120 - 16549-00 Series 9 General Full Guide

Series 9 - General
Full Guide
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NDC Series 9 - General Full Guide
Part Number: 120/16549-00
Issue: B
Date of Release: August 20, 2020
Last Revised: April 14, 2021

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Table of Contents
1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.1 ABOUT THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 QUICK SETUP GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.3 ASSOCIATED DOCUMENTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.4 CONTACT INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
2 SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.1 WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.2 CAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
3 SYSTEM OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.1 SYSTEM COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2 CONFIGURATION EXAMPLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3.2.1 Single Gauge System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3.2.2 Multiple Gauge System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3.2.3 Portable Hand-Held Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
3.3 AIR PURGE WINDOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
3.4 SYSTEM OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
3.4.1 Air Flow Pressure Monitor Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
3.4.2 Internal Gating Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
3.4.3 Temperature Measurement Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
3.4.4 Water Cooling Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
3.4.5 Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
3.4.6 Heater Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
3.4.7 Common Gauge Connector (CGC) Cable Option . . . . . . . . . . . . . . . . . 3-13
4 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.1 INSTALLATION GOOD PRACTICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.2 HAZARDOUS ENVIRONMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.3 SITE REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.4 EMC PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.5 UNPACKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.6 STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.7 INSTALLING THE GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.7.1 Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.7.2 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
4.7.3 Fitting the Air Purge Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
4.7.4 Connecting Water Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
4.8 INSTALLING PERIPHERALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
4.8.1 Molded ABS Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
4.8.2 Stainless Steel Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
4.8.3 Panel-Mounted Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
4.9 ELECTRICAL CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
4.9.1 Mains Power Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
4.9.2 Gauge Services Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
4.9.3 Analogue and Digital Inputs and Outputs . . . . . . . . . . . . . . . . . . . . . . . 4-24
4.9.4 Ethernet Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
4.9.5 Switched Hub Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
Series 9 - General: Table of Contents i

5 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.1 OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.1.1 Home Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.1.2 User Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.1.3 Toolbar Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
5.1.4 Responding to Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5.1.5 Viewing the Software Version and Device Type . . . . . . . . . . . . . . . . . . . 5-7
5.2 SECURITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
5.2.1 Logging In as Supervisor or Engineer . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
5.2.2 Logging Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
5.3 DATA ENTRY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
5.3.1 Numerical Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
5.3.2 Full-Text Keyboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
5.3.3 Standard Localised Keyboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
5.3.4 Chinese Keyboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
5.3.5 Japanese Keyboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
5.4 GAUGE INTERFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
5.4.1 Viewing Measurement Trends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
5.4.2 Sample Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
5.4.3 Trim Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
5.5 GAUGE DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
5.5.1 Viewing Diagnostic Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
5.5.2 Performing an Auto-Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
5.5.3 Performing a Gauge Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
5.6 GAUGE CONTROL PORT BROWSER INTERFACE . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
6 SUPERVISOR AND ENGINEER FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.1 SETTINGS PAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.1.1 Supervisor – GCI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.1.2 Supervisor – OT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.1.3 Engineer – GCI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.1.4 Engineer – OT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.2 ABOUT PRODUCTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.3 LOADING PRODUCTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.4 MANAGING PRODUCTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6.4.1 Creating a New Product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6.4.2 Editing an Existing Product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6.4.3 Copying a Product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
6.4.4 Renaming a Product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
6.4.5 Deleting a Product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
6.4.6 Calibrate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
6.4.7 Auto Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
6.5 LOCAL SETTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
6.6 SETTING THE DATE AND TIME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
6.7 EDITING THE GAUGE AND MEASUREMENT NAMES . . . . . . . . . . . . . . . . . . . . . . . 6-14
6.8 SETTING THE AUTOMATIC GAUGE CHECK INTERVAL . . . . . . . . . . . . . . . . . . . . . 6-15
6.9 ENGINEER-ONLY FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
6.9.1 Selecting Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
6.9.2 Configuring Network Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
6.9.3 Configuring Analogue Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
6.9.4 PID Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
6.9.5 Configuring Digital Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
6.9.6 Configuring Digital Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
ii Series 9 - General: Table of Contents

6.9.7 Configuring Product Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31
7 CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.1 CALIBRATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.1.1 When to Calibrate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7.2 CALIBRATION PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
7.2.1 Using Auto-Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
7.2.2 Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
7.2.3 Using Auto-Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
7.2.4 Performing Full-Range Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24
7.2.5 Checking Gauge Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25
8 MAINTENANCE AND SPARES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8.1 WARNINGS AND CAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8.2 CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8.2.1 Cleaning Gauge Windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
8.3 REPLACING THE GAUGE SOURCE LAMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . 8-2
8.4 REPLACING THE FILTER WHEEL MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
8.5 REPLACING THE REFERENCING MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
9 SYSTEM OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
9.1 INTERNAL GATING OPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
9.1.1 Gauge Mounting Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
9.1.2 Gating Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
9.2 TEMPERATURE MEASUREMENT OPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
9.3 VORTEX COOLING OPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11
9.3.1 Vortex Cooler Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13
9.4 PRESSURE SENSE OPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16
9.4.1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16
9.4.2 GCI Air Pressure Settings and Alarms . . . . . . . . . . . . . . . . . . . . . . . . . 9-17
9.5 COMMON GAUGE CONNECTOR (CGC) CABLE OPTION . . . . . . . . . . . . . . . . . . . 9-19
9.6 BSDU (BATCH SAMPLE DISPLAY UNIT) OPERATION ON SERIES 9 GCIS . . . . . . 9-22
9.6.1 Enabling BSDU Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-22
9.6.2 IO Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-23
9.6.3 Diagnostics and Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-24
9.6.4 Report Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-25
10 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
10.1 SYSTEM ERROR MESSAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
10.2 SERIES 9 GAUGE STATUS LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
11 REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
11.1 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
11.1.1 Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
11.1.2 OT, GCI, GCP, PH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2
11.1.3 Switched Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3
11.1.4 NDC Power Supply Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-4
12 OUTLINE DRAWINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1
12.1 GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1
12.2 PERIPHERAL UNITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2
12.2.1 GCI, PH, OT, GCP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2
12.2.2 GCI / PH Stainless Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-3
WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . W-1
Series 9 - General: Table of Contents iii

iv Series 9 - General: Table of Contents
Table of Figures
Figure 3-1 A single gauge system with GCI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Figure 3-2 A multiple gauge system with GCI and OTs . . . . . . . . . . . . . . . . . . . . . . 3-8
Figure 3-3 A multiple gauge system with GCI and PHs . . . . . . . . . . . . . . . . . . . . . . 3-9
Figure 3-4 A GI connected to a Power Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Figure 3-5 Integrated heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Figure 3-6 Cooler solenoid control option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Figure 4-1 Positioning the gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Figure 4-2 Positioning the gauge with respect to the window . . . . . . . . . . . . . . . . . 4-7
Figure 4-3 Mounting the gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Figure 4-4 Mounting holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Figure 4-5 Easy slide-mounting adapter plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Figure 4-6 Sliding the gauge into the bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Figure 4-7 Retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Figure 4-8 Air purge window (APW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Figure 4-9 Air supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Figure 4-10 Water supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Figure 4-11 Water cooling connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Figure 4-12 Mounting dimensions of peripheral units . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Figure 4-13 Mounting dimensions of stainless steel unit . . . . . . . . . . . . . . . . . . . . . 4-17
Figure 4-14 Panel mounting dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Figure 4-15 Customer panel cutout dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Figure 4-16 M8 mounting screw holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Figure 4-17 M4 earth stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Figure 4-18 Gland nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Figure 4-19 Mains power cable connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Figure 4-20 Gauge services cable connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Figure 4-21 Input/output boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
Figure 4-22 Analogue output board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Figure 4-23 Digital outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
Figure 4-24 Digital inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
Figure 4-25 GCI/PH Ethernet connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Figure 4-26 Switched hub connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
Figure 4-27 Power supply to switched hub connectors . . . . . . . . . . . . . . . . . . . . . . 4-31
Figure 5-1 OT Home page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Figure 5-2 GCI Home page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Figure 5-3 Multi-gauge screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Figure 5-4 Single gauge screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Figure 5-5 Gauge Status box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Figure 5-6 Gauge Status page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Figure 5-7 Device type and software version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Figure 5-8 Security page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Figure 5-9 Keyboard for entering password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Figure 5-10 Editable boxes on Edit Product page . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Figure 5-11 Lightly shaded gray boxes on Gauge Diagnostics page . . . . . . . . . . . . 5-10
Figure 5-12 Changed value shown in box with light yellow background . . . . . . . . . 5-11
Figure 5-13 Sample numerical keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Figure 5-14 Sample full-text keyboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Figure 5-15 Trend graph on Home page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
Figure 5-16 Gauge Diagnostics page – General group . . . . . . . . . . . . . . . . . . . . . . 5-27
Figure 5-17 Gauge Diagnostics page – Version group . . . . . . . . . . . . . . . . . . . . . . 5-28
Series 9 - General: Table of Figures v

Figure 5-18 Gauge Diagnostics page – Motor group . . . . . . . . . . . . . . . . . . . . . . . . 5-28
Figure 5-19 Gauge Diagnostics page – Lamp group . . . . . . . . . . . . . . . . . . . . . . . . 5-29
Figure 6-1 Settings page for a Supervisor on a GCI . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Figure 6-2 Settings page for a Supervisor on an OT . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Figure 6-3 Settings page for an Engineer on a GCI . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Figure 6-4 Settings page for an Engineer on an OT . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Figure 6-5 Load Product page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Figure 6-6 Configure Products page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Figure 6-7 Edit Product page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Figure 6-8 Local Settings page – General group . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Figure 6-9 Local Settings – Information group . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Figure 6-10 Set Date And Time page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Figure 6-11 Gauge Settings page – Names group . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Figure 6-12 Gauge Settings page – Gauge Check group . . . . . . . . . . . . . . . . . . . . 6-15
Figure 6-13 Gauge Selection page – GCI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Figure 6-14 Network Settings page – GCI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Figure 6-15 Gauge Status page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Figure 6-16 Network Settings page – Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Figure 6-17 Analog Output Configuration page . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
Figure 6-18 Controlling a Drying/Wetting/Blending process . . . . . . . . . . . . . . . . . . . 6-22
Figure 6-19 Controlling the flow rate of water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
Figure 6-20 PID Algorithm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
Figure 6-21 Analog Output Configuration page . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
Figure 6-22 PID Configuration page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
Figure 6-23 Digital Output Configuration page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
Figure 6-24 Digital Input Configuration page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
Figure 6-25 Configure Product Lines page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31
Figure 7-1 Configure Products page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Figure 7-2 Auto Trim – Trend page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Figure 7-3 Auto Trim – Statistics page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Figure 7-4 Sampling in progress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Figure 7-5 Sampling completed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Figure 7-6 Sample – Trend page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Figure 7-7 Sample – Statistics page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
Figure 7-8 Sample page, sampling completed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
Figure 7-9 Press Calibrate button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
Figure 7-10 Lab cell highlighted in red when selected . . . . . . . . . . . . . . . . . . . . . . . 7-13
Figure 7-11 Enter lab value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
Figure 7-12 Adjusted column shows re-calculated data . . . . . . . . . . . . . . . . . . . . . . 7-14
Figure 7-13 Uncalibrated Graph with Span = 1, Trim = 0 . . . . . . . . . . . . . . . . . . . . . 7-15
Figure 7-14 Calibrated Graph . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
Figure 7-15 Press Ok to apply new calibration settings . . . . . . . . . . . . . . . . . . . . . . 7-16
Figure 7-16 Outlier cell is filled in orange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
Figure 7-17 Outlier data point is shown in red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
Figure 7-18 Ignore cell is crossed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
Figure 7-19 Configure Products page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
Figure 7-20 Enter new Trim value in product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
Figure 7-21 Gauge/Reference Check page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
Figure 7-22 Gauge/Reference Check results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27
Figure 9-1 Gating function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Figure 9-2 Product flow direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Figure 9-3 Mounting the gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Figure 9-4 Select Height from Gauge Settings page . . . . . . . . . . . . . . . . . . . . . . . . 9-4
Figure 9-5 Select Height Gating from Gauge Settings page . . . . . . . . . . . . . . . . . . 9-4
vi Series 9 - General: Table of Figures

Figure 9-6 Press Continue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
Figure 9-9 Temperature sensor housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
Figure 9-10 Temperature sensor connector and window . . . . . . . . . . . . . . . . . . . . . . 9-8
Figure 9-11 Analog Output Configuration page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
Figure 9-12 Gauge Settings – Temperature page . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10
Figure 9-13 Vortex cooling option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11
Figure 9-14 Vortex cooling assembly drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12
Figure 9-15 Digital Output Configuration page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13
Figure 9-16 Solenoid fitted with fly back diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15
Figure 9-17 IN and OUT ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16
Figure 9-18 Gauge Settings – Air Pressure page . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-17
Figure 9-19 Low air flow alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-18
Figure 9-20 Common Gauge Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-19
Figure 9-21 Cable 105/14876-01SA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-19
Figure 9-22 Connect cable to large cable gland on Series 9 peripheral . . . . . . . . . . 9-20
Figure 9-23 Wiring schematic for connecting to Series 9 peripheral . . . . . . . . . . . . 9-20
Figure 9-24 Terminal designations for connecting to Series 9 peripheral . . . . . . . . 9-21
Figure 9-25 Enabling/Disabling the BSDU option in GaugeToolsXL . . . . . . . . . . . . 9-22
Figure 9-26 Digital Input Configuration page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-23
Figure 9-27 Local Settings page - BSDU group . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-24
Figure 9-28 PuTTy terminal program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-25
Figure 9-29 Header . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-25
Figure 9-30 Sample Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-26
Figure 10-1 Gauge Status Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
Series 9 - General: Table of Figures vii

viii Series 9 - General: Table of Figures
CHAPTER
1
1 Introduction
1.1 About This Manual
This manual describes the installation, operation, calibration and maintenance of Series 9
gauges and peripheral equipment. It is intended for use by installation personnel, suitably-
qualified maintenance staff and trained operators.
As an aid to using the manual for installing and setting up the system, we have provided the
following Quick Setup Guide, which gives the essential steps and takes you quickly to the sec-
tions that describe them.
1.2 Quick Setup Guide

The Series 9 gauge system is designed for ease of installation and setup. Just perform the key
steps in the order given below.
Note: The procedure here assumes that your system includes a GCI. If it does not, you can
still follow the procedure, but you will need to perform the setup steps using the
GaugeToolsXL software and its user instructions.
1. Install the gauge system (see Chapter 4 - Installation).
You might need to read the Overview (see Section 5.1 - Overview) and Data entry
(see Section 5.3 - Data Entry) information in the Operation section before per-
forming the following setup actions on the GCI.
2. Select the user language (see Section 6.5 - Local Settings).
3. Select the gauges (see Section 6.9.1 - Selecting Gauges).
4. Check that no error messages are displayed on the GCI (see Section 5.1.4 -
Responding to Error Messages).
5. Name the gauge(s) and measurement channels from the factory defaults as desired
(see Section 6.7 - Editing the Gauge and Measurement Names).
6. Reference the gauge (allowing the gauge to warm up for 1 hour first)
(see Section 7.2.3 - Using Auto-Reference).
7. Create a Product recipe based on factory settings sheet with the desired response
time (see Section 6.4.1 - Creating a New Product).
8. Select the Product recipe (see Section 6.3 - Loading Products).
9. Auto-trim the gauge to the desired reading (see Section 7.2.1 - Using Auto-Trim).
Series 9 - General: Introduction 1-1

10. Check and if necessary, adjust the gauge trim value against laboratory reference val-
ues (see Section 7.2.2 - Trim).
11. If there is a wide measurement range, perform a full-range calibration

(see Section 7.2.4 - Performing Full-Range Calibration).
12. If the 4-20mA analogue outputs are being used, set the scaling over the full measure-
ment range (see Section 6.9.3 - Configuring Analogue Outputs).
1.3 Associated Documentation

The following documents are associated with this manual.
• Packaging Sheet - detailing all dispatched items, for use as a delivery check list
• GaugeToolsXL User’s Guide : 105/14033-01SA
• GaugeToolsXL Installation Guide and Quick Start : 105/14020-SA
1.4 Contact Information

For enquiries relating to the operation and use of the equipment described in this manual
please refer to www.ndc.com, or the Contact section at the beginning of this manual, for com-
pany contact details.
1-2 Series 9 - General: Introduction

CHAPTER
2
2 Safety Information
2.1 Warnings
• To avoid the risk of electric shock, isolate the mains supply to the equipment before
carrying out any installation, maintenance or repair work.
• The gauge contains items that rotate at high speed and which could cause injury. Do
not operate the gauge unless it is fully assembled.
• Compressed air can be dangerous. Where this is used, observe all relevant local reg-
ulations and follow normal operational good practice for handling compressed air.
• If the gauge is not installed and used in the manner prescribed in this manual, the
safety protection afforded by the equipment may be impaired.
2.2 Cautions
• The gauge and associated equipment contain static-sensitive devices. During installa-
tion, maintenance or repair, observe standard electrostatic precautions to avoid dam-
aging the equipment.
• Clean the gauge windows and external equipment surfaces with clean non-abrasive
materials only, in accordance with the cleaning instructions (see Section 8.2 - Clean-
ing). If in doubt, contact NDC.
Series 9 - General: Safety Information 2-1

2-2 Series 9 - General: Safety Information
CHAPTER
3
3 System Overview
Each Series 9 gauge installation is optimised specifically for a particular application, to suit the
environment in which it will operate and to provide the appropriate process measurements.
3.1 System Components

The Series 9 gauge system has the following key components, which may be configured in a
wide range of stand-alone and multi-gauge configurations.
• Gauge
• Gauge Control Interface (GCI)
• Operator Terminal (OT)
• Power Hub (PH)
• Gauge Control Port (GCP)
• Switched Hub
• Hand-Held Gauge Interface (GI)
The gauges and peripheral unit enclosures are available in various formats and materials for
use in different environments. Each component (excluding the GI) may be supplied in some or
all of the following.
Gauges • Stainless steel, IP67
• Stainless steel, IP67, Atex certified option
Peripherals • Molded ABS enclosed
• Stainless steel enclosed (Atex option)
• Aluminium panel-mounted
Series 9 - General: System Overview 3-1

Gauge
Series 9 gauges are intelligent devices that
perform all of the measurement and processing
functions of the system internally, and provide
direct outputs of the calibrated measurement
values. They also generate the displays shown
on the OT and GCI, which allows, for example,
gauge firmware updates to be automatically
reflected in all operator displays.
The gauges work on the principle that different

product constituents absorb Near Infra-Red
Light (NIR) at specific wavelengths. The
gauges emit NIR light at these wavelengths
and then accurately measure the amount Part No. 120/16000-00SA
reflected from the product. From this, they
generate outputs that are directly proportional
to the amount of each measured constituent in
the product.
There is only one version of the enclosure - cast stainless steel 316L with Sapphire window
and air purge window. They may be fitted with options, including water or vortec cooling,
depending on environmental conditions.
By default, the gauges communicate with other system devices via Ethernet. They are powered from
a 24Vdc supply, and connect to the system by means of a single cable carrying both data and power.
3-2 Series 9 - General: System Overview

Gauge Control Interface (GCI)
The GCI provides supervisor-level access to up
to 16 gauges within the same network. It
includes an embedded universal power supply
(input: 85 Vac – 264 Vac) that outputs 24Vdc
for connection to a single Series 9 gauge.
The GCI provides an Ethernet port to a single

gauge, 2 extra Ethernet ports to support “daisy
chain” gauge networking, and an RJ45 external
Ethernet port for quick connection to a
computer.
The operating and display interface is a Part Nos. 120/16001-01SA (Standard),

10-inch, high-resolution capacitive 120/16268-01SA (Stainless Steel)
touchscreen.
Features allow for direct interaction with the

gauges for functions such as taking sample
measurements and performing calibration, and
for performing supervisor functions such as
maintaining user passwords.
Product definitions can be created through the GCI, each of which is a collection of settings for a
specific gauge and measurement application. These are stored in the gauges and can be recalled
from the GCI.
The GCI can be supplied with an option of up to 4 boards total (any combination). Combination
specific to user requirements include (2) scalable analogue outputs, eight opto-isolated digital inputs
and eight digital outputs. Fieldbus communications protocols supported by the GCI include the
ProfibusDP and DeviceNet gateways.

