GUARDIAN-HD WEB PROFILING SYSTEM

USER MANUAL

Process Sensors Corporation

113 Cedar Street Milford MA 01757 USA
www.processsensors.com
Tel. (508) 473 – 9901
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PAGE INTENTIONALY LEFT BLANK

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Firmware Writer’s
Edition Date Description
Version Initials
Guardian Scanning Frame User Manual – First
1.0 09/29/2014 V3.03 M.J.
Edition
Guardian Scanning Frame User Manual –
1.1 1/15/2016 V4.0 R.W.
Viewer Suite
1.2 9/23/2019 Guardian HD Scanning Frame User Manual – V4.09e C.P.
Viewer Suite + 12” OI

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USA: Europe: Eastern Europe:
Process Sensors Corp Process Sensors Europe Process Sensors Polska
113 Cedar Street, S1 Adelaide House, Unit 4 Dr Ing. Tomasz Stachowiak
Milford, MA 01757 Corbygate Business Park ul. Modlinska 310 / 312 lokal 216
Tel: (508) 473-9901 Corby, Northants NN17 5JG UK 03-152 Warzawa
Fax: (508) 473-0715 Tel: (44) 015 36408066 Tel: (48) 226739526
[email protected] Fax: (44) 015 36407813 Fax: (48) 226739527
[email protected] [email protected]

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Warranty, Exclusions and Limitations

The workmanship and the materials of all products manufactured by

Process Sensors Corporation are warranted for a period of two years
from the date of shipment. This warranty covers parts and labor
required to correct defects within the scope of the Corporation’s
warranty.

Excluded from the warranty coverage are products a) which have been
subjected to electrical, mechanical or other misuse or abuse b) which
have been disassembled or repaired, or attempted to be, by other
than PSC or its authorized servicing agents.

The foregoing warranty shall be in lieu of all other warranties,

expressed or implied, and the Corporation expressly disclaims any
warranty for merchant ability or fitness for a particular purpose.

Unless otherwise agreed in writing by the Corporation, repairs and

replacement parts provided by the Corporation under its warranty
shall be guaranteed only for the non-expired portion of the original
warranty on the repaired product.

The liability of PSC to any purchaser or user of its products shall not in
any case exceed the cost of correcting defects in a product as herein
provided and, upon expiration of the two years from the date of sale,
all such liability shall terminate. In no event shall the Corporation be
liable for interruption of operations, loss of profit, or special or
consequential damages.

Software Updates

Future revisions of the software that correct errors will be made

available to customers at no charge. Improvements and
enhancements to the software will be available for a nominal fee.

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Table of Contents

Chapter 1. Introduction
1.1. Using this manual
1.2. About the Guardian-HD Scanning Fame
1.3. Unpacking the system

Chapter 2. Principal of Operation

Chapter 3. Guardian-HD Scanning Frame Main Components

3.1. Automated Scanning Frame Assembly
3.2. Remote Scan Controller Box
3.3. NIR MCT Transmitter
3.4. Viewer Suite PC Software

Chapter 4. Guardian-HD Scanning Frame Various Configurations

4.1. “Elite” PC Based Guardian-HD Scanning Frame
4.1.1. Installing the Viewer Suite Software
4.1.2. Registering the Viewer Suite Software
4.1.3. PC Based Guardian-HD Scanning Frame System Functionality
4.1.4. PC Based Guardian-HD Scanning Frame Operation Guide
4.1.5. PC Based Guardian-HD Scanning Frame Header Bar Options
4.1.6. Frame Selections – PC System
4.1.7. MCT Sensor Selections

4.2. “Essential” 12” OI Guardian-HD Scanning Frame

4.2.1. Operations Mode
4.2.2. Product Recipe
4.2.3. Operator Interface Display Screens
4.2.4. Diagnostics
4.2.5. MCT Transmitter Settings
4.2.6. Scanner Settings
4.2.7. Engineering Menu

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Chapter 5. Guardian-HD Scanning Frame Installation & Outputs

5.1. Sighting the MCT Transmitter
5.2. Vibration
5.3. Strong Light
5.4. Temperature and Environment
5.5. Humidity & Dust-Window Air Purge
5.6. Reflections from Material Surface
5.7. AC Power Connections
5.8. Control & Communication Cables
5.9. Analog & Digital I/O Connections

