Microwave Anti Collision Alignment / Setup
Contents
1. of alignment is to get the Sensor Value as low as possible and or the Signal Voltage as high as possible If the Sensor Value gets below 20 or the Signal Voltage above 2 00V perform another Cal Mount and return 5 If required use two way radio to communicate between individuals aligning amp watching the control amplifier 6 The first action is to slowly move the Receiver horizontally Left to the Right until it reads the best possible value according to the above Next adjust the unit vertically up amp down until you locate the optimum alignment Lock the Receiver unit in place 7 Perform the same step sequence with the Sender unit amp lock it in place Thursday 12 May 2011 Page 7 A higher level of performance 6 Final Calibration Change the Amplifier from Alignment Mode into Boom Protection Mode and then perform a Calibrate Mounting see Figure 1 Software Flow Chart Return the unit to normal run mode After calibration the ideal Sensor Value should display less than 10 and the ideal Signal Voltage is greater than 2V Use the arrow buttons to scroll through these diagnostics during normal run mode If you cannot attain either of these after final calibration repeat steps 5 1 amp 6 If you still cannot attain either value check the Gain diagnostic using arrows in run mode If this value is over approximately 85 94 2 possible max then the unit is struggling to successfully Calibrate wi2. A higher level of performance HAWK GLADIATOR MICROWAVE COLLISION PREVENTION SWITCHES SET UP PROCEDURE 1 Introduction Hawk Gladiator Microwave Switches can be used to detect amp indicate a possible collision and therefore prevent boom collisions of large machinery Microwave switches are typically placed longitudinally on each side of the boom and when required on each side of the counterweight The Microwave Sender unit pulses microwave energy to the receiver approx 200 pulses per second and if the beam is broken the Hawk Microwave Switch indicates a possible collision via relay for machine movement to be halted by the machine control system Microwave Switches have anti crosstalking connection amp setup options for two or more systems present on a single machine For two systems one unit is set to Master mode and the other to Slave The Master unit controls the pulsing for both systems For more than 2 systems a Hawk Microwave Sequencer unit should be used In this case the Sequencer acts as the Master and all connected Microwave systems are programmed as Slaves There are various stages of commissioning that shall be performed in the following order e Mounting Location Check e Cross Talk Prevention Wiring and Device Configuration e Visual alignment e Software Alignment e Final Calibration e Collision Simulation e Setting Switch Parameters do not set the switch value until after alignmen
3. and has no software or hardware bridges or bypasses in place and the selected delays are appropriate for the speed of the machine movement A Microwave Switch that has been calibrated correctly and has the correct switch parameters and delays MAY NOT prevent a collision due to various factors including tt e Hardwired Bridge Isolation or Bypass of the Microwave Relay e Software Bridge Bypass of Microwave Relay e Excessive Software Delays in Control System e Insufficient braking slowing of the machine e Poor Placement of Microwave prevents sufficient time to slow stop the machine movement It is therefore critical that a Live Collision Test be performed to ensure that the Control System will slow the movement of the machine sufficiently and eventually stop the machine movement with sufficient time actually prevent a collision when an obstruction has been detected by the Microwave Switch A Live Operational Test involves slowly and carefully driving the machine in various directions towards obvious obstructions or hazards and testing the operation of the microwave switches the delays and control system and adjusting any necessary parameters to ensure correct operation The client must then calculate the maximum velocity and deceleration times of the machine to determine that the microwave switch parameters hardware delays and software parameters are indeed adequate Thursday 12 May 2011 Page 9
4. der and Receiver in BOTH planes then inserting Stainless Steel washers behind the square flange of the Sender or Receiver will be necessary The alignment procedure below will require Two 2 persons and the use of an Elevated Working Platform WEP will greatly assist with both the visual and software the alignment procedures The use of a Two Way Radio will greatly reduce the time required to align the microwave switches Thursday 12 May 2011 Page 5 A higher level of performance 4 1 Receiver Visual Alignment Person A is positioned near the sender and visually looking towards the remote distant Receiver whilst Person B moves the Receiver both vertically and horizontally until the receiver is pointing at the sender Please note that 10 Degrees of misalignment at this stage is acceptable at this point as the software alignment will be used at a later stage for more accurate alignment 4 2 Sender Visual Alignment Person A is positioned near the Receiver and visually looking towards the Sender distant Receiver whilst Person B moves the Sender both horizontally and vertically until the receiver is pointing at the sender Please note that 10 Degrees of misalignment at this stage is acceptable at this point as the software alignment will be used at a later stage for more accurate alignment 5 Software Alignment Software alignment is simply the movement of the sender or receiver left right amp up down by one person whilst a