Operator Terminal (OT)
The OT is dedicated to one individual gauge
and is located near to it in the process. It
includes an embedded universal power supply
for connection to a single Series 9 gauge.
The OT provides an Ethernet port to a single

gauge, 2 extra Ethernet ports to support “daisy
chain” gauge networking, and an RJ45 external
computer.
The operating and display interface is a

10-inch, high-resolution capacitive
touchscreen. It enables the operator to carry
out process-related tasks such as viewing
measurement and product sampling.
The OT cannot change any process-critical

gauge settings or perform any supervisory
tasks.
Fieldbus communications protocols supported

by the OT include the ProfibusDP and
DeviceNet gateways.
Power Hub (PH)

The PH includes an embedded universal power
supply (input: 85 Vac – 264 Vac) that outputs
24Vdc for connection to a single Series 9
gauge.
It is an integrated Ethernet hub that provides an

Ethernet port to a single gauge, 2 extra
Ethernet ports to support “daisy chain” gauge
networking, and an RJ45 external Ethernet port
for quick connection to a computer.
Part Nos. 120/16001-02SA (Standard),

120/16268-02SA (Stainless Steel)

Gauge Control Port (GCP)
The GCP powers one gauge. It includes an
embedded universal power supply
for connection to a single Series 9 gauge. The
GCP is an integrated Ethernet hub that
provides an Ethernet port to a single gauge,
2 extra Ethernet ports to support “daisy chain”
gauge networking, and an RJ45 external
computer.
The GCP can be supplied with an option for

(2) scalable analogue outputs, eight opto-
isolated digital inputs and eight digital outputs.
Fieldbus communications protocols supported
by the GCP include the ProfibusDP and
DeviceNet gateways.
Switched Hub
The switched hub serves as a sealed 4-port
switched Ethernet hub for the gauges in multi-
gauge systems. It can also provide the Part No. 120/16435-01
interface for communication between the
Series 9 network and a factory network,
allowing only the required data to pass
between the two.

Hand-Held Gauge Interface (GI)
The GI connects to the PH, OT, GCI and GCP
via an RJ45 Ethernet cable.
It comprises a rugged 10-inch touch-screen

tablet with IP65 sealing, and comes with a wrist
strap for convenience.
The GI runs the Android operating system, with

access to the following:
Part No. 120/16479-01SA
• Measurement display and trending
• Product sampling
• Gauge diagnostics
• Gauge product configuration tools
The GI includes an option to add a Docking

station for measurement viewing in the control
room.

3.2 Configuration Examples
The following examples show typical configurations of Series 9 gauges to illustrate the appli-
cation of the system components.
3.2.1 Single Gauge System
Figure 3-1 A single gauge system with GCI
Figure 3-1 shows a Series 9 gauge that is connected by a Services cable to the GCI (Gauge
Control Interface). The GCI provides an interface to the plant control system via Ethernet and
its analogue and digital I/O. The gauging system is powered from an 85-264 VAC,
50/60Hz cable that is provided by the customer to the GCI.

3.2.2 Multiple Gauge System
Example 1
Figure 3-2 A multiple gauge system with GCI and OTs
Figure 3-2 shows a system with multiple gauges, each gauge connected to an OT (Operator
Terminal). The OTs are daisy chained and connected to a central GCI (Gauge Control Inter-
face). The GCI is connected to a PLC or SCADA system.

Example 2
Figure 3-3 A multiple gauge system with GCI and PHs
Figure 3-3 shows a system with multiple gauges, each gauge powered from a PH (Power
Hub). The PHs are networked together with a central GCI (Gauge Control Interface).
3.2.3 Portable Hand-Held Option
Figure 3-4 A GI connected to a Power Hub

Figure 3-4 shows a GI (Hand-Held Gauge Interface) that connects to a Power Hub. The con-
nection is through an RJ45 patch cable. The GI is positioned near the gauge for sampling and
configuration. There is an optional Docking station located in the control room for measure-
ment viewing.

3.3 Air Purge Window
The Air Purge Window (APW) is used where the atmosphere in which the gauge is required to
operate contains a high level of dust or other pollutants. Using a clean air supply, it reduces
gauge window contamination by maintaining an area of positive air pressure over the window
surface (see Section 4.7.3 - Fitting the Air Purge Window).
3.4 System Options

3.4.1 Air Flow Pressure Monitor Option
An optional air flow pressure monitor board is available inside the Series 9 gauge to alert the
operator when the air supply has failed or not been turned back on after a system shutdown
and cleaning (see Section 9.4 - Pressure Sense Option).
3.4.2 Internal Gating Option

This option enables the gauge to make reliable measurements of discontinuous products by
switching the infra-red measurement system on only when there is product in the beam-patch
area. It operates by using two infrared sensors located within the gauge to detect changes in
the distance between the gauge window and the viewed surface.
The option is available with small and large beam patch (see Section 9.1 - Internal Gating
Option).
3.4.3 Temperature Measurement Option

The temperature measurement option provides the ability to measure the temperature of the
product at the gauge location or a remote location, and display the readings on one channel of
the OT and GCI (see Section 9.2 - Temperature Measurement Option).
3.4.4 Water Cooling Option

Series 9 gauges can be fitted a water based heat exchanger with water inlet and outlet con-
nectors. This allows cooling water to be circulated, enabling the gauge to work in high ambient
temperatures (see Section 4.7.4 - Connecting Water Cooling).

3.4.5 Cooling
3.4.5.1 Temperature Monitoring
The Series 9 gauge has an internal temperature sensor that is used both as an input for the
automatic cooling system and for over-temperature protection. It will output a temperature
warning if the gauge exceeds 70°C/158°F and shut it down when it exceeds 75°C/167°F to
reduce the maximum internal temperature and preserve the gauge electronics.
3.4.5.2 Vortex Cooling Option
Figure 3-5 Integrated heat exchanger
The internal temperature of the gauge is typically 15°C/59°F above ambient. The Vortex cool-
ing option is used for environments exceeding 50°C/122°F. This cooling option uses a vortex
unit to create a cold air flow from a compressed-air supply, which is then circulated through a
heat exchanger in the gauge (Figure 3-5). The vortex unit is close-coupled to the gauge, and
factory-fitted as part of the assembly (see Section 9.3 - Vortex Cooling Option).

3.4.5.3 Cooler Solenoid Control (Sensor) Option
An optional cooler solenoid controller optimizes air usage by only cooling the gauge when
needed (Figure 3-6).
Figure 3-6 Cooler solenoid control option
3.4.6 Heater Option

The Heater option allows the gauge to operate in cold environments below 0°C/32°F down to
-30°C/-22°F.
3.4.7 Common Gauge Connector (CGC) Cable Option

This option is used in scanning applications, and connects an NDC High Flex cable to a Com-
mon Gauge Connector on the Series 9 gauge (see Section 9.5 - Common Gauge Connector
(CGC) Cable Option).

CHAPTER
4
4 Installation
4.1 Installation Good Practice
Observe the following points when selecting the mounting location for the gauge.
• Product View
Choose the position for the gauge carefully so that it views only material that is repre-
sentative of the product at the relevant stage in the process (see Section 4.7.1 - Posi-
tioning).
• Site Requirements
Check that the mounting position and the available services conform to the Site
Requirements (see Section 4.3 - Site Requirements).
• Gauge Mounting
Ensure that the gauge support is rigid, and free from vibration during normal opera-
tion.
• Atmospheric Contaminants
If the working environment has a high level of airborne contaminant (e.g. dust and
dirt), attach an air line to the air purge window.
• Electromagnetic Compatibility
Follow the EMC precautions (see Section 4.4 - EMC Precautions) to avoid interfer-
ence from other equipment.
• Ambient Light
Shield the gauge window and measuring area from direct sunlight as this may affect
the sensitivity of measurements.
• Peripheral Unit Location
Peripheral units such as the OT and GCI must be installed where the risk of mechani-
cal damage is low.
Series 9 - General: Installation 4-1

4.2 Hazardous Environments
Series 9 Gauge
Standard Series 9 gauges are not suitable for installation in explosive gas or dust envi-
ronments.
NDC provides special versions of the Series 9 gauge and peripherals, which are certified for
use in non-mining applications, dust or gas explosive atmospheres.
Please consult NDC for details, which are covered by a separate user guide.
4-2 Series 9 - General: Installation

4.3 Site Requirements
The installation site for the Series 9 system components should meet the following environ-
mental and supply requirements.
Environmental
Operating temperature range
Series 9 gauge 0oC - 50oC without cooling
0oC - 70oC with cooling
GCI, OT, GCP, PH 0oC - 50oC
Relative Humidity
Gauge, GCI, OT, GCP, PH 5% - 95% (non-condensing) over the full operating
temperature range
Electrical
Mains supply The power supply requirement is 100W through a single

phase supply in the range: 85Vac - 264Vac, 47-63Hz
Equipment permanently connected to the mains supply should incorporate an accessible and
clearly identifiable isolating device, such as a double-pole isolator switch or circuit breaker,
positioned near to the equipment. Ensure that the isolator is appropriately rated for the cumu-
lative load.
Air Supply
For Air Purge unit option:
20 L/min, measured at the air purge Air supply must be instrument quality – i.e. dry, clean and
window (see Section 4.7.3 - Fitting oil-free.
the Air Purge Window) NDC uses a 40um element filter followed by a 0.01um
coalescing filter to achieve this standard.
Water Supply
For gauge water cooling option:
Ambient temp. up to 70oC Clean water. Flow rate: 200mL/min, Temp: <25oC

4.4 EMC Precautions
Use the following guidelines to minimise the effects of electrical interference.
1. Ensure that the system is supplied with a clean mains supply (instrumentation supply).
2. Lay signal cables in a low-power signal conduit, and mains cables in low-power mains
supply conduit.
3. Ensure that no part of the gauge/system or cabling is placed near sources of strong
EMI (Electromagnetic Interference). Example sources of EMI:
• Large electric motors
• Welding equipment
• Large static discharges
• Infrared ovens
• Microwave ovens
• Large transformers
• Transmitters
• Power control circuits
Note: Do not alter any cables or enclosures without prior permission from the Engi-
neering Department at NDC.
For advice or help on installation concerning EMC, please contact the Customer Care Help-
desk at NDC.

4.5 Unpacking
1. Check against the courier's Delivery Note that all listed items have been delivered.
2. Unpack all equipment in a clean area. Retain the packaging for future use, if possible.
3. Retrieve and keep the documentation included in the packaging:
Packing Sheet - which lists all supplied items
4. Check the equipment carefully for any signs of damage.
5. If any items are missing or damaged, notify the carrier, NDC or the agent of NDC
(see Section 1.4 - Contact Information) as appropriate.
6. If the equipment is to be stored prior to installation, ensure that the storage conditions
are suitable (see Section 4.6 - Storage).
4.6 Storage
Before installation, store the equipment in the environmental range:
Temperature: 0oC - 70oC
Humidity: 5% - 95% (non-condensing)
Include desiccant if there is any possibility of condensation. After storage, allow the equipment
to reach ambient temperature before installation.

4.7 Installing the Gauge
4.7.1 Positioning
The following points should be taken into account when positioning Series 9 gauges.
Direct Viewing
When viewing the product directly, the gauge should be installed above a moving and continu-
ous stream of product without gaps. Ideally, the depth of the product should be at least a few
centimeters - enough to obscure the conveyor surface completely.
In most applications, the gauge should If there is a possibility of gaps in the product,
be fixed to a horizontal mounting so that the gauge must be mounted at an angle.
the infrared beam is perpendicular to the This prevents direct reflection of the infrared
surface of the product. beam from the conveyor surface into the
gauge window, which could affect measure-
ment accuracy.
(A)
(A)
Figure 4-1 Positioning the gauge
Position the gauge at the correct pass height from the product surface, according to the beam
patch size (Figure 4-1). Fluctuations in the product surface should be kept within the allowable
limits shown for the pass height.
Beam patch size Large (60mm) Medium (25mm) Small (10mm)
Pass height (A) 250 ±100mm 200 ±50mm 140 ±20mm

(measured from outside
surface of window)

Window Viewing
Where the process is enclosed, the gauge can view the product through a glass or sapphire
window. In this case:
• To prevent reflections, the gauge must be angled with respect to the window
(Figure 4-2).
• A solid bed of product must be flowing against the viewing window. Otherwise, spuri-
ous reflections and the varying path length of the gauge beam may affect measure-
ment accuracy.
• Arrangements must be made to keep the viewing window free from accumulated
product.
Figure 4-2 Positioning the gauge with respect to the window
Product Surface
Measurements after a dryer or conditioner are best taken as far down stream as possible to
give the product a chance to equilibrate. If there is danger of the surface not representing the
bulk product (from surface drying of a hot product, for example), then a plough or other mech-
anism should be installed just before the gauge location to turn over the product. This is
essential to ensure that the measurements are representative of the bulk product.
Gauges Fitted with Internal Gating Option
The mounting height for gauges fitted with this option must take account of the thickness of the
product. Refer to the gating option section (see Section 9.1 - Internal Gating Option) before
mounting the gauge.

4.7.2 Mounting
The gauge may be attached to any suitable mounting bracket or frame, using the four
M8 x 10mm mounting holes provided in the top of the case (Figure 4-3). Two sets of fixing
screws suitable for attaching the gauge to mounting plates of different thickness are provided
in the Series 9 Gauge Kit.
All dimensions in mm
Figure 4-3 Mounting the gauge

The mounting must be rigid and vibration-free. The mounting arrangement must provide suffi-
cient clearance for fitting and removing connectors, and enable the gauge to be positioned
correctly with respect to the product. The mounting hole positions for the cast and stainless
steel gauges are shown in Figure 4-4.
Figure 4-4 Mounting holes
For details of case and fitting dimensions, refer to the outline drawings (see Chapter 12 - Out-
line Drawings).

An easy, slide-mounting Adapter Plate is supplied with each gauge to facilitate safer manual
handling and installation (Figure 4-5).
Figure 4-5 Easy slide-mounting adapter plate

Figure 4-6 Sliding the gauge into the bracket
The plate is first bolted to the mounting bracket over the production line and the Series 9
gauge is slid into the bracket, which supports the weight of the gauge (Figure 4-6). It is then
simply locked into position with four (4) retaining bolts (Figure 4-7).
Figure 4-7 Retaining bolts

4.7.3 Fitting the Air Purge Window
The air purge window (APW) inhibits window contamination by maintaining a positive air pres-
sure around the window area. It is secured to the gauge by a set screw that locates into a
groove around the outside of the window bezel.
Fit the APW (Figure 4-8) as follows:
1. Check that the cylindrical insert and gaskets are located correctly in the air purge
housing.
Figure 4-8 Air purge window (APW)
2. Fit the APW onto the gauge by sliding in place and fix by tightening the single captive
thumbscrew.
3. Using 6mm diameter pipe, connect a clean, dry and oil-free air supply to the air con-
nector.

4. Regulate the air supply (Figure 4-9).
Typically, the stated air flow (see Section 4.3 - Site Requirements) can be
achieved from a 30 psi (2 Bar) supply delivered through 3m x 6mm Ø pipe
(4mm inside Ø).
If an air-flow meter is not available, a reasonable assessment can be made by

holding your hand a few centimetres below the air purge window and increas-
ing the air pressure until you can feel a gentle air flow.
The figure given for air flow is, in any case, only a guide for a starting value and
should be adjusted according to experience after a period of operation. If win-
dow contamination is significant, increase the air flow until it is reduced to an
acceptable level.
Figure 4-9 Air supply

4.7.4 Connecting Water Cooling
If the gauge is fitted with a water cooling option, connect the water supply to the water in/out
connectors (Figure 4-10). The direction of water flow is not important. The water supply must
comply with the specification given in the Site Requirements (see Section 4.3 - Site Require-
ments).
Figure 4-10 Water supply
The gauge includes push-on connectors (thread size G1/4) to connect to an integrated heat
exchanger to circulate cold water (Figure 4-11). For example, with an ambient temperature of
70°C/158°F, a water flow rate of 200ml/min (@22°C/70°F) will result in an internal gauge tem-
perature of 50°C/122°F.