APPENDECIES

Appendix I Automated Scanning Frame Assembly Overview Drawing + Customer Sign off
sheet 1
Appendix II Guardian-HD Customer Sign off Sheet 2 – MCT Transmitter Mounting Options
Appendix III Guardian-HD Customer Sign off Sheet 3 – MCT Transmitter Mounting Options
Appendix IV Guardian-HD Customer Sign off Sheet 4 – MCT Transmitter Mounting Options
Appendix V Guardian-HD Customer Sign off Sheet 5 – MCT Transmitter Mounting Options
Appendix VI 12” Scan Controller Box
Appendix VII Initial Startup Procedure
Appendix VIII Calibration Check Standard
Appendix IX Customer Wiring Connections
Appendix X Data and Roll Report Logging
Appendix XI Language Selection
Appendix XII EU Declaration of Conformity

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Chapter 1. Introduction

1.1. Using this Manual

This manual is designed to assist you in installing, operating, and maintaining Process Sensors Corporation’s
Guardian-HD Web Profiling System. The manual is broken into chapters as follow:

1- Principal of Operation
This chapter covers the Near Infrared (NIR) technology used in the MCT Transmitter of the Guardian-HD
Scanning Frame to make the different measurements.

2- Guardian-HD Scanning Frame Main Components

This chapter talks about the different components of the various Guardian-HD Scanning Frame
configurations and summarizes its features.

3- Guardian-HD Scanning Frame Various Configurations

This chapter lists the various Guardian-HD Scanning Frame configurations and talks about the
advantages of each of the configurations.

4- Guardian-HD Scanning Frame Installation & Outputs

This chapter covers the Guardian-HD Scanning Frame mechanical installation and shows how to
optimize its performance. Also covered in this section are the different outputs and communication
options.

1.2 About the Guardian-HD Scanning Frame

The Guardian-HD Scanning Frame is a reliable multi-constituent system used to measure on-line moisture,
coatweight, thickness etc… across a moving web. Process Sensors Corporation designed the Guardian-HD
Scanning Frame to simplify the operator’s job on site, control drying / coating systems and to help
manufacturers improve the quality of their processes.

1.3 Unpacking
The Guardian-HD Scanning Frame is usually shipped in multiple shipping boxes due its size and the various
components. When received, remove the packing slip and check the actual equipment received. If you have
any questions about your shipment, please call your Process Sensors Corporation’s Representative. Upon
receipt of shipment, inspect the shipping boxes for any signs of damage in transit. Especially take note of any
evidence of rough handling. Report any apparent damage immediately to the shipping agent.

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Chapter 2. Principle of Operation

Molecular bonds such as O-H in water and C-H in the case of oils and organic coatings absorb NIR light at
discrete wavelengths in proportion to their concentration. Absorption is quantified by comparison of the
signal at the measurement wavelength with that obtained at one or more reference wavelengths where there
are no unique absorptions. Measurement is achieved by focusing light through NIR measurement and
reference filters within a rotating wheel. An internal and external voltage signal is generated for each filter,
the latter results from collection of back-scattered light onto a concave mirror and reflection onto the
detector. The ratioed external/internal filter signals provide a voltage that is due to product, not gauge
effects. Filter signals are combined within an algorithm to generate a proportional output which when
calibrated provides a direct reading.

Figure 1: Inside of the MCT NIR Transmitter

Typical Constituents Include:

O-H for Moisture & Alcohol

C-H for Oils, Fats, Adhesives & Plastics
N-H for Proteins, Ammonia & Amines

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Chapter 3. Guardian-HD Scanning Frame Main Components

The different configurations of the Guardian-HD Web Profiling Systems are made up of various components as
shown in Figure 2 below. The various components are as follows:
- Automated scanning frame assembly
- Scan Controller Box
- NIR MCT Transmitter
- Viewer Suite PC software

Figure 2: Guardian-HD Scanning Frame Overview

In this chapter, we will talk about the different components of the Guardian-HD Scanning Frame and explain the
operational function of each of them.

3.1. Automated Scanning Frame Assembly

The automated scanning frame assembly is comprised of a Heavy-Duty belt driven actuator and brushless
stepper motor to provide precise path and position control.

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3.2. Remote Scan Controller Box

The scan controller box is connected to the Guardian-HD with a maximum of 3-meter cables. The scan
controller unit is powered from the mains. It supplies 24V to the stepper motor and the NIR MCT
transmitter. There are two cables between the scan controller box and the Guardian-HD one is for the
stepper motor controller and the other is for communications to the MCT NIR transmitter.