5. ed correctly and that the amplifiers are each set to the correct operating mode Slave The Sequencer unit acts as the Master CROSS TALK PREVENTION FOR MORE THAN 2 UNITS REMOTE ONLY Operation is similar to cross talk prevention are connected is approx 3ms More than one for 2 units except that the GMSEQ Microwave unit can be connected to each channel note that sequencer will operate as the Master and each each unit connected to the same channel will be individual Microwave unit will operate as a Slave part of the same slave sequence in the pulsing The sequencer will control and step from CH1 to CH2 to CH3 to CH4 then return to CH1 Within the menu of each individual Microwave The maximum time between scans if 4 channels Unit select Slave mode in the Advanced Menu under Operating Mode a ll SLAVE 1 Bani MMs SLAVE 2 un GLAOATO MIOFORAAE REMOTE SMPUPER SLAVE SLAGATOR ME ACASAE REBOTE SMP LP FLAVE GMSEQ Microwave Sequencer Terminal CH1 CH2 CH3 CH4 TO TO SLAVES SLAVE4 Thursday 12 May 2011 Page 4 a th nj z T r Sees Sr Ane eye OT p TOM ane A v a feb b Ea A Trim Trea mr ra p a Y QI j ri ATTO o Pe TIT i YW BaDULCHEE LAREGERE ACIL It is critical that the installation provides the ability to move the sender and receiver up BOTH and down and left to right If there is no mechanism on the mounting brackets to mechanically alter the alignment of a Microwave Sen
6. nother person watches the Sensor Value or Signal Voltage on the amplifier LCD display The Sensor Value will decrease when the alignment is improved The Voltage Signal will increase as alignment is improved NOTES e Software alignment CAN ONLY be performed when the Amplifier has been set into Alignment Mode e DO NOT attempt to align the devices without first setting the amplifier into Alignment Mode To set the Amplifier into alignment mode see the below software flow chart amp follow the alignment steps Figure 1 Software Flow Chart EE Boom Protect ReCatculete App Type CAL Blocked Chute of aged ty Abgnmernt Cal Mounting EEX Yes No ty a Switch Point s 76 default ty On Delay Adj CALI 0 5s default t lon wi gt 0 Ss default z Failsafe Hi Lo CAL Relay Action Default Hi NC Thursday 12 May 2011 Page 6 A higher level of performance 5 1 Hardware Alignment Sender amp Receiver 1 Set the Amplifier into Alignment Mode Perform Cal Mounting operation When this is complete press RUN several times to return the unit to standard run mode The default run display is Switch Value You can use the arrows to scroll through the operational diagnostics to find Signal 3 After the Cal Mount the unit will display approx 48 Scroll with the down arrow and you will see Signal 1 20V value approximately 1 20V along with the Sensor Value on the 2 line 4 The goal
7. t this may create a CAL Error e Setting of Switch Delays e Operational Test Thursday 12 May 2011 Page 1 A higher level of performance 2 Mounting Location Check Note the recommended mounting locations for the Sender amp Receiver pairs each parallel amp back to back system faces the opposite direction Receiver Sender Sender Receiver ee EO ot Counterweight om gt mo Om lt e me Sender Receiver Receiver Sender The Microwave should ideally have a 2 meter exclusion zone around a straight line between the Sender and Receiver Over distance the beam will soread and bounce off metallic objects The Sender amp Receiver should be mounted on secure amp stable arm which extends outside amp below the boom or counter weight ideally to a length of 3 meters The arm must be completely stable The slightest shift will adjust the beam angle increasing the likelihood of nuisance trips Hawk recommends MA15 extension tubes for each sensor The tubes reduce beam spread making alignment more accurate amp deflect false pulses You should establish the suitable placement of the mounting arms amp sensors prior to commissioning Thursday 12 May 2011 Page 2 A higher level of performance eo wa HAWK 3 Cross Talk Prevention Two Systems Installations with Two 2 Microwave Switches on a common plane should be wired and configured as in a Master Slave configuration Installations with More than T
8. th the current mounting conditions including alignment amp obstacles creating reflected echoes If you are unable to proceed past this point contact Hawk technical support with photos of the application set up for assistance Thursday 12 May 2011 Page 8 A higher level of performance 7 Collision Simulation Hawk Microwave Device Switch Point parameter can be set between 0 and 100 To avoid false trips this should not be set too low You can check the switching by placing a steel plate in front of the sender or receiver unit A collision test is simply moving the mobile machinery into a position where an obstruction is between the sender and the receiver and noting the Blocked on the LCD Display This reading will guide the user in the selection of the correct switch Point as well as the time delay settings NOTE If your client WILL NOT provide permission for a collision simulation contact your supervisor immediately and explain that a Collision Supervision test if CRITICAL to ensure that the instruments will operate as required 8 Setting Switch Parameters Once the simulation is complete the final Switch Point setting can be confirmed amp entered see Figure 1 9 Setting Switch Delay Confirm amp enter your appropriate delay time for switching 10 Operational Test A correctly operating Microwave Switch will only prevent a collision if the control system that is watching the switch relay operation is actually working
9. wo 2 systems should be wired into a Microwave Sequencer 3 1 Cross Talk Prevention Two Systems Refer to the user manual to ensure that the instruments are wired correctly and that the amplifiers are each set to the correct operating mode to prevent Crosstalk Overview shown below CROSS TALK PREVENTION FOR 2 UNITS REMOTE ONLY Within the menu for each unit select Master The wiring needs to be as indicated with a for one system and select Slave for the shielded connection cable between the two second system These settings are located units The selected Master has a connec in the Advanced menu then under Operation tion to Master Out and GND DC and the Mode selected Slave has a connection to Slave In and GND DC Operation Mode has 3 selections 1 Remote The shield is conncted to the Ground or 2 Master 24Vdc ve terminal on each unit 3 Slave MAS TER SLAVE Receiver 1 Sender 1 Receiver 2 Sender GLADIATOR MICROWAVE REMOTE AMPLIFIER MASTER GLADIATOR MICROWAVE REMOTE AMPLIFIER SLAVE won Neen oe manne Software selected Thursday 12 May 2011 Page 3 A higher level of performance 3 2 Cross Talk Prevention More than Two Systems Installations with More than Two 2 Microwave Switches 2 switches mounted on the Boom and 2 Switches mounted on the Counterweight shall be wired into a Microwave Sequencer in accordance with the User Manual Refer to the user manual to ensure that the instruments are wir
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