Figure 4-11 Water cooling connectors
Note that condensation on the outside of the enclosure may be an issue if the gauge is cooled-
too much compared to the ambient temperature.

4.8 Installing Peripherals
4.8.1 Molded ABS Units
The mounting for the OT, GCI, Gauge Control Port and Switched Hub is identical. All units
have four mounting holes through the rear of the enclosure, which can be used to fix them to a
wall or other flat surface, or to the NDC mounting plate option.
Make sure that the chosen location provides adequate clearance below the unit for insertion
and removal of cables. The cables to the unit should be placed away from heavy-duty power
cables and cables carrying high frequencies to other equipment.
To mount a peripheral unit (Figure 4-12):
1. Undo the 4 screws in the corners of the lid with an M5 Allen key and open the hinged
lid.
2. Fix the unit to a suitable flat surface using the mounting holes.
3. Complete all electrical connections to the unit (see Section 4.9 - Electrical Connec-
tions).
4. Refit the lid and screw down tight.
Figure 4-12 Mounting dimensions of peripheral units

4.8.2 Stainless Steel Units
Make sure that the chosen location provides adequate clearance below the unit for insertion
and removal of cables. The cables to the unit should be placed away from heavy-duty power
cables and cables carrying high frequencies to other equipment.
The mounting of the unit is made through 4 x M5 threaded boss at the rear and needs to be
made through a suitable wall plate.
Complete all electrical connections to the unit (see Section 4.9 - Electrical Connections).
Figure 4-13 Mounting dimensions of stainless steel unit
See Figure 4-13. All dimensions are in mm.
4.8.3 Panel-Mounted Units

Some peripheral components, such as the GCI, are available for panel mounting into existing
equipment. These comprise a front panel (1) with the working assemblies (pcb, touch screen,
etc.) attached, and a rear cover (2). Both items are secured to the mounting panel by four
threaded studs (3). See Figure 4-14.

Note: The maximum allowable mounting panel thickness is 9mm.
Figure 4-14 Panel mounting dimensions

Figure 4-15 Customer panel cutout dimensions
To mount the unit:
1. Create the aperture and mounting holes in the relevant panel, as shown in
Figure 4-15.
2. Fit the front panel and secure with the mounting studs.
3. Complete all electrical connections to the unit (see Section 4.9 - Electrical Connec-
tions).
Note: The cables must be supported to prevent strain on the pcb connectors.
4. Fit the rear cover and secure with the screws supplied.

4.9 Electrical Connections
The following section provides details of the electrical connections for the Series 9 gauging
system.
The electrical connection to the gauge is made through a supplied services cable with a circu-
lar screw lock connector. However, the gauge must be permanently connected to earth
through one of its M8 mounting screw holes using a 4mm square (minimum) cross-sectional
area earth braid (Figure 4-16).
Figure 4-16 M8 mounting screw holes
All the peripherals must also be permanently connected to earth through its M4 earth stud
using a 4mm square (minimum) cross-sectional area earth braid (Figure 4-17).
M4 earth stud
Figure 4-17 M4 earth stud

Connections to all the peripherals (GCI/GCP/OT/PH) are routed through cable glands and
made to screw terminations that have a common arrangement, as per the following sections.
The gland nut must be tightened with a torque wrench to 3.5Nm to form a good seal with the
cable braids trapped in the gland, as per Figure 4-18.
Figure 4-18 Gland nut
4.9.1 Mains Power Connection

The power supply requirement is 100W through a single phase supply in the range:
85Vac - 264Vac, 47-63Hz.
The mains power cable provided by the user, must be 3-core mains cable, double insulated,
18 AWG (minimum) wire gauge with an outside diameter in the range Ø6.0mm to Ø10.0mm to
ensure it will seal in the cable gland.
The cable should be routed through the gland closest to the power terminals as shown in
Figure 4-19, following the legend on the board, terminated from left to right; 1 = Earth,
2 = Neutral. 3 = Live.

Figure 4-19 Mains power cable connection
4.9.2 Gauge Services Cable Connections

The gauge cable connector is first mated to gauge connector and locked in place using the
connector screw lock ring in a clockwise motion.
The free end of the gauge cable is terminated to the screw terminals marked "ETH2 24V"
using the following table. See Figure 4-20.
"ETH2 24v"
Wire Colour Function
terminal
Pair 1 White Tx- Ethernet Tx-
Pair 1 Orange Tx+ Ethernet Tx+
Pair 2 White Rx- Ethernet Rx-
Pair 2 Green Rx+ Ethernet Rx+
Pair 3 White UNFUSED + Power output +24Vdc
Pair 3 Brown UNFUSED + Power output +24Vdc
Pair 4 White UNFUSED - Power output 0Vdc return
Pair 4 Blue UNFUSED - Power output 0Vdc return

Figure 4-20 Gauge services cable connection
Note that the twists in the pairs must be continued up to the termination point.
The FUSED + and - terminals provide 24Vdc output power for other options.

4.9.3 Analogue and Digital Inputs and Outputs
The GCI and GCP can be populated with up to four input/output boards that can plugged in
and stacked in two rows, as shown in Figure 4-21, for example.
Analogue output
board #1
Digital output
board #3
Digital input Analogue output

board #4 board #2
Figure 4-21 Input/output boards

4.9.3.1 Analogue Output Board
Figure 4-22 Analogue output board
Provides two isolated Analogue outputs that can be set for 0-10v (V) or 4-20mA (I) by the slide
switches as shown on the board legend (as V and I) with the following connections.
Terminal Number
Function
Left to right
1 Channel 1 +
2 Channel 1 -
3 Channel 2 +
4 Channel 2 -

4.9.3.2 Digital Outputs
Figure 4-23 Digital outputs
Provides eight N/O relay contacts (125vac/60vdc/1A maximum ratings) with connections in the
table below.
Terminal Number
Function
Left to right
1 and 2 Relay contact 1

4.9.3.3 Digital Inputs
Figure 4-24 Digital inputs
Provides eight Opto-isolated inputs (Low 0vdc and High 3vdc-30vdc) with connections in the
table below.
Terminal Number
Function
Left to right
1 Input 1
2 Input 2
3 Input 3
4 Input 4
5 Input 5
6 Input 6
7 Input 7
8 Input 8
7&8 Common 0v

4.9.4 Ethernet Cable Connections
Figure 4-25 GCI/PH Ethernet connection
The communication between GCI/OT/GCP/PH units is through an Ethernet protocol, with the
connection made through the screw terminal connectors marked "ETH3" and "ETH4" on the
motherboard of each unit.
The cabling linking each unit together must be Industrial Cat5E type network cable (normally
supplied) with an outside diameter in the range Ø6.0mm to Ø10.0mm, with connections made
as per the table below for each end.
"ETH3"
Wire Colour "ETH4" Function
terminal
Pair 1 White Tx- Ethernet Tx-
Pair 1 Orange Tx+ Ethernet Tx+
Pair 2 White Rx- Ethernet Rx-
Pair 2 Green Rx+ Ethernet Rx+
Note that the twists in the pairs must be continued up to the termination point.

4.9.5 Switched Hub Connections
The switched hub provides eight switched Ethernet ports for connection to Series 9 gauges
and peripherals, and for interfacing with a factory network, according to system requirements.
The connector functions are identified in Figure 4-26. Details of specific gauge, peripheral,
power and other connections to the hub are given in the relevant sections.
Figure 4-26 Switched hub connectors
Connector Function
PL16 Earth connections
PL17 24vdc Power in
PL1, PL2, Ethernet connections to GCI, OT, PH, GCP and user network
PL3, PL4,
PL5, PL6,
PL7

Connector Function
SK9 System services, typically for connection of laptop running GaugeToolsXL

software.
4.9.5.1 Power Supply to Switched Hub
An NDC 24V power supply unit (PSU) is supplied with the switched hub. This is connected to
the switched hub as detailed below.
PSU Wire Colour Function Switched Hub
Red +24V In PL17 / 1
Blue 0V PL17 / 2
Green Earth (Ground) PL16 / 1-4 (optional)

FS 3 FS 4
Pl13 Pl9 PL11 PL15

3 2 1 8 7 6 5 4 3 2 1 6 5 4 3 2 1 4 3 2 1
+24V IN
+24V OUT
GATE2
TX+
+24V OUT
TX–
GATE 1
EARTH
EARTH
TX-
TX+
RX+
RX-
EARTH
0V IN
FS 1 FS 2
Pl12 Pl8 Pl10 Pl14

3 2
+24V IN 1 8 7 6 5 4 3 2 1 6 5 4 3 2 1 4 3 2 1
+24V OUT
GATE2
+24V OUT
GATE 1
EARTH
EARTH
TX+
TX–
TX-
TX+
RX+
RX-
EARTH
0V IN
Figure 4-27 Power supply to switched hub connectors
Gauge 1 Gauge 2
Connector Connector Function
PL12 PL13 Power in
PL8 PL9 Ethernet and power to single-cable Series 9 Gauges
PL10 PL11 Ethernet and power out for connection to Series 9 peripherals
PL14 PL15 Earth and option function (Gate)

CHAPTER
5
5 Operation
5.1 Overview
The two Series 9 operator interfaces are:
• The GCI (Gauge Control Interface) which can monitor and control multiple
gauges.
• The OT (Operator Terminal) which is dedicated to a single nearby gauge.
The GCI provides access to all user-controllable functions, subject to user passwords, includ-
ing those used for gauge configuration and calibration. The OT provides access to the range
of functions normally required for day-to-day operation. In all other respects, operation of the
two interfaces is identical, and this section covers both.
In addition to these system interfaces, a standard web browser may be used to configure
aspects of the Gauge Control Port (see Section 5.6 - Gauge Control Port Browser Interface),
which has no user interface of its own.
5.1.1 Home Page

The default display for both the GCI and OT interfaces is a Home page, which appears auto-
matically a few seconds after the interface is powered up.
A Home page displays up to four continuously-updated gauge measurements. Various other

operating functions may be selected by touching the appropriate toolbar buttons on the bot-
tom. See Section 5.1.3 - Toolbar Buttons.
A Home page may show a Trend chart in addition to the numeric gauge measurement. If there
are at least two available Home pages, you can switch to a different Home page by touching
one of the circle icons, or the < and > icons to scroll backward or forward.
On the GCI, the Home pages can display measurements from different gauges. On the OT,
they can display measurements only from the single associated gauge.
Series 9 - General: Operation 5-1

Measurement Value Current
Product
Gauge Name Channel Brings up
Trend chart
Toolbar Buttons Gauge Status
Figure 5-1 OT Home page
5.1.2 User Levels

The gauge supports 3 user levels:
• Operator – this is the default user. The user is automatically logged on as the
Operator when the interface is powered up. This user does not require a pass-
word.
• Supervisor – this user requires a password. A user logged on as a Supervisor

has access to more functions than the Operator user.
• Engineer – this user is primarily for use by NDC engineers. It also requires a
password. A user logged on as an Engineer has access to more functions than
the Supervisor or Operator user. For example, an Engineer has the capability of
configuring the analogue and digital outputs.
Section 5.2.1 - Logging In as Supervisor or Engineer shows how to log on as a Supervisor or

Engineer.
5-2 Series 9 - General: Operation

The toolbar buttons shown on the bottom of the screen will vary, depending on which user is
currently logged on, and whether the device is a GCI or OT. See Section 5.1.3 - Toolbar But-
tons.
Measurement Value Current

Product
Gauge Name Channel Brings up
Trend chart
Toolbar Buttons Gauge Status

Multi-Gauge
Figure 5-2 GCI Home page

Figure 5-3 shows a multi-gauge screen.
Figure 5-3 Multi-gauge screen
A tap from the multi-gauge screen takes you to the screen for a single gauge (Figure 5-4).
Swipe to switch between these two screens.
Figure 5-4 Single gauge screen

5.1.3 Toolbar Buttons
The toolbar buttons shown vary, depending on:
• whether the device is a GCI or an OT
• which user is currently logged on: Operator, Supervisor or Engineer.

See Section 5.1.2 - User Levels.
These buttons are described below.
Button Description
Home – Brings up the Home page.
Back – Returns to the previous page.
Sample – Brings up the Sample page for taking sample

measurements for calibration.
Product Selection – This button is available to the

Supervisor or Engineer, on the GCI only. It brings up the
Load Product page for loading a Product.
Security – This button brings up the Security page for

logging in or out as a Supervisor or Engineer.
Gauge Diagnostics – This button is available only to the

Operator. It brings up the Gauge Diagnostics page.
Configuration – This button is available only to a

Supervisor or Engineer. It brings up the Settings page.
Note that the Settings page differs, depending on whether
the user is logged on as a Supervisor or Engineer, and
whether the interface is a GCI or OT.
Gauge/Ref. Check – This button appears on the Gauge

Diagnostics page. It brings up the Gauge/Ref. Check
page.

5.1.4 Responding to Error Messages
The Gauge Status is shown in the box on the bottom right of every screen (Figure 5-5). If the
gauge(s) are functioning properly, the message “All OK” is displayed.
Gauge Status box
Figure 5-5 Gauge Status box
Touch the Gauge Status box to bring up the Gauge Status page (Figure 5-6). This page shows
the Gauge Name, Status, IP Address and duration of uptime.
Figure 5-6 Gauge Status page

When a fault occurs on a gauge, it is indicated by a highlighted message in the Gauge Status
box, in place of the normal “All OK” message. If there are multiple errors, the one with the
highest priority is displayed.
1. Touch the highlighted error message to display the Gauge Status page.
This lists all gauges with their current status, showing the gauge(s) generating errors.
2. Refer to the error message descriptions (see Section 10.1 - System Error Messages),
and take the relevant actions to clear the error conditions.
3. As each error condition is cleared the associated error message is automatically

removed. On removal of the last error, the message reverts to “All OK”.
5.1.5 Viewing the Software Version and Device Type

To display the page that shows the software version and device type (GCI or OT), slowly tap
the Gauge Status box on the bottom right of the screen (Figure 5-5). After seven taps, that
page should appear (Figure 5-7). If the page appears briefly, then disappears, continue tap-
ping until it reappears.
The information shown on this page will be helpful if you are contacting NDC for technical sup-
port.
Software Version Device Type
Figure 5-7 Device type and software version
Note: The information above (excluding the device type) is also accessible to a Supervisor
or Engineer by selecting Information on the Local Settings page. See Section 6.5 -
Local Settings.

5.2 Security
The gauge supports 3 user levels: Operator, Supervisor and Engineer. See Section 5.1.2 -
User Levels for a description of these users.
Note: Auto Logout Feature
If you are logged in as a Supervisor or Engineer, and there is no screen activity

(i.e., button touches) within the Auto LogOff Time period on the Local Settings page,
you will automatically be logged out, the current user will revert to Operator, and the
Home page will be displayed,
5.2.1 Logging In as Supervisor or Engineer

The Supervisor and Engineer users require a password. To log in as a Supervisor or Engineer:
1. Touch the Security button. The Security page will appear (Figure 5-8).
Figure 5-8 Security page
2. The topmost button shows the user that is currently logged on. Operator is the default
user.
Touch the Supervisor or Engineer button.

3. Enter the password for Supervisor or Engineer using the displayed keyboard
(Figure 5-9). See Section 5.3 - Data Entry.
If the password that you entered is correct, you will be logged in as a Supervisor or
Engineer.
Figure 5-9 Keyboard for entering password
Note: If you have forgotten the Supervisor or Engineer password, check the Forgotten
Password box in the displayed keyboard, and a message will appear with a code that
you can provide to NDC to obtain a temporary password.
5.2.2 Logging Out

The Log Out function is only relevant if you are currently logged on as a Supervisor or Engi-
neer. To log out:
1. Touch the Security button. The Security page will appear (Figure 5-8).
2. Touch the Log Out button.
This will cause the current user to be set to Operator, and the Home page to be dis-
played.

5.3 Data Entry
Pages that allow any sort of data entry, such as a name or numerical value, have touch-sensi-
tive fields which appear as white boxes. For example, Figure 5-10 shows editable boxes on
the Edit Product page (which appears only on the GCI).
Figure 5-10 Editable boxes on Edit Product page
If a setting is shown in a lightly shaded gray box (such as the ones shown on the Gauge Diag-
nostics page, Figure 5-11), this indicates that it is read-only.
Figure 5-11 Lightly shaded gray boxes on Gauge Diagnostics page
When you touch a data entry field, a full-text keyboard or numerical keypad is displayed, as
appropriate for the required entry.
If a new value is entered for a field in a product, that field is shown in a lightly shaded yellow
color (Figure 5-12).

Figure 5-12 Changed value shown in box with light yellow background
There are several different versions of both the full-text keyboard and numerical keypads. The
version displayed depends on the current interface language (see Section 6.5 - Local Set-
tings), and on the particular data entry function.
5.3.1 Numerical Keypad

Figure 5-13 shows a sample numerical keypad that is displayed when the Sample Time box is
touched on the Sample page. Note that the cursor that indicates the current position is
denoted by the flashing vertical sign.
Cursor
Figure 5-13 Sample numerical keypad
Selected keys appearing on the numerical keypad are described below.

Key Function
Delete – Deletes the character previous to the cursor
Clear – Clears the current entry
+/- – Changes the sign of the current value (e.g., to enter a minus sign (-) to
designate the value as negative)
Decimal Point – Inserts a decimal point
Back – Moves the cursor back by one character
Forward – Moves the cursor forward by one character
Cancel – Cancels the current entry
Enter – Confirms the current entry and closes the keypad

5.3.2 Full-Text Keyboard
Figure 5-14 shows a sample full-text keyboard that is displayed when the Rename button is
touched on the Configure Products page (GCI only). Note that the cursor that indicates the
current position is denoted by the flashing vertical sign.
Cursor
Figure 5-14 Sample full-text keyboard
Some of the keys (e.g., Enter and Cancel) on the full-text keyboard are identical to those on
the numeric keypad. See Section 5.3.1 - Numerical Keypad for a description of those keys.
Additional keys are described in the table below.
Key Function
Caps - Toggles between upper-case and lower-case text entry.
The alphabetical keys show the current state. Lower case is the default state.
Clear - Clears the current entry
Shift - Toggles Shift mode on and off.
Shift mode is automatically canceled after a character is entered.