Figure 3: Motor Controller Unit

Figure 3 above shows the scan controller unit of a Guardian-HD Essential Scanning Frame with 12” operator
interface. As you can see in the above Figure 3, the power, Motor Controller and MCT Sensor connections
(left to right), the analog output and web break terminals are located behind the display on the mainboard
and are wired through the 2 strain relief connectors on the underside of the unit.
It is used to configure the OI based Guardian-HD Scanning Frame. It enables the set-up of the sensor’s
parameters, scan parameters and display parameters.

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3.3. NIR MCT Transmitter

The NIR MCT transmitter is a multi-constituent measuring device enclosed in a custom sheet metal enclosure
and attached to the automated scanning frame assembly at various orientations depending on the application.

It performs an optical measurement by emitting and collecting near infrared light at well-defined
measurement and reference wavelengths for one or more measurements (Up to three constituents
simultaneously). The light that isn’t absorbed is captured, focused onto a lead sulfide detector and converted
into an electrical signal. These electrical signals generated for each near infrared filter are fed into an
algorithm to generate an output proportional to % moisture or coat weight. The measurement is then
calibrated versus a primary reference technique to ensure the output is directly proportional.

Figure 4: MCT NIR Transmitter with Optical Eyes

The NIR MCT transmitter, shown in Figure 4 above, is comprised of a two-part painted aluminum enclosure
with a glass or plastic viewing window in the bottom section and a single multicore flexible cable which runs
along the length of the scanner track to the scan controller unit.

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The following is the NIR MCT Transmitter Main Components:

Light Source
A quartz-halogen light bulb running at reduced voltage generates infrared energy.

Filter Wheel
Up to six infrared and visible filters are held in a circular disc. A single timing notch is machined in the edge of
the disc.

Filter Wheel Motor

A precision brushless DC motor is used to accurately rotate the filter disc in front of the infrared light beam.

Detector
A PbS detector is used to convert the infrared light energy collected by the concave collecting mirror into
electrical pulses.
Transmitter’s Electronics
The MCT transmitter contains a 24V power supply, a single PCB comprising analogue and digital processing
electronics and serial communications.

3.4. Viewer Suite PC Software

The Viewer Suite PC software is used to configure the various configurations of the Guardian-HD scanning
frame systems. It enables the set-up and storage of sensor’s parameters, scan parameters and display
parameters. The Viewer Suite software could be installed on a customer owned PC and used with the
Guardian-HD Scanning Frame. It also can be installed on an industrial touch screen PC supplied by Process
Sensors Corporation as a part of the Guardian-HD Scanning Frame System.

The software can be used to communicate with just one or multiple scanning frames.

Chapter 4. Guardian-HD Scanning Frame Various Configurations

There are two different configurations for the Guardian-HD Web Profiling Systems which are suitable for
different applications and they are as follows:
• PC Based Guardian-HD Scanning Frame “Elite”
• OI Based Guardian-HD Scanning Frame “Essential”

In this chapter, we will talk about each of the two configurations listed above.

4.1. PC Based Guardian-HD Scanning Frame configuration

The PC based Guardian-HD scanning frame is the most common configuration as it gives the end user the
most flexibility and it is comprised of the following main components:
• Automated Scanning Frame Assembly
• Remote Scan Controller Box

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• NIR MCT Transmitter
• Viewer Suite Software
• Touch Screen 19” Industrial Rated PC

4.1.1. Installing the Viewer Suite Software

Please follow the following instructions when installing the Viewer Suite PC software:

• Download the software from the support pages at www.Processsensors.com

• You first have to register to gain access. Once you have access you have 2 options to

download ViewerSuite, with Internet and without Internet, the without Internet will supply

the required drivers as part of the install.

Figure 5: Download ViewerSuite

• Open up the .Zip file and launch the PSCViewerSuiteSetup installer package

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Figure 6: PSC Viewer Suite Welcome Page

• Click Next

Figure 7: PSC Viewer Suite Welcome Page

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Figure 8: PSC Viewer Suite – Select Installation Folder

• Click Next

Figure 9: PSC Viewer Suite – Confirm Installation

• Click Next

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Figure 10: Pop-up Question while Installing the Software

• Click Yes

Figure 11: To install specific product

• Select the version of software that you purchased. For example, select Viewer Suite software for the
Guardian-HD scanning frame system.

