test level relay action.
(3) Sensitivity dial
• Turn clockwise for switching in clean environments and
object detection.
• Turn counter-clockwise for difficult applications, dusty/
wet environments.
(4) Hi / Lo switch
• Hi mode for clean environments and object detection.
• Lo mode for difficult applications, dusty/wet environments.
(5) FSH / FSL switch
• FSH relay normally closed.
• FSL relay normally open.
(6) Receiver status LEDs
• Green - High illumination for good signal,
Low illumination for weak signal.
• Red - Relay indication. Illuminated when closed.
• Blue - Cal mount indication - flashes during Cal
mount, will stay illuminated if Cal mount fails.
(7) Cal Mount switch
• 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.
• Switch up to initiate Cal mount, wait several seconds,
then switch back down. Unit will automatically complete
Cal mount routine.
(8) Test switch
• Can be used for a failsafe / test relay. See full manual
for further information.
(9) Delay pot
• Rotate clockwise to increase Relay on/off delay time.
(10) Signal contact
• Signal can be read with voltmeter across Signal
contact point and earth screw (or other ground
reference). 2.4-2.5V is full signal. 0V is no signal.
D
e
l
a
y
2.5 Sec
0.5 Sec
15 Sec
Functionality Layout - Integral System
**
**
D
e
l
a
y
FSHHI
LO FSL
CAL TEST
OFF OFF
Signal
S
e
n
s
i
t
i
v
i
t
y
microwave sender
STATUS
ON
1 2
ON
1 2
D
e
l
a
y
FSHHI
LO FSL
CAL TEST
OFF OFF
Signal
S
e
n
s
i
t
i
v
i
t
y
1 2 3 4 5 6 7 8 9 10
ON
1 2
ON
1 2
3
4
567
9
microwave sender
STATUS
1
2
10
8
remote
Signal
STATUS
3
4
1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10
1 2 3 4 5 6 7 8 9 10
1 2 3 4 5 6 7 8 9 10

Setup Procedure
Gladiator Gen 3 Microwave Series
19
Setup Procedure - Remote System
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 & 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 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 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
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 normally closed relay, failsafe Low for normally open relay.
QuickSet
Cal Mounting
Yes / No
Relay Action
FailSafe Hi
UnLock
0
Sensor Value
CAL
CAL
Press
Press
CAL
CAL
CAL
Press
Press
Press
Press CAL
CAL
Press
CAL
CAL
CAL
RUN
Press
Press
Press
Press
Twic e
Switch Point
76%
Delay Adjust
2.0S
Yes
50%
0.1S
FailSafe Hi
FailSafe Low
App Type
Blocked Chute
CAL
Press
QuickSet
UnLock
0
Sensor Value
0%
CAL
CAL
Press
Press
Press
Advanced
Press
To view Operational
Diagnostics
RUN
CAL
CAL
Default Unlock
code = 0
Standard parameters
Advanced parameters
Note: Older software revisions may have different parameters or menu structure

Setup Procedure
Gladiator Gen 3 Microwave Series
20
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 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).
5. Select the sensitivity
There are two adjustments controlling the sensitivity
of the switch point:
5.1 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.
5.2 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.
Setup Procedure - Integral System
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. Perform 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.
Other manuals for Gladiator
5
Table of contents
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