Key Function
Alt - Toggles full-text keyboards between alternative characters and the

standard keypad display.
Modified Characters - Where relevant for the current language, these enable
accented and other modified characters to be entered.
,
Pinyin - Toggles between Pinyin and standard entry modes when the current
language is Chinese.
Change - Toggles the full-text keyboards between Hiragana, Katakana and

standard entry modes when the current language is Japanese.
The full-text keyboard is included in the following three categories:
• Standard localised keyboard for languages using Roman and Cyrillic alphabets
(see Section 5.3.3 - Standard Localised Keyboard)
• Chinese (see Section 5.3.4 - Chinese Keyboard)
• Japanese (see Section 5.3.5 - Japanese Keyboard)

5.3.3 Standard Localised Keyboard
The standard localised keyboard provides access to the basic Roman and Cyrillic character
sets of upper and lower case letters, numbers and punctuation. It also supports language-spe-
cific alternative and modified characters.
There are several modes of operation, as shown in the table below.
Lower-case mode (Default)
Toggle the Caps key to

select this mode. This
mode provides numbers
and lower case letters.
Caps mode
Toggle the Caps key to

mode provides numbers
and upper case letters.
Shift mode
Touch the Shft key to

mode provides punctuation
characters and upper case
letters.
Shift mode is automatically

canceled after a character
is entered.
Alternative mode
Touch the Alt button to

mode provides alternative
characters appropriate to
the current language.
Alternative mode is auto-

matically canceled after a
character is entered.

Modified Character mode
Provides accented and

other modified characters.
Modified Character mode is

automatically cancelled
after a character is entered.
5.3.3.1 Modified Characters
Where modified characters are available, one or more character modifier keys are added.
These keys are displayed in orange, for example:
or
To enter a modified character:
1. Touch the appropriate character modifier key.
The modifier is entered in the text box, and keys that have modified alternatives are
displayed.
2. If necessary, touch the Shft key to access other characters.
3. Do one of the following.
• Touch the required character key. The character will appear in the text box, and
the modified character mode will be cancelled.
• Touch the Space key to exit modified character mode.
5.3.4 Chinese Keyboard

When the selected language (see Section 6.5 - Local Settings) is Chinese, the keyboard has
two main operating modes.
Pinyin (default)
Pinyin is a system for entering

Chinese characters by spelling
out their sound using standard
Roman characters.
Literally translated, Pinyin

means 'spell sound' or the
'spelling of the sound'.

Standard mode
The keyboard operates as

described for the standard
localised keyboards (see Sec-
tion 5.3.3 - Standard Localised
Keyboard).
The Pinyin key toggles between the two modes.
The general procedure for using Pinyin entry is as follows.
1. Select Pinyin mode.
The keyboard enables only those letters that are valid for starting a character sound.
2. Touch the appropriate letter.
This appears in middle bottom button, and the letters that are valid for continuing the
sound are enabled on the keyboard.
selected letter appears in middle bottom button
3. Continue using the letter keys to spell out the required character sound until the num-
ber keys are enabled.
At this point you can either:

• continue to select letter keys to define the sound or;
• select a number key to define the tone of the sound (approximately similar to add-
ing an accent).

When a number key is selected, the top row of keys changes to display valid Chinese
characters for the spelled sound.
4. Touch the required character, which then clears the roman letters and number in the
middle bottom button.
5. Repeat this process to add all required characters.
Note: Extensive information on the Pinyin entry system can be found at:
http://www.pinyin.info/ and http://en.wikipedia.org/wiki/Pinyin.

5.3.5 Japanese Keyboard
When the selected language (see Section 6.5 - Local Settings) is Japanese, the keyboard pro-
vides access to three writing systems, each of which has different operating modes.
Hiragana (default)
In Hiragana, you can also

access the Kanji entry system.
Katakana
The keyboard provides for

direct entry of full- and half-
width characters.
Standard
The keyboard operates as

described for the standard
localised keyboards
(see Section 5.3.3 - Standard
Localised Keyboard).
The Change key toggles between the three writing systems.

5.3.5.1 Hiragana
The Hiragana keyboard provides two systems of character entry.
Direct Hiragana mode in

which characters selected on
the keyboard are added
directly to the text box.
Kanji mode (default)

Provides the ability to enter
Kanji characters by selecting a
sequence of Hiragana charac-
ters.
The Kanji key toggles between the two systems.
Using Direct Hiragana Entry
1. Select the Kanji key.
2. Enter characters, as required, direct from the keyboard.
3. Use the , , or key as necessary to access shifted charac-
ters and voiced modifiers (see Section 5.3.5.3 - Voiced Modifiers).

Using Kanji Entry
The general procedure for using Kanji entry is as follows.
1. Touch the required character key.
This will narrow the keypad selection to only those characters that can still complete a
Kanji character. The Space key shows selected character, with the total number of
Kanji characters available for selection in parentheses.
For example, after touching the key, the keyboard shows this:
2. At this point you can do either of the following:
• Narrow the search for Kanji characters by selecting further characters.
• View currently available Kanji characters.
The procedures are illustrated in the examples below.
Narrow the search View Kanji characters
• Select another character. The number • At any point in the process of enter-
of keys available for further selection is ing characters, the Space key shows
reduced. the number of available valid Kanji
characters. Touch the key to view
them.

Narrow the search View Kanji characters
• Continue to add keyboard characters. • If there are more Kanji characters

When the search cannot be narrowed than it is possible to display, touch
any further, the available Kanji charac- the Space key to view more.
ters are displayed.
• Select the required Kanji character. The • If the required Kanji character is
selected character will appear in the available, select it to enter it into the
text box. text box.
• If not, touch the Delete key to return

to the narrowing process.
• The keyboard is now ready for entry of

the next Kanji character.
• Repeat this process to add all required

Kanji characters.
Note: Extensive information on the Kanji entry system can be found at:
http://en.wikipedia.org/wiki/Kanji

5.3.5.2 Katakana
The Katakana writing system provides several modes of operation:
Caps mode
Use the key to toggle in and

out of Caps mode.
Shift mode
Use the key to toggle in and out
of Shift mode.
Shift mode is automatically cancelled after

a character is entered.
Half width mode displays a keyboard of

half-width characters.
Use the Change key to toggle
between half width and full width charac-

ters.
Modified Character mode
Use the , , or
key as necessary to access shifted char-

acters and voiced modifiers
(see Section 5.3.5.3 - Voiced Modifiers).
Modified Character mode is automatically

cancelled after a character is entered.

5.3.5.3 Voiced Modifiers
The Hiragana and Katakana full-width modes support character modifiers for voiced and semi-
voiced sound marks. The associated keys are displayed in orange.
To enter a modified character:
1. Touch the appropriate character modifier key.
The keys that have modified alternatives are displayed.
2. If necessary, touch the key to access other characters.
3. Do one of the following.
• Touch the required character key. The character will appear in the text box, and
the modified character mode will be cancelled.
• Touch the Delete key. The modified character mode will be cancelled.

5.4 Gauge Interface
The Gauge Interface provides facilities for performing tasks related to a particular gauge. You
can take sample measurements or make adjustments to the gauge.
5.4.1 Viewing Measurement Trends

It is possible to view a continuously-updated trend graph for any individual gauge measure-
ment channel. This can be done from a Home page:
– Displaying a Trend from a Home Page
Touch the Home button to bring up the Home page, then touch the
Trend button. Figure 5-15 shows the trend graph that appears on the Home page. The
graph X-axis spans 60 seconds. If desired, it can be changed to 30 minutes or 12 hours,
by touching the 30m or 12h button. Y-axis is centered on the average measured value
over this time. The measured value for the selected measurement channel is shown in a
box above the graph.
X-axis
scale
buttons
Figure 5-15 Trend graph on Home page
5.4.2 Sample Function

The sample function is used in conjunction with the Trim function for calibrating gauges
against standard laboratory reference measurements. For information on its use, refer to the
Calibration section (see Section 7.2.2.1 - Obtaining Samples and Calibration).

5.4.3 Trim Function
The Trim function is used in calibration procedures to align the gauge measurements with val-
ues obtained using laboratory reference samples. For information on it use, refer to the Cali-
bration section (see Section 7.2.2 - Trim).

5.5 Gauge Diagnostics
The Gauge Diagnostics function provides facilities for:
• Viewing a range of diagnostic data from the gauge
• Re-referencing the gauge
• Conducting a reference check
5.5.1 Viewing Diagnostic Information

The Gauge Diagnostics page displays various diagnostic information about the gauge. Opera-
tors can access this page by touching the Gauge Diagnostics button. Supervisors
and Engineers can access this page by touching the Configuration button, and
then selecting Gauge Diagnostics on the Settings page.
There are at least 4 groups of information that can be viewed on the Gauge Diagnostics page,
selectable by touching General, Version, Motor or Lamp from the left pane of the screen.
If your system includes options, additional groups will be accessible here as well.
The General group (Figure 5-16) displays information such as the internal temperature of the
gauge and the window contamination level.
Figure 5-16 Gauge Diagnostics page – General group

The Version group (Figure 5-17) displays information about the version of the software and
application in the gauge.
Figure 5-17 Gauge Diagnostics page – Version group
The Motor group (Figure 5-18) displays information about the motor, such as the target and
current speeds.
Figure 5-18 Gauge Diagnostics page – Motor group

The Lamp group (Figure 5-19) displays information about the lamp, such as the current and
voltage.
Figure 5-19 Gauge Diagnostics page – Lamp group
Section 10.1 - System Error Messages describes which parameters on the Gauge Diagnostics
page to monitor when error messages are shown.
5.5.2 Performing an Auto-Reference

This is described in the Calibration section (see Section 7.2.3 - Using Auto-Reference).
5.5.3 Performing a Gauge Check

This is described in the Calibration section (see Section 7.2.5 - Checking Gauge Stability).

5.6 Gauge Control Port Browser Interface
The Gauge Control Port has no built-in user interface. Instead, its software includes a web
server, which allows configuration functions to be presented on a PC running a standard web
browser such as Chrome.
To use the web browser interface:
1. Obtain the IP address of the Gauge Control Port from the Factory Settings Sheet
(see Section 1.3 - Associated Documentation).
2. Connect a PC network port to the Ethernet RJ45 connector on the Gauge Control
Port.
3. Start a web browser on the PC and enter the Gauge Control Port IP address.
The Gauge Control Port web page should be displayed, which provides access to
functions and to other pages.
The functions provided by the browser interface operate in a similar way to the GCI, except
that pop-up keyboards or numeric keypads are not displayed. Where a text or numeric entry is
required, type it in using the PC keyboard.
The functions of the available buttons are as described in Section 5.1.3 - Toolbar Buttons. Use
the PC mouse to make selections.

CHAPTER
6
6 Supervisor and Engineer
Functions
This chapter discusses functions that can only be performed by users with security levels
Supervisor and Engineer. Some of these functions are accessible only on the GCI.
(Section 5.2.1 - Logging In as Supervisor or Engineer describes how to log in as a Supervisor
or Engineer.)
6.1 Settings Page

Users logged on as a Supervisor or Engineer can access the Settings page by touching the
Configuration toolbar button. Icons on the Settings page vary, depending on whether
the user is a Supervisor or Engineer, and whether the interface is a GCI or OT.
6.1.1 Supervisor – GCI

Figure 6-1 shows how the Settings page appears to a Supervisor logged on to a GCI.
Figure 6-1 Settings page for a Supervisor on a GCI
Series 9 - General: Supervisor and Engineer Functions 6-1

6.1.2 Supervisor – OT
Figure 6-2 shows how the Settings page appears to a Supervisor logged on to an OT.
Figure 6-2 Settings page for a Supervisor on an OT
6.1.3 Engineer – GCI

Figure 6-3 shows how the Settings page appears to an Engineer logged on to a GCI.
Figure 6-3 Settings page for an Engineer on a GCI
6-2 Series 9 - General: Supervisor and Engineer Functions

6.1.4 Engineer – OT
Figure 6-4 shows how the Settings page appears to an Engineer logged on to an OT.
Figure 6-4 Settings page for an Engineer on an OT

6.2 About Products
Series 9 gauges have a small number of user-configurable settings that govern the way they
measure. Products are named collections of these settings, stored in the individual gauges for
recall as required. Their function is to enable gauges to be adjusted quickly and accurately
whenever the process product is changed.
Normally, gauges are supplied with the required products pre-installed as part of the factory
configuration. Details of these are provided on the Factory Settings Sheet (see Section 1.3 -
Associated Documentation). These products may be modified, and new ones created, using
the procedures described in this section.
Note: To avoid confusion in these instructions between the products stored in the gauges
and the products from which the gauges are taking measurements, where necessary
we have used the terms “gauge product” and “process product” respectively.
6.3 Loading Products

Note: This function is accessible on the GCI only.
This function can be used recall a selected product in the system gauges. When this is done,
the values stored in the product become the current gauge values for making measurements.
They are also the values that will be modified by any changes made through the Edit Product
function or through calibration adjustments.
1. Touch the Product Selection button to open the Load Product page
(Figure 6-5).
Figure 6-5 Load Product page

Alternatively, bring up the Configure Products page (Figure 6-6):
Configuration > Configure Products
2. Select the relevant product from the list.
3. Touch the Load button.

6.4 Managing Products
Note: The Configure Products page and its buttons are accessible on the GCI only.
To bring up the Configure Products page (Figure 6-6), touch the Configuration but-
ton, then touch Configure Products.
Figure 6-6 Configure Products page
The buttons on the Configure Products page are described below.
Note: The Load button on this page performs the same function as the Load button on the
Load Product page (Figure 6-5) - that is, it loads a selected product.

6.4.1 Creating a New Product
The following procedure has the effect of creating and storing a new product in selected sys-
tem gauges. In each gauge, the current gauge settings are used as the initial settings for the
new product. The settings can then be changed by editing the product.
1. Open the Configure Products page (Figure 6-6):
2. Touch the New button.
3. Enter a Name for the product using the keyboard provided.
4. Touch the Description box and enter a description of the product using the keyboard.
5. Touch the Enter button to save the entry.
6. Follow the procedure below (Section 6.4.2 - Editing an Existing Product) to edit the
settings in the product.
6.4.2 Editing an Existing Product

The Edit Product function allows the settings in the product to be adjusted according to
requirements. Some of these settings are described below.
• Algorithm The measurement algorithm supplied with the gauge is optimised

for the intended gauge application. Refer to the Factory Settings
sheet supplied with the equipment for the required algorithm.
The algorithm should not be changed unless either:
• the Factory Settings sheet specifies a different algorithm for
different products, or;
• the gauge is to be used for a different application to the one

for which it was supplied. In this case, contact NDC
(see Section 1.4 - Contact Information) for advice on select-
ing an appropriate algorithm.
• Trim Refer to Calibration overview (see Section 7.1 - Calibration

Overview).
• Span Refer to Calibration overview (see Section 7.1 - Calibration

Overview).

• Response Response Time is the time (in seconds) over which the gauge
Time output is integrated. The appropriate value depends on the
nature of the measured product. It should be short enough to
indicate short-term rates of change whilst long enough to give a
meaningfully stable measurement value.
• Control and The alarm outputs from the Series 9 system can be used to
Alarm Limits trigger visible warnings at the measurement thresholds specified
Low/High in these two fields.
To edit product settings:
2. Select the product you wish to edit from the list.
3. Touch the Edit button, and the Edit Product page will appear (Figure 6-7).
Figure 6-7 Edit Product page
4. The name of the gauge(s) and measurement channel(s) are shown in the left pane of
the page. Select the channel you wish to edit. The settings for the selected channel
will be displayed.
5. Set the values as needed.
6. Touch the Save Changes button. (This button and the Cancel Changes button are
disabled until one or more changes have been made to the settings. If the Cancel
Changes button is touched, the changes will be erased, and the settings will revert to
their original values.)

6.4.3 Copying a Product
This procedure creates a new product, with all settings copied from an existing one.
2. Select the product you wish to copy from the list.
3. Touch the Duplicate button.
4. Enter a Name for the product using the keyboard provided.
5. Touch the Description box and enter a description of the product using the keyboard.
The new product will be added to the list.

7. Edit the settings of the new product as required (see Section 6.4.2 - Editing an Exist-
ing Product).
6.4.4 Renaming a Product

To rename a product:
2. Select the product you wish to rename from the list.
3. Touch the Rename button.
4. Edit the Name entry for the product using the keyboard provided.
5. (Optional) Touch the Description box and edit the description of the product using the
keyboard.
The updated product name and description will appear in the list of products.

6.4.5 Deleting a Product
When a product is no longer needed, it can be removed permanently.
2. Select the product you wish to delete in the list.
3. Touch the Delete button.
4. Touch OK to confirm the deletion.
The product will be removed from the list of products.
6.4.6 Calibrate
This is described in the Calibration section (see Section 7.2.2.1 - Obtaining Samples and Cali-
bration).
6.4.7 Auto Trim

This is described in the Calibration section (see Section 7.2.1 - Using Auto-Trim).

6.5 Local Settings
1. Touch the Configuration button to bring up the Settings page.
2. Open the Local Settings page by touching the icon(s) below.
Supervisor
Local Settings
Engineer
Configure Display (OT) or Display Settings (GCI)
> Local Settings
Figure 6-8 Local Settings page – General group
3. There are 3 groups of information in the left pane: General, Information and Mod-
ules.
4. The General group (Figure 6-8) includes the following settings:
Language – selects the interface language for the GCI or OT.
Auto LogOff Time – sets the period after which a Supervisor or Engineer will be
automatically logged off if there is no screen activity.
Brightness – sets the screen brightness.
Temperature Display – sets whether the internal temperature on the Gauge

Diagnostics page is shown in Celsius or Fahrenheit.