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Figure 12: Installation Complete

• Click Close.

4.1.2. Registering the Viewer Suite Software

When you purchase any of the Viewer Suite software versions then you need to register the software and its
key to activate the software. Failure to do this will cause the software to revert to the ‘Lite’ version after 30
days. Below are instructions on how to register the software:

• Run the program and select ‘Help-Register Product’

Figure 13: Product Registration

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Figure 14: Product Registration Page 2

• Enter your company name, country and zip code and choose the way to Register.

• If you save it ensure it’s somewhere you will remember!

Figure 15: Saved File Location

Once you have saved the text file email it to [email protected] to receive your
activation code.

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Figure 16: File Saved Confirmation

Once you receive your code go back to the connect screen, click on ‘Help-Enter Product Key’ and paste the key
into the space provided. Then click the Activate button.

Figure 17: Enter Product Key

Having done this your software is now activated.

4.1.3. PC Based Guardian-HD Scanning Frame System Functionality

The PC Based Guardian-HD Scanning Frame system scans the web and measurement data is displayed as
the following:

1. A cross web profile. The profile is displayed as a histogram; positive and negative deviations from the
TARGET, the divisions are referred to as zones. The scanning width is divided by the number of zones,
the number of which lies between 0 -100, the zone average is displayed for each zone. The same
number of readings are taken “cross-web” regardless of the number of zones, so the greater the
number of zones the lower the number of data points averaged per zone. Zone number is chosen to
best correlate with positioning of coating nozzles or locations where a change to the coat weight can
be affected and monitored.

2. A second display which is selectable between a profile format (for a second constituent) and a
historical trend format of the first constituent’s scan averages.

3. A live reading and scan average is displayed at the head of the Profile screen.
Data can additionally be logged to an Excel or CSV file. Selectable data includes:
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a- Zone averages
b- Scan averages
A new file can be generated every hour or every 24 hours according to the button selected. Data is
logged at the end of every scan.

4.1.4. PC Based Scanning Frame Operation Guide

Quick Start-up
Control of both the sensor measurement and the scanning parameters are through the Scan View windows
based s/w. The PC communicates with the scanning frame and sensor via Ethernet, this can be wireless or
hard wired (the socket is present in the scan controller unit). Should Ethernet connectivity fail for any reason,
serial and USB communication is possible through removal of the cover of the scan controller unit.

Data Connection
The software initially opens up in the Connections Options as shown in Figure 18 below.

The IP address and port settings are already installed for the first device located. The Viewer Suite Software
searches for any Ethernet device within the same IP sub net, recognized devices will be displayed in the box
below the connect button. If no units are found press the Re-Scan button. Note the IP address of the
computer and devices must fall within the same subnet. Select the device you wish to connect to and press
the Connect button.

Figure 18: Software Connect Screen

Highlight the unit found and press the connect button, the screen should appear similar to the above
once connected.

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Profile Screens

As mentioned before, the Viewer Suite software could be used to communicate with one or more Guardian-
HD scanning frames. It also could be configured to measure one or more constituents. (Up to three
constituents and product temperature)

Below are some screen shots showing the different pages of the software:

Figure 19: Single Constituent / Single Frame Screen Shot

Frame (Frame 1): This indicates the frame name and location that may be customized by the user.

Recipe: New Recipe (1): This indicates the name of the ‘customer product recipe’ that is currently being used
by the display and sensor.

Moisture: This is the title of the constituent being measured by the sensor. It is customized by the user for
different applications.

Average: This is the average value of the moisture calculated from all readings taken across a single scan.

Position: This indicates the sensor location across the web. The ‘zero’ point is the motor end stop position.

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Stop/Start: This button will stop and start an individual scanning frame.

Park: This button will park the sensor on an individual scanning frame.

Set Point: This button will present a numeric keypad so that the sensor reading may be adjusted to match the
true value of the measured constituent.

Trend Icon: This is a short cut for parking the sensor a static position on the web and changing the cross-web
profile display into a down web trend graph.

Dual Profile: When the second Profile has been activated, this allows it to be temporarily switched off so that
the main profile display can be enlarged on the whole screen.