5. The Information group (Figure 6-9) displays information about the GCI/OT, including
software version and build date, IP Address, CPU load and time since the last reboot.
Figure 6-9 Local Settings – Information group
6. The Modules group displays information about the AnyBus module.

6.6 Setting the Date and Time
2. Open the Set Date And Time page (Figure 6-10) by touching the icon(s) below.
Supervisor
Date/Time
Engineer
Hardware Settings > Date/Time
Figure 6-10 Set Date And Time page
The current date and time are displayed on the bottom of the page.
3. To change the date:
a. Touch a date on the calendar.

A Set Date To <selected date> button will appear.
b. Touch the Set Date To ... button.
4. To change the time:
a. Touch the HOURS, MINUTES and SECONDS lists to select the current time.
b. Touch the Set Time To ... button.

6.7 Editing the Gauge and Measurement Names
The Edit Names function enables you to assign meaningful names to the gauge and to each
of the measurement channels, in place of the factory defaults.
The assigned names are used throughout the GCI and OT functions. In particular, they appear
on the Home pages to identify the displayed measurements.
2. Open the Gauge Settings page (Figure 6-11) by touching the icon(s) below.
Supervisor
Gauge Settings
Engineer
Hardware Settings > Gauge Settings
Figure 6-11 Gauge Settings page – Names group
3. “Names” should already be selected in the left pane. The Gauge and Channel
Names appear to its right. Enter new names as required for the gauge and any of the
channels.
It is common practice for:

• the Gauge Name to reflect its position in the process (e.g. Dryer 1 Exit).
• each Channel Name to represent the constituent being measured (e.g. Moisture
or Oil).

6.8 Setting the Automatic Gauge Check Interval
Gauge checking can be carried out automatically, at regular intervals by following the proce-
dure below.
2. Open the Gauge Settings page (Figure 6-12).
Supervisor
Gauge Settings
Engineer
Hardware Settings > Gauge Settings
Figure 6-12 Gauge Settings page – Gauge Check group
3. Select Gauge Check in the left pane.
4. By default, Automatic interval is set to Disabled. To enable automatic gauge check-

ing, touch the Automatic interval box, select the interval for gauge checking
then select OK.

6.9 Engineer-Only Functions
This section describes functions that are accessible only to a user logged in as an Engineer.
Selected functions below are accessible only on the GCI.
6.9.1 Selecting Gauges

Note: This function is accessible on both the GCI and the OT.
6.9.1.1 Adding Gauges to the GCI or OT
Using this procedure you can list all gauges available on the system, and select the one(s) you
wish to be accessible from the particular GCI or OT. This is essential before functions, such as
configuring a gauge or viewing its outputs, can be performed from the GCI or OT.
2. Touch the Configure Display (OT) or Display Settings (GCI) icon.
3. Touch the Select Gauges icon to open the Gauge Selection page
(Figure 6-13).
Figure 6-13 Gauge Selection page – GCI
4. Two lists are displayed: the Available Gauges list on the left shows a button for each
available gauge, and the Selected Gauges list on the right shows the gauges that
have been selected.

5. To select a gauge, touch the associated gauge’s button in the Available Gauges list,
and the selected gauge will appear in the Selected Gauges list. Alternatively, touch
the All button to select all available gauges.
6. To remove a gauge from the list of selected gauges, touch its button in the Selected
Gauges list. Alternatively, touch the None button to remove all the gauges from the
Selected Gauges list.
7. When done making your selections, touch the Save button, then touch the Restart
GCI or Restart OT button to restart the GCI/OT.
6.9.2 Configuring Network Settings

Note: These functions are accessible on both the GCI and the OT.
6.9.2.1 GCI/OT Network Setup
To set the IP Address and other network settings for the GCI/OT:
2. Touch the Hardware Settings icon.
3. Touch the Network Configuration (OT) or Configure Network (GCI) icon to

open the Network Settings page for the OT/GCI (Figure 6-14).
Figure 6-14 Network Settings page – GCI

4. If the GCI/OT IP settings will be assigned automatically, touch the Automatic IP
Address box. That box will change to blue, to indicate that it has been selected.
5. Otherwise, to manually enter the IP settings for the GCI/OT:
a. Touch the Manual IP Address box.

That box will change to blue, to indicate that it has been selected.
b. Individually touch each of the four fields that are separated by periods and use the
keypad on the right to enter the IP Address, Subnet mask and Default Gateway
settings for the GCI/OT.
c. When done entering the values, touch the OK button on the keypad.
6.9.2.2 Gauge Network Setup
To set the IP Address and other network settings for the gauge:
1. Touch the Gauge Status box (Figure 5-5) to bring up the Gauge Status page
(Figure 6-15).
Figure 6-15 Gauge Status page
2. Touch the gear button to open the Network Settings page for the gauge
(Figure 6-16).

Figure 6-16 Network Settings page – Gauge
3. If the gauge IP settings will be assigned automatically, touch the Automatic IP

Address box. That box will change to blue, to indicate that it has been selected.
4. Otherwise, to manually enter the IP settings for the gauge:
a. Touch the Manual IP Address box.

That box will change to blue, to indicate that it has been selected.
b. Individually touch each of the four fields that are separated by periods and use the
keypad on the right to enter the IP Address, Subnet mask and Default Gateway
settings for the gauge.
c. When done entering the values, touch the OK button on the keypad.
6.9.3 Configuring Analogue Outputs

Note: This function is accessible only on the GCI.
Four analogue outputs are available from a GCI or GCP. By default, they are assigned as
4-20mA current outputs representing the four measurement channels of a single gauge.
This function allows each of the outputs to be reconfigured according to requirements. For
each output you can:
• Assign it to any available gauge, a gauge function (temperature or window

contamination) or PID control.
• If a gauge is selected - assign it to any measurement channel of the gauge.
• Choose or manually set the low and high limits of the output.
• Choose the output type (current or voltage) and scaling.

This selection must be matched by the slide switches on the GCI/GCP pcb
(see Section 6.9.3.1 - Analogue Output Signal Selection).

3. Touch the Analogue Outputs icon to open the Analog Output Configuration
page (Figure 6-17).
Figure 6-17 Analog Output Configuration page
4. There are four available analogue outputs, numbered 1 through 4, on the left pane.
Select an output (e.g., Output 1).
5. Touch the Source box and select the source of the analog output - Disabled,
Measurement, Gauge Function or PID Control. (Selecting Disabled will disabled
the analog output.) PID Control is covered in Section 6.9.4 - PID Control.
6. Touch the Gauge box and select a gauge.
7. If Measurement or PID Control was selected for Source in step 5, touch the
Channel box and select the measurement channel to be assigned to the output.
PID Control is covered in Section 6.9.4 - PID Control.
8. If Gauge Function was selected for Source in step 5, the analog output will indicate
the value of the function selected by the Function box. Touch the Function box and
select Temperature or Window Contamination.

9. By default, the Limits box is set to the following:
• Fixed Limits – Allows you to set the low and high measurement values man-
ually. This option provides a voltage or current output that is directly propor-
tional to the analog output source.
Additionally, if Measurement or PID Control was selected for Source in step 5,

there are two other choices for Limits:
• Control Limits – Uses the Control Limit Low and Control Limit High val-
ues set in the product as the maximum and minimum current or voltage from
the analogue output.
• Alarm Limits – Uses the Alarm Limit Low and Alarm Limit High values set
in the product as the maximum and minimum current or voltage from the ana-
logue output.
10. If Fixed Limits was selected for Limits in step 9:
• Set High Limit to the measurement or function value corresponding to the

maximum voltage or current from the analogue output.
• Set Low Limit to the measurement or function value corresponding to the

maximum voltage or current from the analogue output.
11. Touch the Output Mode box and select the analogue output: 0-10 V or 4-20 ma.
12. The Output Value box continuously updates to show the current value of the ana-
logue output in V or mA. The Source Value box continuously updates to show the
current value of the source of the analog output.
(These boxes are shown in a lightly shaded gray background to indicate that they are
not touchable boxes.)
6.9.3.1 Analogue Output Signal Selection
The analogue output signal selection is done through the slide switches of the analogue output
board of the GCI/GCP. See Section 4.9.3.1 - Analogue Output Board.

6.9.4 PID Control
A PID control loop can be enabled on any of the measurement channels in the Series 9
gauge, with its output through one of the optional analogue outputs in the GCI or GCP.
6.9.4.1 PID Control Applications
The PID output provides a 4-20mA / 0-10V control signal to automatically adjust an actuator to
increase or decrease the parameter being measured, such as moisture in a drying or wetting
process.
Possible applications could include moisture control through drying or water addition, or per-
haps blending, such as gluten addition to flour to control protein levels through a suitable actu-
ator (Figure 6-18).
Figure 6-18 Controlling a Drying/Wetting/Blending process

An actuator for water addition could be a proportional valve like that shown in Figure 6-19,
using the PID 4-20mA control output to change the flow rate of water into a process to reach
the desired target level.
Figure 6-19 Controlling the flow rate of water
6.9.4.2 PID Algorithm
The Setpoint or Target is set through the Product recipe, and the error value
(target – measured) is fed into the PID algorithm, as depicted in the block diagram in
Figure 6-20.
Figure 6-20 PID Algorithm

6.9.4.3 GCI Configuration
The GCI allows analogue outputs to be assigned to control outputs.
3. Touch the Analogue Outputs icon to open the Analog Output Configuration
page (Figure 6-21).
4. Set the Source to PID Control.
5. Select the Gauge for the control loop.
6. Select the Channel for the control loop.
7. If the selected gauge channel supports PID Control, the PID Configuration button will
be enabled. See Section 6.9.4.5 - PID Configuration. (If the PID Configuration button
is disabled, the control loop is not available on that channel, and the analogue output
will not change value.)
8. The remainder of the boxes on the Analog Output Configuration page are used to con-
figure the analog output, i.e., allowing the output error to be scaled to the 0-10V or
4-20ma range. See Section 6.9.3 - Configuring Analogue Outputs.

6.9.4.4 PID Operation
Each PID loop uses the difference between the target value (set in the measurement recipe)
and the active measurement value. The error value (target – current) is passed to the PID con-
trol loop, which applies the PID terms to the error.
Each PID controller can be configured using the PID Configuration page (Figure 6-22),
accessed via the PID Configuration button on the Analog Output Configuration page
(Figure 6-21).
6.9.4.5 PID Configuration
The PID Configuration page (Figure 6-22) is available for each PID control loop to set the PID
terms, which can be adjusted empirically to provide stable control, i.e. for the moisture level to
reach the target quickly and to stay at that level with little deviation.
Figure 6-22 PID Configuration page
The following can be configured:
• Proportional Term, Integral Term and Derivative Term – These configure how
the PID controller will act upon the error value.
• Control Min and Max – These limits are used to overcome integral windup and
will cap the control values within the given limits. I.e. if an error is consistently in
one direction, the control output will continue to be corrected in the opposite direc-
tion. The limits ensure that the control cannot be saturated by a large integral
term, allowing the controller to recover more quickly once the control comes back
into range.
• Control Lag Time – The control lag is the process reaction time to the point mea-
sured, and can be set between 0 and 600 seconds. This will delay the effect of the
control by the given lag time.

The PID Configuration page also shows the following data:
• Input Error – The difference between the target and current measurement value.
• Output – The output from the PID controller (with the limits applied).

6.9.5 Configuring Digital Outputs
Eight digital outputs are available from a GCI or GCP. These can be configured to provide sta-
tus outputs corresponding to gauge measurement channels or gauge functions.
3. Touch the Digital Outputs icon to open the Digital Output Configuration page
(Figure 6-23).
switch
closed
switch
open
Figure 6-23 Digital Output Configuration page
4. There are eight available digital outputs, numbered 1 through 8, on the left pane.
A switch open/closed icon, indicating the state of the output, appears before the out-
put name. The icon is green if the switch is closed, red if the switch is open.
Select an output from the left pane (e.g., Output 1).
5. Touch the Source box and select the source of the digital output - Disabled, Mea-
surement Alarm, Communication Alarm, Gauge Alarm, Gauge Warning or
Gauge Function. (Selecting Disabled will disable the digital output.)

7. If Measurement Alarm was selected for Source in step 5, touch the Channel box
and select a measurement channel.
8. The digital output will indicate the state of the function selected in the Function box.
If Measurement Alarm was selected for Source in step 5, touch the Function box
and select a measurement alarm condition: High Alarm, Low Alarm or High/Low
Alarm.
If Gauge Alarm was selected for Source in step 5, touch the Function box and select
a gauge alarm condition: Any Alarm, Window Cont. (Contamination) Alarm, Tem-
perature Alarm or Air Flow Alarm.
If Gauge Warning was selected for Source in step 5, touch the Function box and
select a warning occurrence: Any Warning, Window Cont. (Contamination) Warning
or Temperature Warning.
If Gauge Function was selected for Source in step 5, touch the Function box and
select a function: Sampling In Progress, Sample Paused or Cooler Control.
9. Touch the State When Active box and select the state of the digital output when the
alarm/warning condition or function selected in step 8 is occurring or active – Open or
Closed.
10. Touch the State When Offline box and select the state of the digital output when the
alarm/warning condition or function selected in step 8 is not occurring or offline –
Open or Closed.
11. The Current State box continuously updates to show the current state of the digital
output – Open or Closed.
(This box is shown in a lightly shaded gray background to indicate that it is not a
touchable box.)

6.9.6 Configuring Digital Inputs
Eight digital inputs are available from a GCI or GCP. These can be associated with various
gauge functions, depending on the options fitted on the gauge.
3. Touch the Digital Inputs icon to open the Digital Input Configuration page
(Figure 6-24).
Figure 6-24 Digital Input Configuration page
4. There are eight available digital inputs, numbered 1 through 8, on the left pane.
A switch open/closed icon, indicating the state of the input, appears before the input
name. The icon is green if the switch is closed, red if the switch is open.
Select an input (e.g., Input 1).
5. Touch the Target Type box and select the type for the digital input - Disabled, Gauge
Function or GPIO (General-purpose input/output). (Selecting Disabled will disable
the digital input.)

7. If Gauge Function was selected in step 5, the following selections are available in the
SubType box: Start Sample (start collecting a sample), Sample Collect (continue
collecting a sample), Sample Pause (pause sample collection) and External Gating.
If GPIO was selected in step 5, there will be sixteen available GPIO sub inputs/outputs
for the SubType.
8. Touch the Mode box and select whether the input should be activated when it is open
or closed – Activate on Open or Activate on Closed.
9. The Input State box continuously updates to show the current state of the digital input
– Open or Closed.
(This box is shown in a lightly shaded gray background to indicate that it is not a
touchable box.)

6.9.7 Configuring Product Lines
This applies to Series 9 systems with multiple gauges.
The Product Lines feature allows gauges to be split into separate groups, referred to as
"lines", making them simpler to identify and manage. If multiple lines are defined, the Home
page will show each line as a grouped page, and the user will be able to scroll between lines.
2. Touch the Display Settings icon.
3. Touch the Configure Product Lines icon.
The Configure Product Lines page will appear (Figure 6-25).
Figure 6-25 Configure Product Lines page
By default, all gauges are included in the line named "Default". This line cannot be
renamed or deleted. The "Default" line is not a real product line, but acts as a place
holder for gauges that have not yet been assigned to a line.

– To add a new product line:
a. Touch the New button and enter a name for the line.
b. Assign one or more gauges to the line by touching the gauge buttons under
“Select Gauges”.
Those buttons will turn black when touched to indicate that they are selected.
– To rename a product line:
a. Select the line by touching its button.
b. Touch the Rename button and enter the new name for the line.
– To delete a product line:
a. Select the line by touching its button.
b. Touch the Delete button.
Note that there is no confirmation before the line is deleted.
6.9.7.1 Loading Products
When the Product Selection button is touched to bring up the Load Product page,
and multiple lines are configured, the user will be prompted to select a line. The selection dia-
log displays the names of the configured lines, except the “Default” line. Gauges belonging to
the “Default” line are listed individually.
The user may select a product line, or one of the unassigned gauges.
Selecting a gauge takes the user to the Product Load page for the gauge. When a line is
selected, the Load Product page for the line is displayed. This lists the products that are com-
mon to all gauges assigned to the line. Once a product is selected and the Load button is
pressed, that product will be sent to all gauges in that line.
Notes:
1. If the Product Selection button is touched and lines are configured, but not all
gauges are selected in those lines, the user will be presented with a list to select a line
or gauge.
2. If the Product Selection button is touched and no lines are configured except the
Default line, the user will be prompted to select a single gauge.
3. Product loads from the Configure Product page (accessed by touching the Configura-
tion button and then Configure Products) will still be performed on a single gauge.

CHAPTER
7
7 Calibration
7.1 Calibration Overview
All Series 9 gauges are configured and pre-calibrated during manufacture to suit the specific
applications for which they are supplied. Consequently, new gauges can normally be put into
service immediately, subject only to verifying the calibration.
The gauges should then be stable and provide consistently accurate measurements over long
periods. However, if you wish to check the stability of the gauge output at any time, this can be
done using the Auto Reference Standard or the Gauge Check function of the GCI
(see Section 7.2.5 - Checking Gauge Stability).
Calibration requirements of Series 9 gauges are limited to adjustment of the output using Trim
and Span values only.
Trim
The Trim value applies a positive or negative offset to the final output. It can be adjusted to
increase or decrease the gauge output to align with the local laboratory reference method val-
ues.
In most circumstances, this is sufficient calibration for a gauge measuring at a target value.
Even if the pre-calibrated Span is not optimum for the product over a wider measurement
range, making a Trim-only adjustment will produce high-accuracy results at or near the target
with minimum effort.
The default Trim value is 0.00. The graph shows the effect (y) on the gauge output of a
change in Trim value.
y
c = Trim x = Laboratory reference y = Gauge output
Series 9 - General: Calibration 7-1

Span
The Span value changes the slope of the gauge output: that is, the change in output for any
given change in absorption by the measured product. For some applications, Span adjustment
may be needed to align the gauge measurements with laboratory reference samples over a
range of values, as illustrated below. In such cases, it is necessary to perform a full-range cal-
ibration.
The default Span value is 1.00.
m = Slope of line x = Laboratory reference y = Gauge output
Example
The following example illustrates how the Span and Trim adjust the calibration.
The figure below shows 2 lines:
• The red line is the perfect calibration
• The blue line is the gauge data that was collected and plotted against the refer-
ence method.
The gauge is reading high at the low end, and low at the high end. Therefore, the
Span needs to be adjusted.
7-2 Series 9 - General: Calibration

Gauge data plotted
against reference
Perfect calibration
Afte
The Span changes the measurement sensitivity. The gauge calibration line is now at the same
sensitivity as the perfect calibration (same gradient).
Gauge calibration
line
Perfect calibration
The next step is to move the gauge calibration line down the Y-Axis so that the readings lie on
the perfect calibration line. This is done by adjusting the Trim.