Figure 20: Single Constituent / Single Frame Screen Shot with Scan Average

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Figure 21: Dual Constituents / Single Frame Screen Shot

Figure 22: Single Constituent / Single Frame Screen Shot with Trend

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Figure 23: Single Constituent / Single Frame Screen Shot with Zone Average

Figure 24: Dual Profile Screen Shot

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Figure 25: Four Frames – Single Constituents Each

Figure 26: Two Frames – Single Constituents Each

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Figure 27: Four Frames – Single & Dual Constituents

4.1.5. PC Based Guardian-HD Scanning Frame Header Bar Options

This section will walk you through the different button in the header bar options of the Viewer Suite PC
software.

Menu Buttons
On the top left of the profile screen are a series of different Menu selections.

Figure 28: Viewer Suite Software Header Bar

The ‘Frame’ selections apply to menu choices that apply to a single scanning frame.
The ‘Global’ are selections that are global, and their actions will be applied to all scanning frames connected to
the profile display computer.

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File Button

Figure 29: File Button – Viewer Suite Header Bar Options

This selection allows the settings of the Guardian-HD scanning frame and sensor (MCT Transmitter)
to be uploaded and downloaded.

Settings Button

Figure 30: Settings Button – Viewer Suite Header Bar Options

This selection presents a table from which user may configure the layout of the PC screens and access to
various setup parameters.

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Check for Updates

Figure 31: Check for Updates – Viewer Suite Header Bar Options

This selection allows the user to check the Internet for updates to the Viewer Suite Software.

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Application Settings

Profile Screen: This allows access to the profile display format settings, password to enter this section is
Engineering Password 2882.

Figure 32: Application Settings – Viewer Suite Header Bar Options

Movement Indicator: This offers a choice between a vertical line or a horizontal bar, with moving marker,
under the display to indicate the sensor’s position.

Charts X Axis: This sets the scaling of the X axis of the Profile to be in Zone numbers or in distance.

Set Zones: This allows the zones to indicate a zone number or a zone width.

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Global Stop: This allows the color of the multi frame ‘Global Stop’’’ button to be red or green when all the
frames are stationary.

Measurement Units: This switches the units between inches and millimeters.

Chart Title Fore Color: Allows the color of the title name to be altered.

Alarm Line Thickness: This alters the thickness of the colored alarm lines on the profile display.

Chart Title Font Size: This alters the font size of the chart title name.

Trace Line Thickness: This alters the thickness of the chart data trace.

Display Frame Side Indicators: These are user defined labels for the frame ends, these can be modified in
Frame Engineering.

Display Web Break and Park messages: This displays over the profile a message when the sensor is in “Park” or
“Web Break”.

Round chart range to whole numbers: This displays the Y axis range in whole numbers.

Display Linked Calibration: This displays next to Recipe the Linked Sensor Calibration associated with it.

Enable Static Sensor Mode: This allows for displaying a Guardian Profile and a Static Sensor reading on the
same display.

Display Last Scan: This displays on the chart with a white line the prior scans readings.

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General

Figure 33: General Settings – Viewer Suite Header Bar Options

Touchscreen Mode: Makes the control buttons bigger for touchscreens.

Password Timeout Minutes: This resets factory user level menu options after a defined time.

Native Language: This allows the Viewer Suite to know that language that the PC is configured for.

Displayed Language: This allow the text displayed in Viewer Suite to be switch to other languages than
English.

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Edit Password

Figure 34: Edit Password – Viewer Suite Header Bar Options

The selection allows the user to change the factory User default password of 0000 to an alternative four-digit
number.

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Reports

Figure 35: Roll Report Settings – Viewer Suite Header Bar Options
This allows the user to review stored Roll Reports. Any report may be viewed, edited and deleted.

View

This removes and adds the Settings menu.

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Global Menu Buttons

When connected to multiple frames the Global menu option appears that allows the user to make global
selections on all frames.

Figure 36: Global Menu Buttons

Disconnect: This presents the software connection screen listing all the names and IP addresses of the frames
connected to the PC so that all or specific frames are connected to the Viewer Suite.

Recipe Select: This presents a list of Recipe names that when selected will be used by all frames.

Figure 37: List of Recipes

Park: This is a Park button which when touched will make all sensors move to their ‘park positions’

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Global Stop
This button when touched will make all sensors immediately stop moving.

Figure 38: Global Stop Button

4.1.6. Frame Selections – PC Based Guardian-HD Scanning Frame

Configuration Password Protection

Access to The Guardian-HD Frame, NIR sensor and Viewer Suite Parameters are protected by three levels of
password.