Gauge calibration
line
Perfect calibration
Finally, the calibration data matches the perfect calibration line. The gauge is calibrated and
therefore, validation can now take place.
Gauge calibration
matches
Perfect calibration

7.1.1 When to Calibrate
When What you should do Notes
• After installing • Auto-reference This is essential. Do not omit.

a new gauge (see Section 7.2.3 -
Using Auto-Reference)
• Auto-trim Optional. Can make the fine

(see Section 7.2.1 - Trim adjustment easier to
Using Auto-Trim) perform, but not essential.
• Trim (see Section 7.2.2 - Essential. Ensures

Trim) measurements at/near target
are accurate.
• Full range calibration Necessary only if accurate

(see Section 7.2.4 - Per- measurements are required
forming Full-Range Cali- over a range of values.
bration)
• After changing • Auto-reference Essential.

source lamp or
filter wheel
motor
• On change of • Check trim against sam- Confidence check.

product ples of new product and
adjust if necessary
• Whenever • Stability check Confidence check.

check of long- (see Section 7.2.5 -
term accuracy Checking Gauge Stabil-
is required ity)

7.2 Calibration Procedures
7.2.1 Using Auto-Trim
Note: The Auto-Trim function is only available for the Current Product.
The GCI Auto-Trim function is intended as an initial method of adjusting the gauge to provide
approximately correct outputs at the target values. It is very quick and easy to use, and does
not require the preparation of special laboratory samples.
Auto-Trim should not be used in place of the Trim procedure (see Section 7.2.2 - Trim) where
accurate gauge readings are required.
The values obtained using Auto-Trim automatically update the current gauge products
(see Section 6.2 - About Products).
1. Touch the Configuration button, then touch Configure Products to

bring up the Configure Products page (Figure 7-1).
2. The Select Product table lists all available products, along with a description and
Product ID.
Select the current product from the list. This will cause the Auto Trim button to be
enabled.
3. Touch the Auto Trim button.
This will bring up the Auto Trim – Trend page (Figure 7-2), showing the gauge reading
and a Trend graph of the measurement.

Numeric button
Figure 7-2 Auto Trim – Trend page
4. Touch the Numeric button on the lower right side of the page to display the Auto Trim
– Statistics page (Figure 7-3). (When this button is touched, it will be replaced by the
Trend button, which, if touched, will re-display the Auto Trim – Trend page.)
Trend button
Figure 7-3 Auto Trim – Statistics page
5. Touch the Start Sample button.

6. The gauge will start sampling the product for 10 seconds. An indicator bar will appear,
showing the progress of sampling (Figure 7-4). While this is occurring, a Cancel Sam-
ple button is also visible, which, if touched, will abort the sampling process.
Sampling progress indicator
Figure 7-4 Sampling in progress
7. When sampling is completed, the final average and standard deviation (S.D.) of the
sampled values will remain on the screen (Figure 7-5). Enter the target value in the
Target box and touch the Apply button.
A Sample ID button will display the default Sample ID for the sample. This ID may be
changed by touching that button, and using the keypad to enter a different ID. Addi-
tionally, there is a Save Sample button for saving the sample average and standard
deviation values, along with the Sample ID.
Figure 7-5 Sampling completed

8. Touch the Apply button to apply the calculated trim automatically, and the trimmed
measurement will update on the screen.
7.2.2 Trim
The Trim function is used in calibration procedures to align the gauge measurements with val-
ues obtained using laboratory reference samples.
A manual Trim adjustment is conducted in two distinct phases:
• Obtaining the sample data on which the new trim value will be based.
• Calculating and applying the new Trim value to update the stored gauge products.
These are described below.
7.2.2.1 Obtaining Samples and Calibration
This process involves taking a number of gauge readings and corresponding laboratory refer-
ence samples with the product at or near the target values. Data from these samples can then
be used to determine the optimum gauge Span and Trim values.
Sample Collection Notes
• The gauge must be mounted 1m from the sampling point.
• Use the sampling function within the GCI or OT to collect a timed sample.
• During the gauge sampling period:
− Collect material from the top surface.
− Collect material from where the gauge has viewed.
− Collect multiple material samples.
• Use a sealable bag or container to store the sample.
− If using a bag, expel the air and consider double bagging.
• Reference the material as soon as possible.
− Mix the sample prior to referencing.
− Always run duplicate reference analysis to help reduce reference error.

Procedure
Note: This function uses the Sample function, and is accessible on both the GCI and the OT.
1. Touch the Sample button on the Home page to bring up the Sample page
for the relevant gauge.
This page shows the gauge reading and a Trend graph of the measurement
(Figure 7-6).
The Numeric button on this page, when touched, switches to the Sample – Statistics
page (Figure 7-7). This will cause a Trend button to appear in its place, which, if
touched, will re-display the Sample – Trend page.
Numeric button
Figure 7-6 Sample – Trend page
2. Enter the Sample Time and Sample Delay values (in seconds):
• Sample Time is the period over which measurements will be recorded and aver-
aged. Set this to the time it takes to walk from the GCI or OT to the sampling loca-
tion by the Series 9 gauge.
• Sample Delay sets a delay between touching the start button and the start of
sampling. Set this to the time it takes to collect sufficient material to allow multiple
replicate reference tests to be carried out.

3. View the Trend graph to ensure that the process is steady. When the production pro-
cess is stable and the constituents to be calibrated are approximately at the target lev-
els, touch the Start Sample button to start sampling.
If a delay has been set, the delay time will count down to 0 before sampling starts.
4. The screen will switch to the Sample – Statistics page (Figure 7-7), and the gauge will
start sampling the product for as long as the sample time. An indicator bar will appear,
showing the progress of sampling. While this is occurring, a Cancel Sample button is
also visible, which, if touched, will abort the sampling process.
Trend button
Figure 7-7 Sample – Statistics page
5. Throughout the sample period, collect the product samples from the process line and
place them in sealed containers for laboratory analysis.
For meaningful results, the product samples must be taken from just after the gauge
location, and over the same time periods as the gauge records the samples.
6. Sampling stops automatically after the Sample Time, and the average and standard
deviations (S.D.) of the measurement are displayed (Figure 7-8).

Figure 7-8 Sample page, sampling completed
7. The Sample ID button shows the default Sample ID that has been assigned to that
sample. That ID can be changed, if needed, by touching that button and entering a
new ID.
The displayed values can be saved for comparison with the laboratory-determined
values by touching the Save Sample button. If the sample is saved, then it will be
added into the Calibration Tool for the active Product. (Touching the Discard Sample
button will cause those values to be discarded. If the sample is discarded, the Sample
ID will not increment.)
When collecting a gauge sample using the Sample Function, the Span and Trim val-
ues being used at the time are recorded. The Calibration Tool uses the stored Span
and Trim values to re-calculate each data point to allow all sample data with reference
values collected for the selected Product to be included in the calibration calculation.
8. Repeat the procedure multiple times (typically 10) to obtain a representative collection
of gauge readings and corresponding reference samples.
9. Process the reference samples according to your established laboratory method to

obtain the reference values.
10. You can use the embedded calibration tools to adjust the gauge reading to your labo-
ratory reference method.
11. To use the Calibration Tool, you must login as either the Supervisor or Engineer:
• There must be sample data collected and saved to the associated Product.
• A minimum of 5 data points – with reference values – are required for the Cal-
ibration Tool to calculate new calibration settings.
12. Touch the Configuration button, then touch Configure Products.

13. Select the required product, then press Calibrate (Figure 7-9).
Figure 7-9 Press Calibrate button
14. Enter the laboratory reference value into the Lab column:
a. Select the corresponding cell - the box will highlight in red (Figure 7-10).
Figure 7-10 Lab cell highlighted in red when selected

b. Select the cell again and enter the lab value (Figure 7-11).
Figure 7-11 Enter lab value
c. Repeat for the other component measurements.
15. As soon as 5 reference values have been entered into the table, the Calibration Tool
will fill in the Adjusted column with the data re-calculated to the suggested calibration
settings (Figure 7-12).
Table Graph –
Graph –
button calibrated
uncalibrated
button
button
Figure 7-12 Adjusted column shows re-calculated data

16. Three new buttons will appear next to the Table button when 5 or more reference val-
ues have been entered (Figure 7-12):
• Graph - uncalibrated
• Graph - calibrated (with new Span & Trim settings)
• Apply - allows the new settings to be applied to the associated product
17. Press the Graph - uncalibrated button to view the data all normalised
to Span = 1, Trim = 0 (Figure 7-13).
The best-fit line through the data shows the type of calibration fit required. If the line is
parallel to the perfect calibration line, then this represents a 'Trim Only' calibration. If
the best-fit line shows a slope change to the perfect calibration line, this represents a
full 'Span & Trim' calibration.
Suggestion box
Figure 7-13 Uncalibrated Graph with Span = 1, Trim = 0
The Suggestion box notifies what type of calibration change is required. It will also
show instructions if insufficient data is available.

18. Press the Graph - calibrated button to view the data with the new cali-
bration settings applied (Figure 7-14).
Figure 7-14 Calibrated Graph
19. When satisfied with the suggested calibration settings, press Apply and then press
Ok (Figure 7-15). This will download the new calibration settings to the selected prod-
uct. If this is the active product, the new settings will also be downloaded into the
gauge.
Figure 7-15 Press Ok to apply new calibration settings

20. If there are any statistical outlier data points, these will be highlighted in two ways:
• Table view – the associated Adjusted cell will be filled in orange

(Figure 7-16)
Figure 7-16 Outlier cell is filled in orange
• Graph view – the data point will be shown in red (Figure 7-17)
Figure 7-17 Outlier data point is shown in red
The Suggestion box will also indicate that an outlier is present in the given suggested
calibration change comment.

• The outlier data point will be included in the calibration calculation unless the
associated Ignore cell is crossed (Figure 7-18).
Figure 7-18 Ignore cell is crossed
With the outlier ignored, the Suggestion box returns to a standard calibration change
recommendation.

7.2.2.2 Calculating and Applying Trim
This procedure saves a Trim adjustment in a product, based on values obtained using the
Sample function.
1. Obtain the appropriate sample data as described above.
2. Touch the Configuration button, then touch Configure Products to

bring up the Configure Products page (Figure 7-19).
3. Select the product from the table, then touch the Edit button to edit the product
(Figure 7-20).

Figure 7-20 Enter new Trim value in product
4. Calculate the new Trim value:
T1 = T0 + (LabM - GM)
where:
T1 = New Trim value
T0 = Current Trim value
LabM = Average of laboratory reference values
GM = Average of gauge sample measurements
5. Enter the new Trim value in the Trim box.
6. Touch the Save Changes button to save the Trim value in the product. (If the Cancel
Changes button is touched, this will cause that value to be discarded.)

7.2.3 Using Auto-Reference
7.2.3.1 Performing an Auto-Reference
Note: This function is accessible only to an Engineer on both the GCI and OT.
1. Obtain the Auto Reference Standard that was supplied for use with the relevant
gauge.
Do not use any other ARS, as the characteristics may be slightly different and this
will affect the accuracy of the reference procedure.
2. Place the ARS in the same location as the gauge and allow at least 1 hour for it to
warm or cool to the ambient temperature.
3. Fit the ARS to the gauge (see Section 7.2.3.3 - Fitting the ARS).
4. Touch the Configuration button, and then touch Gauge Diag-

nostics on the Settings page.
5. Touch the Check button to bring up the Gauge/Reference Check page

(Figure 7-21).
Figure 7-21 Gauge/Reference Check page
6. Touch the Re-Reference button to start the process.
A ten-second countdown is displayed while the sampling is in progress, followed by a

success or fail message.

7.2.3.2 Auto-Reference Failed
If a fail message is displayed, it indicates that the correction required is beyond the capability
of the normal Auto-Reference process.
Note: The number in the message has no operational significance, but may be required by
NDC to assist with diagnosis of the problem. Please make a note of the number.
Possible causes are:
• Gauge window contaminated, or Auto Reference Standard window contami-

nated externally.
In this case, clean the window(s) and repeat the Auto-Reference procedure.
• Auto Reference Standard not fitted correctly, or not allowed to equalise to
the ambient temperature.
Check, and then repeat the auto-reference.

• Auto Reference Standard contaminated internally.
This can happen as a result of poor storage conditions, resulting in the formation
of water vapour within the unit. In this case, return the Auto Reference Standard to
NDC.
• Gauge faulty.
If the error is not caused by contamination as described, it is possible that the

gauge is faulty. In this case, contact NDC.
7.2.3.3 Fitting the ARS
The Auto Reference Standard (ARS) is an essential system accessory for checking and cor-
recting aspects of gauge accuracy. The external Auto-Reference procedure cannot be per-
formed without it.
The ARS target is housed in a robust plastic enclosure, and can be simply mounted onto the
Air Purge Window using built-in magnets.
If a standard air purge window is fitted, it is not necessary to remove it in order to fit the ARS.
Attach the ARS to the gauge as follows:
1. Shut off the air supply to the air purge assembly, where fitted.
2. Insert the ARS into the window bezel as far as it will go, until it snaps in place.

ARS ARS mounted to gauge

7.2.4 Performing Full-Range Calibration
In most circumstances, adjustment of Trim (see Section 7.2.2 - Trim) is sufficient to provide
accurate measurements around a target value.
Where the application requires measurement across a range of values, however, it may be
necessary to perform a full-range calibration involving the determination of optimum values for
both Trim and Span.
This is not generally recommended for routine calibration because it is time consuming and
requires product to be made with a wide variation in the levels of the measurement parame-
ters.
Note: The easiest way to do a full-range calibration is to use the Calibration Tool within the
GCI (see Section 7.2.2.1 - Obtaining Samples and Calibration).
The general method described here can be used as an alternative.
1. To provide a starting point for the full-range calibration, set the gauge Trim using the
Auto-Trim procedure (see Section 7.2.1 - Using Auto-Trim).
2. Obtain gauge and laboratory sample data over the required measurement range using
the Sample function (see Section 7.2.2.1 - Obtaining Samples and Calibration).
The accuracy of the predicted Span value depends on the measurement range over
which data is collected, and the number of samples taken. As a guide, the range
should cover at least 70% to 130% of the target value, with a minimum of ten samples.
3. Perform a linear regression (least squares or orthogonal) using the laboratory refer-
ence value as the independent variable (x) and the gauge output as the dependent
variable (y).
y
y
m=
x
x

The equation of the best-fit line is given by:
y = mx + c
where
m is the slope of the best-fit line
c is the y intercept of the best-fit line
4. Calculate the new Span value S1 from:
S1 = S0 / m
where S0 is the original Span (as used during data collection).
5. Calculate the new Trim, T1 from:
T1 = (T0 - c) / m
where T0 is the original Trim value (as used during data collection).
6. Enter the calculated values of Trim and Span, using the GCI Edit Product function
(see Section 6.4.2 - Editing an Existing Product).
7.2.5 Checking Gauge Stability

Series 9 gauges are self-compensating for factors such as aging of their internal source lamp,
and are substantially unaffected by ambient light or environmental temperature changes within
their operating temperature range. Consequently, the gauges should be stable and provide
consistent measurements over long periods of operation.
If you wish to check this for any reason, it can be done using either of the methods described
below.
Note: By far the most common reason for drift in the gauge output is window contamination.
It is vital, therefore, that the window is kept clean during normal operation, either by
regular cleaning or by fitting an Air Purge window. The window should be cleaned
before any reference check is performed.
Checking the Gauge Output with the ARS
To do this, you will need a product (see Section 6.2 - About Products) with a Span value of
1.00 and a Trim value of 0.00.
1. If necessary, create a new product (see Section 6.4.1 - Creating a New Product) with
a Span value of 1.00 and a Trim value of 0.00, and save it with a meaningful name
such as Stability Check.
2. Load the product to the gauge to be tested.
3. Fit the ARS to the gauge (see Section 7.2.3.3 - Fitting the ARS).
4. Check the gauge outputs on the Home page and record for future reference.
5. Remove the ARS and load the normal operating product.

6. Repeat this procedure at intervals and check that the gauge output remains consistent
over time.
Using the Gauge Check Function
Note: This function is accessible only to a Supervisor or Engineer on both the GCI and OT.
This function can be used without loading a special product. It checks the gauge output
against the ARS and provides a date- and time-stamped percentage reading, which rep-
resents the deviation from ideal.
It is important to understand that this is a very sensitive check, and that some deviation from
0% is normal. As an indication, a reading of 100% is equivalent to the threshold for failure of
the Auto-reference procedure (see Section 7.2.3 - Using Auto-Reference). Anything below
30% is insignificant for all practical purposes.
1. Fit the Auto Reference Standard (see Section 7.2.3.3 - Fitting the ARS) to the gauge.
2. Touch the Configuration button, and then touch Gauge Diag-

nostics on the Settings page.
3. Touch the Check button to bring up the Gauge/Reference Check page

(Figure 7-21).
4. Touch the Gauge Check button to start the check.
The screen will show a 10-second countdown and then display a table showing the
result of the gauge check (and references), together with previous results
(Figure 7-22).
The Details column provides an indication of how good the check or reference was
with a traffic light system (green, yellow, red) to give a quick indication of good (<3%),
marginal (3 to 5%), or bad results (>5%).

Figure 7-22 Gauge/Reference Check results
5. Exit from the results page and remove the ARS from the gauge.