User Password: This has a factory default of 0000 and may be changed by the user to an unknown four digit
number. When entered it allows an operator access to the Recipe and Diagnostic functions of the Guardian-
HD System.

Engineering Password: This is a fixed password 2882 that allows and engineering of administration person
access to all the frame and sensor setup and calibration functions. WARNING entering this mode without
knowledge of functions can make the Guardian misfunction.

Factory Password: This is a fixed password that allows PSC personnel to access system parameters that
when altered will have a significant influence on the way the Guardian-HD System operates.

Figure 39: User Scanning Selections

Figure 40: Engineering Selections

Figure 41: Factory Selections

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Frame-Recipe Setup

The Guardian-HD System uses a ‘Recipe’ format to allow the user to configure the correct parameters for
products being measured.

Each Recipe consists of several items:

• Recipe Name
• Linked Sensor Calibration
• Scanner Movement Format
• Profile Display Scaling

Figure 42: Recipe Parameters

To configure a Recipe, follow the instructions below:

• Click on Add New. A highlighted ‘New Recipe’ name will be presented in the Select Recipe column.
• Highlight the New Recipe name and type in a name relevant to the Product being manufactured.
• Click on the arrow in the ‘Linked Calibration’ box and select the name of the sensor’s calibration
relevant to the Recipe.
• Enter the number of Zones across the X axis of the profile display. Min is 5, Max is 100
• Enter the scan speed for sensor to traverse the web. Min is 1.0, Max is 5.0. This value is the speed
control voltage used by the motor.
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• The approximate voltage to speed conversion is as follows. This conversion is approximate as it is

dependent on the frame length.

Voltage in/sec mm/sec

1.0 2.0 5.0
1.5 3.0 76.0
2.0 4.0 102.0
2.5 5.0 127.00
3.0 6.0 152.0
3.5 7.4 188.0
4.0 8.5 216.0
4.5 9.5 241.0

• Enter the Park position for the sensor, (not all scanners will have an off-web park position). This is
the distance from the motor end stop on the frame.
• Enter the Display values relevant to the Recipe. Range is the min/max scale of the profile Y axis. Alerts
will turn the measured profile yellow and alarms will turn the measured profile red. Target sets the
ideal constituent level of the recipe.
• Auto Set: This will apply a fixed set of values to the display parameters.
• Type in a Target value and then Click Auto Set.
The Auto parameters are
Range: +/- 4
Alert: +/- 1
Alarm: +/- 3
• Display Profile Values. When checked this will present an average value above each zone in the profile.

Motor / Idler / Scan Width

These values will be inactive when the scanning frame is using automatic edge detection to set the scanning
width. They become active if the scanner is set to the ‘Fixed’ width scan format.

Alarms Dialogue: This allows you to calculate the Range/Alert/Alarm automatically based on the Target
value or a range that is selectable.

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Move & Park Mode

If activated the Guardian-HD Frames may be configured to operate in a ‘Move & Park’ mode where the
sensor moves to several fixed positions on a web and ‘parks’ there to make a short time average of the
measured coating before moving to the next position. When the idler edge of the web is reached the sensor
will ‘fly back’ to position number 1 and repeat the sequence.
Refer to the Move & Park section later in the manual for setup of this operational mode.

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Frame-Cal Routine-Calibration Routine for Frame Sensor
This selection allows the user to develop or adjust the on-frame sensor’s calibration coefficients.

Figure 43: Sensor Calibration

To use this calibration routine the user needs to have the following data and/or samples:
1. The names of the web materials to be measured that have been entered into the sensor’s memory.
2. The constituents to be measured, which have been entered into the sensor’s memory.
3. A set of data pairs for the sensor readings from samples with known levels of coating or moisture. The
wider the range of samples the better the calibration.
Procedure
Select one of the sensor calibration names that are stored in the sensor. Click on the down arrow in the
‘Sensor Calibration’ name box. This will present a list and on selecting will transfer the Source Zero & Span
values into the data boxes.
Highlight the first data box in the LAB column and type in the coat weight or moisture value for one of the
samples. Hit Tab and type in the MCT sensor reading that the sensor gave when viewing that sample. Hit
Enter.
Repeat for all the samples available.
When all the sample pairs have been entered click on ‘Calculate Span & Zero’.
The routine will present a graph of the data pairs entered in the table. Any outlying data points may be
deleted from the table.

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Figure 44: Calibration Graph

Click on Stats to review the linear regression statistics.