CHAPTER
8
8 Maintenance and Spares
This chapter covers general cleaning of Series 9 components, and corrective maintenance to
the level of the parts designated as customer replaceable items.
8.1 Warnings and Cautions

When carrying out any maintenance on the system, observe the following to avoid injury to
personnel and damage to the equipment.
BATTERY WARNING
There is a rechargeable PCB-mounted battery in the Series 9 sensor – NO attempt

should be made by the user to replace it. If there are issues regarding this, please con-
sult NDC or their representative.
• If the gauge has been operating in very high temperature environment, allow ade-
quate time for it to cool before handling.
• Compressed air can be dangerous. Isolate the Air Purge window compressed air sup-
ply before working on a gauge.
• Do not power up the gauge when the case is open. The filter wheel rotates at a very
high speed, and could cause injury.
• Gauge maintenance must be carried out in a clean room away from the working area
of the equipment.
• While the gauge case is open, take care not to touch any optical surfaces.
• When working on any system components, observe standard anti-static precautions.
8.2 Cleaning
External surfaces of gauges and other system components should be cleaned periodically
with a damp non-abrasive cloth only.
Keep cables and connectors free from contaminants that could cause chemical damage.
Clean gauge windows as described below.
Series 9 - General: Maintenance and Spares 8-1

Caution: If solvents are needed to remove contamination, it is essential to consult the Cus-
tomer Care Department of NDC or their agent first, giving precise details of the
solvent.
8.2.1 Cleaning Gauge Windows

Clean the gauge window using a soft lint-free cloth.
Where necessary, use warm water and a mild detergent. Do not use abrasive cleaners of
any kind.
If a solvent is needed to remove contaminants, contact NDC or their agents first.
8.3 Replacing the Gauge Source Lamp Assembly

To replace the Source Lamp Assembly:
1. Remove power from the gauging system.
2. Disconnect the services cable from the sensor.
3. Using a 4 mm Allen key, undo the 4 fixings screws within the corners of the sensor lid
and carefully slide the chassis out from the enclosure.
Slide chassis out from enclosure
4. Place the chassis facing downwards on a flat, clean surface.
8-2 Series 9 - General: Maintenance and Spares

5. Locate the lamp, as indicated in the figure below.
Lamp
6. Unplug the two lamp assembly leads.
7. Undo the two lamp fixing screws with a 2.5mm Allen key, and withdraw the lamp
assembly from its mounting.
8. Fit the new lamp (part number 120/16107-01SA) and reassemble the sensor following
the reverse of this procedure. Take care not to touch the lamp glass as this may
cause lamp failure.
If accidental contact is made, clean the glass with isopropyl alcohol (IPA).
9. Switch the gauge on and allow 2 hours for it to reach full operating temperature, then
auto-reference the gauge (see Section 7.2.3 - Using Auto-Reference).
8.4 Replacing the Filter Wheel Motor

To replace the filter wheel motor:
and carefully slide the chassis out from the enclosure. See figure in step 3 of
Section 8.3 - Replacing the Gauge Source Lamp Assembly.

5. Locate the filter wheel motor (1), as indicated in the figure below.
(3) Motherboard PCB

(1) Filter wheel motor
(4) Vibration PCB

(2) Fixing screws
6. Unplug the filter wheel motor ribbon cable connector from the motherboard PCB (3).
7. Unplug the vibration PCB (4) ribbon cable connector.
8. Undo the filter wheel motor assembly fixings screws (2) with a 4 mm Allen key
9. Lift the filter wheel assembly away from the Chassis. Do not touch the optical
surfaces of the filter wheel.
If accidental contact is made, clean the optical surfaces with isopropyl alcohol (IPA).
10. Note the orientation of the filter wheel, with the bush containing the grub screw
towards the end of the motor shaft.
11. Loosen the grub screw and carefully withdraw the filter wheel from the motor shaft.
If the filter wheel does not come off easily, do not attempt to pull it off as this
may damage the motor bearings. Instead, grip the wheel by its edges and use a
small Allen key or similar tool to push the motor spindle out from the wheel.

12. Remove the 3 x motor fixing screws using a 1.5 mm Allen key, as shown in the figure
below.
Filter wheel motor
Motor fixing screws
13. If the instrument is within the warranty period, return the faulty motor to NDC for
replacement. If not, discard the motor.
14. Fit the filter wheel to the new motor (part number MO/0387-06).
If the wheel is a tight fit, do not attempt to push it on while holding the motor. Place the
back end of the motor shaft against a hard surface and then push the filter wheel on
as far as it will go.
15. Tighten the filter wheel grub screw.
16. Fit the motor assembly, and reassemble the sensor, following the reverse of the previ-
ous steps.

8.5 Replacing the Referencing Motor
To replace the referencing motor:
and carefully slide the chassis out from the enclosure. See figure in step 3 of
Section 8.3 - Replacing the Gauge Source Lamp Assembly.
5. Locate the referencing motor, as indicated in the figure below.
Referencing motor assembly

Collecting mirror

6. Remove the collecting mirror by removing the 3 x M4 screws (item 17 below) with a
3 mm Allen key, then carefully lift and store it away.
Reference paddle
7. Carefully unplug the motor lead, remove the two pozi drive screws securing the refer-
ence motor clamp (8,10,21) and lift away the motor and reference paddle (5).
8. Remove the reference paddle from the motor shaft by undoing the grub screw and
sliding it off the shaft.
9. Fit the reference paddle to the new motor, by sliding along the motor shaft until it bot-
toms out and tightening the grub screw.
10. Reassemble the parts, following the reverse of the previous steps.

CHAPTER
9
9 System Options
The options described in this section apply to some or all of the gauges and applications of the
Series 9 system covered by this manual.
9.1 Internal Gating Option

This option enables the gauge to make reliable measurements of discontinuous products by
switching the infra-red measurement system on only when there is product in the beam-patch
area. It operates by using two infrared sensors located within the gauge to detect changes in
the distance between the gauge window and the viewed surface. If the distance is greater than
a defined threshold - indicating that there is no product in the beam patch - the gauge is gated
off.
The option is available with small and large beam patch, in stainless steel versions of the
gauge only.
The gauge should be positioned as shown below, and installed in accordance with the installa-
tion instructions (see Section 4.7 - Installing the Gauge).
The gating function can only operate correctly with a solid background (i.e. a product moving
on a solid belt or with a background target).
In all cases, it is important that no metallic or reflecting surfaces are present within 20mm of
the visible gauge patch at all distances, this applies even when the product is absent.
A E
C D
Figure 9-1 Gating function
Series 9 - General: System Options 9-1

Small beam patch Large beam patch
A Nominal gate distance 140mm ±1mm 250mm ±5mm
B Mean height of product
C Minimum product size 30mm 85mm
D Minimum product separation 25mm 85mm
E Gauge window centre line
F Gauge window
Note: If the product is changed after gauge installation to one of significantly different thick-
ness, the gating operation may become unreliable. In this case, the gauge should be
repositioned to correct the pass height, as above, and the gating should then be reca-
librated.
9.1.1 Gauge Mounting Information
The product flow direction

must be across the gauge
as shown, in either
direction
Figure 9-2 Product flow direction
9-2 Series 9 - General: System Options

Figure 9-3 Mounting the gauge
9.1.2 Gating Setup

To ensure reliable operation for any particular product, the gating sensors must be calibrated
for product thickness, using the GCI.
1. Log in as a Supervisor or Engineer.
3. Engineer only: Touch the Hardware Settings icon.
4. Touch the Gauge Settings icon.

This will bring up the Gauge Settings page
5. Select Height from the left pane for the gauge of interest (Figure 9-4).

Figure 9-4 Select Height from Gauge Settings page
6. Select Height Gating (Figure 9-5).
Figure 9-5 Select Height Gating from Gauge Settings page

7. Ensure that there is nothing on the belt or conveyor, and press Continue (Figure 9-6).
Figure 9-6 Press Continue
8. Place the minimum height product on the belt/conveyor with the beam patch aligned
roughly in the centre, and press Continue (Figure 9-7).

9. If successful, press Continue (Figure 9-8).

9.2 Temperature Measurement Option
The temperature measurement option provides the ability to display the temperature of the
product on one channel of the OT and GCI. It uses an externally mounted, self-contained IR
temperature sensor in an IP65 sealed housing, that is connected via a 20 m cable (total length
from gauge to temperature sensor) to the Series 9 gauge housing (Figure 9-9).
Temperature
Sensor
Housing
Air purge
inlet
Figure 9-9 Temperature sensor housing
The temperature sensor can operate in the range 0oC -120oC. It delivers real-time measure-
ment of product temperature in a different location to the gauge's NIR measurement(s), The
measurement signal is treated like the other gauge measurement signals, and is output via the
network or, where fitted, analogue output arrangements.

Temperature
Sensor
Window,
pointing at the
product
Temperature Sensor
Connector to Gauge
Figure 9-10 Temperature sensor connector and window
The temperature sensor can be fitted to the lid of the Series 9 gauge, as shown in Figure 9-9
and Figure 9-10, using the supplied screws, or it can be positioned remotely, limited by the 20
meter cable.
Temperature Sensor Air Purge
The temperature sensor is surrounded by an air purge assembly. This reduces contamination
of the sensor window, and improves measurement stability by keeping the sensor at a con-
stant temperature.
Installation
There are no additional installation requirements, other than the connection of an air supply to
the sensor air purge assembly. The air supply connecting point is located on the underside of
the gauge, and is made through a quick release fitting, using a 6mm outside diameter tube to
a regulated filtered air supply that is dry and clean (oil and dust-free).
• Air pressure = < 0.5 bar
• Air volume = ca. 1 m³/h
Calibration of Temperature Output
The temperature output can be calibrated via the Analog Output Configuration page on the
GCI (Figure 9-11).

To bring up this page:
1. Log in as an Engineer.
4. Touch the Analogue Outputs icon.
5. Select an output from the left pane (e.g., Output 3).
6. Set the Source to Gauge Function.
7. Set the Function to Temperature.
8. The temperature output is calibrated via the High Limit, Low Limit and Output Mode
fields.
9. The Output Value field shows the current value of the analogue output, and the
Source Value shows the temperature value.
Temperature Measurements and Emissivity
The temperature measurements and product emissivity are accessible through the Gauge
Settings page on the GCI (Figure 9-12).

Figure 9-12 Gauge Settings – Temperature page
5. Select Temperature from the left pane.
6. The Temperature field shows the measured temperature of the product.
7. The Sensor Temperature field shows the sensor body temperature.
8. The default emissivity factor is 95%, which is suitable for measuring the temperature
of most materials.
If the measured product materials has a significantly different emissivity, enter the
appropriate value in the Emissivity field.

9.3 Vortex Cooling Option
This cooling option uses a vortex unit to create a cold air flow from a compressed-air supply,
which is then circulated through the gauge interior.
The option comprises the vortex unit, factory-fitted to the gauge, and a filter module to provide
clean and dry air (Figure 9-13).
Figure 9-13 Vortex cooling option

Installation
WARNING: COMPRESSED AIR CAN BE DANGEROUS.

Do not operate the cooler at pressures above 10.3 Bar (150psi).
Do not operate with input air above 43oC (110oF)
Use the following assembly drawing (Figure 9-14) to connect the air set.
Figure 9-14 Vortex cooling assembly drawing
Connect a 7 bar supply to the filter regulator unit using a ½ inch diameter tube.
1. Set the air purge valve to the fully-open position.
2. Adjust the air pressure control for a reading on the pressure gauge of:
• 4 Bar, (60psi) for ambient temp. 45oC to 60oC
• 5.5 Bar, (80psi) for ambient temp. 60oC to 70oC

9.3.1 Vortex Cooler Control
It is possible to automatically control the Series 9 Vortex cooler option using an external sole-
noid to keep the internal temperature of the gauge at 35C. The advantage of this is that it
saves compressed air and prevents the gauge from being over-cooled.
The solenoid is driven by one of the digital outputs (optional) in the GCI, which is configured
through the Digital Output Configuration page, shown in Figure 9-15 for Output1.
Figure 9-15 Digital Output Configuration page
1. Log in as an Engineer.
4. Touch the Digital Outputs icon.
5. Select an output from the left pane (e.g., Output 1).
6. Set the Source to Gauge Function.
7. Set the Function to Cooler Control.
8. The States refer to the actual relay contacts being either open or closed circuit.

9.3.1.1 Electrical Connections
The air solenoid electrical connections can be made as follows, assuming the solenoid control
voltage is 24vdc, using one of the relay contacts, shown in Figure 9-16 for Output 1.
Note: The output is protected by a fuse and the solenoid must not consume more than
1Amp at 24vdc.
The solenoid must also be fitted with a protective the fly back diode, as shown in Figure 9-16.

Figure 9-16 Solenoid fitted with fly back diode

9.4 Pressure Sense Option
The Series 9 gauge uses an Air Purge Window (APW) to keep the window surface clean,
which is essential in dirty environments, as contamination on the window will affect the accu-
racy of the measurement.
The Air purge window relies on a good flow of air to be effective, requiring at least 20L minute.
The pressure sense option is a system that incorporates a calibrated restrictor and pressure
sensor (0 to 4 Bar) in the gauge to monitor the air pressure, and has alarm indicators if the
pressure/flow drops below or exceeds configurable levels.
9.4.1 Installation
The Series 9 sensor includes two ports with quick release fittings for 6mm diameter tubing, as
per Figure 9-17:
• The upper port marked IN should be connected to a regulated clean air supply
that can deliver 2bar and 20 L/min., measured close to the inlet port.
• The lower port marked OUT should be connected to the APW.
Figure 9-17 IN and OUT ports

9.4.2 GCI Air Pressure Settings and Alarms
Using the GCI:

This will bring up the Gauge Settings page.
5. Select Air Pressure from the left pane to show the Air Pressure settings screen
(Figure 9-18).
Figure 9-18 Gauge Settings – Air Pressure page
6. The Active value shows the actual pressure being measured.
Note that the internal air restrictor has been factory set, so that with 1.5 Bar at the
inlet, the flow rate to the Air Purge Window will be 20L/min.
The pressure measurement is linear, but is not scaled to any particular pressure units.
However, it will display an active value of 0.85 with 1.5 Bar inlet pressure, so the inlet
pressure should be adjusted at the regulator to show a level of 0.85.

7. The High and Low thresholds are the alarm level settings.
The Low threshold is set to be 0.80, so any air pressure/flow rate drop will result in a
Low Air Flow alarm, as shown in Figure 9-19.
Figure 9-19 Low air flow alarm

9.5 Common Gauge Connector (CGC) Cable Option
For scanning applications, the Series 9 gauge can be supplied with a Common Gauge Con-
nector (Figure 9-20) as an option to interface with NDC's High Flex robotic cable
105/14876-01SA (Figure 9-21).
Figure 9-20 Common Gauge Connector
Figure 9-21 Cable 105/14876-01SA

The tail end of the cable can be fitted into one of the Series 9 peripherals through the large
cable gland (Figure 9-22).
Figure 9-22 Connect cable to large cable gland on Series 9 peripheral
The wire and terminal designations into the Series 9 peripheral are shown in the schematic
(Figure 9-23) and photo (Figure 9-24) below.
Figure 9-23 Wiring schematic for connecting to Series 9 peripheral

Figure 9-24 Terminal designations for connecting to Series 9 peripheral

9.6 BSDU (Batch Sample Display Unit) Operation on
Series 9 GCIs
The BSDU option provides a report of sample data via a TCP/IP port when sample data is col-
lected.
9.6.1 Enabling BSDU Operation

The BSDU feature is automatically enabled if the device is configured as a SENCON OEM
device. The BSDU option can also be enabled on any device using GaugeToolsXL (with a suit-
able license). To do this, drag the GCI onto the gauge utility tool and select the Features tab.
The BSDU option can then be enabled or disabled by checking or unchecking the Enable
BSDU sampling option box, and then pressing the Apply button (Figure 9-25).
Figure 9-25 Enabling/Disabling the BSDU option in GaugeToolsXL
After enabling or disabling the setting, make sure that the unit is restarted by pressing the
Reboot button, so the change can take effect.

9.6.2 IO Configuration
The GCI will need to have a digital input card fitted. Then, log in as an Engineer and navigate
to the Digital Input Configuration page:
3. Touch the Digital Inputs icon to open the Digital Input Configuration page (Fig-
ure 9-26).
Figure 9-26 Digital Input Configuration page
4. Select an input from the left pane.
5. To set the input to provide BSDU functionality, set the Target Type to BSDU and then
select the correct SubType.
Two SubType options are available:
1. Sample Collect
This input will control the duration of the sample. When the input is active, the
sample data will be collected. I.e. the sample will start when the input is first acti-
vated and finish when the input is deactivated, and the report will then be gener-
ated.

2. Sample Pause
This input allows data within a sample period to be ignored. While this input is
active, data will not be added to the sample data. This will also affect the utilisation
percentage e.g. if this input is active for 10% of a sample period, the utilisation fig-
ure will drop to 90% (i.e. 90% of the sample period had valid data).
9.6.3 Diagnostics and Settings

If the BSDU is correctly enabled, an additional group, BSDU will be displayed on the Local
Settings page (Figure 9-27). If this is not available, see Section 9.6.1 - Enabling BSDU Opera-
tion.
2. Open the Local Settings page by touching the icon(s) below.
Supervisor
Local Settings
Engineer
Display Settings > Local Settings
Figure 9-27 Local Settings page - BSDU group
This page displays the current state – “Ready”, “Sampling” or “Paused”, and the duration and
utilisation of the active sample (utilisation is the percentage of the time the sample has not
been paused while active).

The user can also see and change the next batch ID. This batch ID will be auto-incremented
on each batch event.
9.6.4 Report Output

The BSDU report is generated on TCP port 25333. The GCI listens on port 25333 for connec-
tions and will then service all live connections with the same data.
To view the report data, use a terminal program such as puTTy (Figure 9-28):
1. Type in the IP address of the GCI – enter your GCI's IP address here.
2. Type in the BSDU port number (25333).
3. For PuTTy, make sure that the Raw connection type is selected.
Figure 9-28 PuTTy terminal program
When the terminal connects, you should see a header message in the form (Figure 9-29):
Figure 9-29 Header

Each time a report is created (on the completion of each batch), a report will be generated that
will contain a header section, and then a section for each gauge connected to the GCI.
The header section will contain:
• Batch number
• Duration
• Utilisation
Each gauge section will contain:
• Gauge name
• Active recipe name
• A report line for each channel. Each line will contain the channel name, the sam-
ple average and the sample SD in brackets.
An example of a report is given below (Figure 9-30).
Figure 9-30 Sample Report

CHAPTER
10
10 Troubleshooting
10.1 System Error Messages
Series 9 gauges have built-in diagnostics to monitor certain key operating parameters and to
provide appropriate error messages on the GCI and OT. The following table provides brief
explanations of the messages together with the recommended action. Some of the diagnostic
parameters listed in the table are shown on the Gauge Diagnostics screen (see Section 5.5.1
- Viewing Diagnostic Information) - if this is the case, those parameters are marked “Yes” in
the “Shown on Gauge Diag. screen” column of the table.
Note: There may be more than one error condition at a time. The errors are priority-rated,
and the highest priority one is displayed in the Gauge Status box, on the bottom right
corner of the screen (see Section 5.1.4 - Responding to Error Messages).
In the event of an error message, check the listed possible causes and take the appropriate
remedial actions. If these do not clear the error, please contact NDC for advice.
Diagnostic Parameter
Shown
Diag. parameter on
Error
and units Gauge Fault State Recommended Action
message
Diag.
screen
Lamp voltage Lamp voltage (V) Yes VL < 0.95 X nominal If lamp current is also low,
low error (4.8V or 4V) lamp power supply failure:
change mother PCB.
If lamp current is high, lamp
failure: change lamp.
(see Section 8.3 - Replacing

the Gauge Source Lamp
Assembly)
Lamp voltage Lamp voltage (V) Yes VL > 1.05 X nominal Lamp power supply failure:
high error (4.8V or 4V) change mother PCB.
Series 9 - General: Troubleshooting 10-1

Shown
Diag. parameter on
Error
message
Diag.
screen
Lamp current Lamp current (A) Yes IL < 0.9 X nominal If lamp voltage is also low,
low error (2.9A or 2.7A) lamp power supply failure:
change mother PCB.
If lamp voltage is normal,
lamp failure: change lamp.

Assembly)
Lamp current Lamp current (A) Yes IL > 1.1 X nominal If lamp voltage is also high,
high error (2.9A or 2.7A) lamp power supply failure:
change mother PCB, also
lamp.
If lamp voltage is not high,
lamp failure: change lamp.

Assembly)
Lamp hours Lamp running Yes lamp run hours > 43800 Warning, lamp requires
exceeded time (days/hours) replacement: change lamp

Assembly)
FW motor FW motor running Yes motor run hours > 43800 Warning, filter motor requires
hours hours (days/ replacement: change motor
exceeded hours)
the Filter Wheel Motor)
N/A FW target motor Yes N/A N/A

speed (rpm)
FW motor FW motor speed Yes Software unable to Motor control failure. Try
failure (rpm) control motor speed to resetting gauge, if fault per-
target to within 10rpm sists: change motor.

10-2 Series 9 - General: Troubleshooting

Shown
Diag. parameter on
Error
message
Diag.
screen
Excessive FW motor Yes Excessive vibration Warning, vibration detected:

vibration vibration (raw) detected at motor mount change motor
>100
Window Window Yes WC value > 0.5: WC value > 0.5: window
contaminated contamination Warning needs cleaning
level (calibrated WC value > 1: Fault WC value > 1: window
units 0.0 to 1.0) cleaning fault
(see Section 8.2.1 - Cleaning

Gauge Windows)
Gauge Internal Yes <0°C Check ambient temperature

temperature is Temperature (°C) (0 to 50°C)
too low
Gauge Internal Yes >70°C Check ambient temperature

too high
Gauge Internal Yes >75°C Check ambient temperature

too high and
the gauge
should
shutdown
N/A Time since last Yes N/A N/A

reboot (days/
hours)
N/A Firmware version Yes N/A N/A
Excessive Installation No Installation vibration, Excessive Installation vibra-

Installation vibration on measured with the filter tion: check mounting
vibration demand (raw) wheel not running >100
Window Window No Raw window Check window contamination

contamination contamination contamination level <200 board connections
board fault board connected
(YES or NO)

Shown
Diag. parameter on
Error
message
Diag.
screen
Gauge power +24V power No +24V rail < +20V Gauge power low: check
supply fault supply (Voltage) 24vdc connection
mother PCB +12V mother PCB No ±12V mother PCB >±5% Mother PCB fault: change
12V power supply (Voltage) error mother PCB
fault
signal PCB +12V signal PCB No ±12V signal PCB >±5% Signal PCB fault: change
12V power supply (Voltage) error signal PCB
fault
signal PCB 5V +5V signal PCB No ±5V signal PCB >±5% Signal PCB fault: change
power fault supply (Voltage) error signal PCB
primary signal channel 1 No Signal cannot be kept Reference signal error: check
reference within required limits with NDC
signal error
primary signal channel 2 No Diag Sample signal error: is gauge

sample signal looking at product?
error
auxiliary signal channel 3 No Signal cannot be kept Reference signal error: check
reference within required limits with NDC
signal error
auxiliary signal channel 4 No Signal cannot be kept Sample signal error: is gauge
sample signal within required limits looking at product?
error
low window Air purge flow No The desired 20L/min Low window air purge pres-
air purge (L/min) gives a raw value of 5000 sure: check air supply
pressure units and anything below
this will give an error.
internal internal standard No Internal standard fails to Internal standard error: check
standard error deploy correctly with NDC
failed
Motherboard Motherboard No Cannot read Check motherboard connec-

ID fault present (startup Motherboard ID tions
check)
Signal board Signal board No Cannot read signal board Check signal board connec-
ID fault present (startup ID tions
check)

10.2 Series 9 Gauge Status Light
The Series 9 gauge has a LED located on rear panel which can be used for diagnostics pur-
poses (Figure 10-1).
Figure 10-1 Gauge Status Light
On power up, the Status light will flash alternately between red and green to show that the
gauge is powered and initialising. After a minute and half, the light will turn green, flashing off
every few seconds as a live heart beat.
If a gauge error occurs, the LED will flash in sequence, showing the most significant error first.
The sequence starts with an off period, followed by a sequence of alternating green and red.
The number of red flashes in the sequence gives an indication of the most significant error as
follows:
−1 Signal error (low or high signal error)
−2 Temperature error
−3 Voltage error (one or more power rails are at invalid levels)
−4 Window contamination
−5 Motor error (main filter wheel motor or internal reference motor)
−6 Lamp error (lamp failure detected)
−7 Communications error
−8 Air flow error
− 10 Self-test conditions (e.g. incorrect hardware configuration)
Note: Only error states will trigger these sequences, not warning states - E.g. temperature
warnings will not trigger the status LED sequence.
If the gauge undergoes a soft reset, the Status LED will be orange until the gauge restarts.

CHAPTER
11
11 Reference
11.1 Specifications
11.1.1 Gauge
Dimensions
Enclosure material Stainless steel 316L
Window material Sapphire
Width 200 mm
Height 247 mm
Length 348 mm
Weight including APW 12.5 Kg
Cable/gland clearance : 100 mm
Environmental sealing IP67 NEMA 6
Pollution degree Degree 1
Ambient Temperature Range
Storage 0oC - 70oC
Operating 0oC - 50oC (70oC with water or vortex air cooling)
Cable length (Data and power) 10 or 20 metres as standard
Cable type CAT5e
Power Supply +24V d.c. +10% -20%, 30W
Working Distance from window : 250 mm +/- 100 mm : beam patch 60 mm diameter
Sampling area
200 mm +/- 50 mm : beam patch 25 mm diameter
140 mm +/- 25 mm : beam patch 10 mm diameter
Series 9 - General: Reference 11-1

External Temperature Option
Temperature sensor
Sample patch size 25 mm diameter at 250 mm distance
Working distance 250 mm +/- 100 mm
Measurement Range 0°C to 120°C
Accuracy +/- 1°C (+/- 2°F)
Repeatability +/- 0.5% of reading or +/- 0.5 °C, whichever is the greater
over the full temperature range
Measurement output One of the four available gauge measurement channels
Air supply required approximately 1 m³/h, clean, dry, instrument-quality air
Environmental rating IP65 (NEMA-4)
11.1.2 OT, GCI, GCP, PH

Dimensions - Molded Composite Material
Width 306 mm
Height 230 mm +26 mm large gland clearance
Depth 93 mm
Note: Above values do not include cable

clearance and connector removal clearance.
Weight 3 Kg excluding connected cables
Dimensions - Stainless Steel (GCI, OT)
Width 306 mm
Depth 91 mm

clearance and connector removal clearance or
mounting strap dimensions.
Weight 6 Kg excluding connected cables
Storage 0oC - 70oC
11-2 Series 9 - General: Reference

Operating 0oC - 50oC
Relative humidity 5% to 95% (non-condensing) over the full

operating temperature range
Power supply input 85-264vac 50/60Hz, 100W via screw terminals
Inputs / Outputs
Standard communications Ethernet - 2 x screw terminal ports, 1 x RJ45
Optional communications Profibus DP or DeviceNet
Optional analogue board 2 x 4-20 mA /0 to 10vdc isolated

(GCI & GCP)
Optional Digital input board 8 x Opto-isolated inputs

(GCI & GCP) (Low 0vdc and High 3vdc-30vdc)
Digital output board 8 x Normally Open relay contacts

(GCI & GCP) (125vac/60vdc/1A maximum ratings)
11.1.3 Switched Hub

Dimensions
Width 250 mm
Depth 66 mm

clearance and connector removal clearance.
Weight 1.5 Kg excluding connected cables
Atex Certification Zone 22 (non-mining applications, dust explosive

atmospheres)
Enclosure Molded composite material
Storage 0oC - 70oC

Power supply 24V d.c. +/-20%, 5W
Series 9 - General: Reference 11-3

Inputs / Outputs
Communications Ethernet - 7 x screw terminal ports, 1 x RJ45
11.1.4 NDC Power Supply Units

Dimensions
Width 265 mm (305 including cable glands)
Width 60 mm
Depth 40 mm
Weight Approx 0.75 Kg
Atex Certification Zone 22 (non-mining applications, dust explosive

atmospheres)
Enclosure Aluminium
Storage 0oC - 70oC

AC Input 90-264Vac, single phase, 1.5-0.75A, 47-63Hz
DC Output 96W Maximum, 24Vdc, 4A
11-4 Series 9 - General: Reference

CHAPTER
12
12 Outline Drawings
12.1 Gauge

;0;'((3

&20021*$8*(
&211(&725

67$786/('
&21),*85('
,7(0
&$37,9(),;,1*)25
$,5385*(5(029$/
$,5385*(,1/(7

Series 9 - General: Outline Drawings 12-1

12.2 Peripheral Units
12.2.1 GCI, PH, OT, GCP
12-2 Series 9 - General: Outline Drawings

12.2.2 GCI / PH Stainless Steel
Series 9 - General: Outline Drawings 12-3

12-4 Series 9 - General: Outline Drawings
Warranty
1. All sales of NDC Technologies products are subject to the contractual terms and condi-
tions of the Order pursuant to which they were sold to Buyer, including Warranty terms.
The following terms are a general summary of the contractual Warranty terms, NOT a
revision or alternative to the contractual terms, and are presented as merely a point of ref-
erence for your information. The contractual Warranty is the complete and exclusive state-
ment of all NDC Technologies warranties to Buyer. In the event the following terms are in
conflict with any of the contractual Warranty terms, the contractual Warranty terms shall
be deemed to control.
The warranty terms contained herein are expressly in lieu of any and all other war-
ranties, expressed or implied, including any warranty of merchantability or fitness
for a particular purpose. In no event shall NDC Technologies be liable for any inci-
dental, consequential or special damages, including but not limited to, any loss of
business, income or profits, expenses incurred for time when the system is not in
operation, and any labor costs relating to or arising out of the performance, func-
tioning or use of the system.
Purchaser assumes the risk for use of this product and agrees to indemnify and
hold NDC Technologies harmless for any and all damage to person or to property
resulting therefrom.
NDC Technologies grants no license under any patent rights except the right, under
only such patents as may be owned or acquired by NDC Technologies, to use the
product sold hereby for the purpose for which it is sold. NDC Technologies does
not warrant that the product or its use does not infringe any patent owned by per-
sons other than NDC Technologies.
2. NDC Technologies guarantees all products to be free from defects in material and work-
manship for the following periods1:
• Product and peripherals – 2 years from shipment

• Source lamp – 5 years from shipment
• Filter wheel motor – 5 years from shipment
• Spare parts – 1 year from shipment
• Replacement lamps and motors supplied under warranty – 1 year or up to the
original 5 year warranty from shipment of the sensor, whichever is longer
1
Refer to the contractual terms and conditions of the Order for usage of the warranty.
During this period, NDC Technologies will repair or at its option replace, free of all charges
for parts and labor, any NDC Technologies parts determined by it to have been broken or
damaged due to causes other than improper application, abuse or negligence. NDC Tech-
nologies’ obligation to repair or replace shall not extend to expendable parts which are
subject to normal operating wear.
Series 9 - General: Warranty W-1

Nothing in this paragraph 2 will require NDC Technologies to make repairs or replace-
ments where:
A. The product has been repaired, other than by an authorized NDC Technologies dealer or
an NDC Technologies employee, or altered in any way without the prior written consent of
NDC Technologies; or
B. The product has not been properly maintained in accordance with any operating and
maintenance manual supplied therewith; or
C. The product has been damaged as a result of fire, flood, war, insurrection, civil commo-
tion, acts of God or any other cause beyond the control of NDC Technologies or Buyer.
3. NDC Technologies’ liability shall be limited to the obligations set forth in Paragraph 2.
These shall be the Buyer’s sole and exclusive remedies, whether in contract, tort or other-
wise, provided, however, that in lieu thereof, NDC Technologies at its option may replace
the entire product on an exchange basis or refund the purchase price against the return of
the defective product.
4. NDC Technologies will not be responsible for failure to provide service or parts due to
shortage of materials, labor or transportation strikes or delays, or any causes beyond
NDC Technologies’ control.
5. Unless otherwise specified by NDC Technologies, all warranty repairs will be made at
NDC Technologies’ facility. The customer shall be responsible for all expenses of packing,
freight and insurance in connection with the shipment of products to NDC Technologies
for repair. NDC Technologies will pay the cost of returning the equipment to customer.
If it is mutually determined by the buyer and NDC Technologies that the examina-
tion, replacement or repair takes place at the buyer’s facility, then the buyer will be
responsible for NDC Technologies’ travel and living expenses incurred in traveling
to and from the buyer’s facility, and during the time of the visit, as well as the cost
of field labor and replacement parts unless the parts being repaired or replaced are
determined to have been defective, in which event the cost of said repaired or
replacement parts shall be borne by NDC Technologies. These travel and living
expenses will be billed to the buyer at actual cost to NDC Technologies.
6. No person, including any NDC Technologies distributor, agent or representative, is autho-

rized to assume any liability on behalf or in the name of NDC Technologies, and NDC
Technologies shall not be bound to any understandings, representations, or agreements
with respect to warranties except as set forth in this policy.
7. NDC Technologies requests immediate notification of any claims arising from damage in
transit in order to determine if carrier responsibility exists. If damaged equipment arrives,
save the shipping container for inspection by the carrier and telephone NDC Technologies
as soon as possible.
W-2 Series 9 - General: Warranty

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Series 9 - General

NDC Technologies Phone +44 (0)1621 852244

© 2021 NDC Technologies Intelligence that transforms the world.

NDC Series 9 - General Full Guide

Part Number: 120/16549-00

Date of Release: August 20, 2020

Last Revised: April 14, 2021

Americas +1 626 939 3855

NDC Asia Pacific Customer Service Toll-free contact numbers:

• Thailand: 1800 012 048

Singapore non toll-free number: +65 6579 2411

Email ID: osc-apac@ndc.com

Japan +81 (0)3 3255 8157

China +86 21 61133609

Germany: 0800 1123194

Series 9 - General: Table of Contents i

ii Series 9 - General: Table of Contents

Series 9 - General: Table of Contents iii

Series 9 - General: Table of Figures v

vi Series 9 - General: Table of Figures

Series 9 - General: Table of Figures vii

1.2 Quick Setup Guide

1. Install the gauge system (see Chapter 4 - Installation).

2. Select the user language (see Section 6.5 - Local Settings).

3. Select the gauges (see Section 6.9.1 - Selecting Gauges).

8. Select the Product recipe (see Section 6.3 - Loading Products).

Series 9 - General: Introduction 1-1

11. If there is a wide measurement range, perform a full-range calibration

1.3 Associated Documentation

• GaugeToolsXL User’s Guide : 105/14033-01SA

• GaugeToolsXL Installation Guide and Quick Start : 105/14020-SA

1.4 Contact Information

1-2 Series 9 - General: Introduction

Series 9 - General: Safety Information 2-1

3.1 System Components

• Gauge Control Interface (GCI)

• Operator Terminal (OT)

• Power Hub (PH)

• Gauge Control Port (GCP)

• Hand-Held Gauge Interface (GI)

Gauges • Stainless steel, IP67

• Stainless steel, IP67, Atex certified option

Peripherals • Molded ABS enclosed

• Stainless steel enclosed (Atex option)

Series 9 - General: System Overview 3-1

The gauges work on the principle that different

3-2 Series 9 - General: System Overview

The GCI provides an Ethernet port to a single

The operating and display interface is a Part Nos. 120/16001-01SA (Standard),

Features allow for direct interaction with the

Series 9 - General: System Overview 3-3

The OT provides an Ethernet port to a single

The operating and display interface is a

The OT cannot change any process-critical

Fieldbus communications protocols supported

Power Hub (PH)

It is an integrated Ethernet hub that provides an

Part Nos. 120/16001-02SA (Standard),

3-4 Series 9 - General: System Overview