Figure 45: Calibration Statistics

The calibration routine will calculate the new zero & span values for the sensor calibration for the selected
calibration name.
The important statistic to note is the correlation coefficient. This statistic is an indication of how well the
sensor’s reading will predict the true level of moisture or coating on the web.
Correlations below 0.95 should be used with caution especially if the number of data pairs used is below 5.
If in doubt click the Zero Offset and simply make a shift to the zero setting.
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The calibration statistics may be saved to a file or printed using the appropriate buttons.

After saving the values into a cal. file in the Viewer Suite program, the routine will ask if the new zero and span
values should be save to the sensor. Click on ‘Yes’ to save or ‘No’ to disregard.

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Frame-Diagnostics

The scanner presents a set of frame diagnostic parameters that are monitored to ensure the correct operation
of the scanning frame. If these diagnostic parameters are within specified limits then the ‘flags’ will be green.
The they are out of limit they will be red indicating a possible scanner fault

Figure 46: Scan Diagnostics

Limit Stop: The frame controller detects when the sensor is parked on either the motor or idler limit switch. If
either switch is activated it attempts to move the sensor off the limit stop. If the sensor fails to move from the
limit stop the frame controller assumes the motor kill switch has been activated and sets the LIMIT STOP error
flag.

Limit Switch: During normal operation of the scanning frame the sensor should never hit either the motor or
idler limit switch. If either switch is detected the LIMIT SWITCH error flag is set.

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Limit: The frame controller has 2 virtual limits which default to 10mm either side of the motor and idler
switches. If the sensor reaches either of these limits the LIMIT WARNING flag will be set. This warning is
typically set when the web breaks or the photocells are not correctly configured, and the web detection isn’t
working correctly.

Web Detect: When the scanner is started it attempts to detect the motor web edge before it commences the
scanning operation. If the scan controller fails to detect the web it sets the WEB DETECT error flag and parks.

Web Break: The web brake input has been activated.

Count Error: On the completion of a scan if the scan controller has failed to collect any readings from the
sensor the COUNT ERROR flag will be set. This can be caused by faults in the sensor filter wheel control
system. On scan completion if the number of samples taken fills the available memory the COUNT ERROR flag
is set. Currently the sample arrays can hold up to 450 samples. To resolve the warning either increase the
sample multiplier or increase the speed of the motor.

Comm Error: The scan controller is unable to communicate with the sensor.

Motor and Idler Limit: This will glow red when either of the ultimate width limit switches is triggered.

Motor and Idler Cell; The switch goes on when the photocells cells are seeing the web and off when the
photocells are off the edge of the web and not seeing it.

Scan Time: This indicates the time for the sensor to traverse the web.

Sample Count: This indicates the number of cross web sensor and position readings that are made as the
sensor traverses the web.

Speed: This indicates the speed of the scanner.

Manual Controls: These controls allow the sensor carriage to be stopped and started, plus manual jog of the
sensor left or right

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Frame- Logging Global Settings

Figure 47: Data logging Settings – Viewer Suite Header Bar Options

This data logging selection shown in Figure 47 above allows for the setup of the data logging feature of the
Guardian-HD System.

Default Logging Folder: This allows the user to designate the folder and file for saving the logged data.

Enable Logging: Allows the logging feature to be switched on and off. Logging may be active for multiple
frames or only for designated frames. The setup of individual frames is found in the Engineering section for
the particular frame.

Enable Product-Based Folder: Enables Product based folders.

Raw Data Report

Auto save to file: This allows you four options on when the Auto save to file is triggered.

File Format: Data may be logged in a choice of three forms, CSV with choice of Separator, Excel and XML.

Roll Report

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Auto save to file: This allows you four options on when the Auto save to file is triggered.

File Format: Data may be logged in a choice of three forms, PDF, Word and Excel.

Name Report

Name File: There are 4 file naming options for the report, from automatic format to Custom naming.

Precede with Frame Name: This puts the frame name in front of the Report Filename.

Frame Logging Events

There are three options for Logging, Start new log, Append existing log, Display prompt that can be set for
resuming after a Web break, Web splice, frame park, frame stop and manual stop of logging.

Logging History: You can select the logging history time 3,6,9 or 12 months.

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Unit Specific Settings

These are the specific parameters that are being logged from the Guardian

Frame- General

General-Analogs

The Scan Controller Box offers three analog outputs for control or data logging purposes (As shown in
Figure 48 below). The type of analog signal and the measurement signal (source) may be selected.

Figure 48: Scanner – Analogs

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Source: This is the measurement data source that is connected to an analog output.

Choices are:
Moisture Live
Constituent 1 Live
Constituent 2 Live
Temperature Live
Sensor Position
Constituent 1 Scan Average
Constituent 2 Scan Average

Mode: This selection toggles the mA output between 0-20mA and 4-20mA

Range Lo and Hi: These are the engineering unit values that will scale the mA output.

Fix 2mA and Fix 18mA: If needed these are used to calibrate the analog outputs, by selecting 2mA or 18mA you
force the Scan Controller Box to output these values. With a multimeter measure the outputs (See Appendix for
location of analog outputs in Scan Controller Box). In the Adjust box enter the actual value and the software
will recalibrate the output.

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Frame-Engineering

This Frame selection is only available by use of the Engineering/Administration password.

Constituent 2 Stack Alarm: If the Guardian HD is fitted with a Stack Alarm this should be checked.

Stop on Splice: If the Splice input is used in the Scan Controller Box then this function will stop the Guardian HD
scanning when triggered.

Photo Cell names: This allows you to name the Photo Cell Names that appear on the Profile for Motor and Idler.

Cell Over Run: To get the sensor beam to the edge of the web and not go past it making a false reading the Motor
and Idler Cell Over Run values can be adjusted.

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4.1.7. Sensor Selections

Access to the sensor setup selections requires the Engineering/Administration password to be used.

Sensor-Prod Setup

Figure 49: Sensor-Product Setup

This sensor settings page shown in Figure 49 allows the user to configure the sensor calibration parameters in
the different web materials.

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Add New: This allows multiple product names to be added.

Highlighting the name will present it in the Name Box where the name may be customized.
The New Product names may also be customized to be more meaningful to the user.

Zero & Span: This presents the calibration settings relevant to that product. They may be adjusted when
needed.
Damping: This is the time response of the sensor. For frame sensor it should be left at 0.0
When the sensor is configured to measure multiple constituents the calibration set up for each constituent is
presented.

Sensor-Diagnostics

Figure 50: Sensor-Diagnostics

The diagnostics display shown in Figure 50 above presents a simple overview of several sensor diagnostic
parameters.

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Wheel Speed: This is the filter wheel motor speed

Int. Temperature: This is the internal temperature of the sensor.

System Voltages: These give the voltages of the power supplies used in the sensor.

Filters: This presents bar graph readout of the NIR filter signals used by the sensor to make the constituent
measurements.

Sensor Status: This status section gives the user a quick snap-shot on the sensor’s operational status. If all the
parameters are within specification the ‘flags’ will be green. If any are out of specification the flag will be red.

Motor: The error flag will be triggered by either of the two following motor problems:
• Motor Stopped: If the opto. switch does not detect the filter wheel’s timing slot.
• Motor Error: If the motor speed does not reach the selected RPM to +/- 1 after 20 seconds.

Detector: The detector error flag will be triggered by either of the two following detector problems:
• Thermistor Error: This is when the thermistor voltage is out of range.
• Cooler Error: This is when the detector’s temperature fails to reach the set point within 60 seconds.

Int. Temp: This is triggered when the electronics board temperature is greater than 65 degrees C.

Lo Signal: This is triggered when the AGC applied reaches its maximum level and a filter value of 5V can not be
reached.

Hi Signal: This is triggered when the AGC applied is at minimum and a filter signal is at 5V.

Dirty Win: This is triggered when the “clean window” value drops by 50%.

Vcc Fault: This is triggered when the +5V value is below 4.6V or above 5.5V.

Vp Fault: This is triggered when the +15V value is below 13V or above 17.5V.

Vn Fault: This is triggered when the -15V value is below -16V or above -14V.

Gain: This section presents the sensor pre-amp gain factors that are used by the sensor to maximize the filter
signals for different reflectivity of web materials.

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Sensor-General-Analog

Analog Inputs: When a frame sensor is fitted with a product temperature sensor the analog input of the
sensor will be active and the setup of the optical pyrometer is presented in this section.

Analog Outputs: Frame sensors are rarely fitted with analog output modules as any analog outputs from the
cross web system are available from the frame end scan controller electronics. However, if additional sensor
analog outputs are required this screen allows for their set up.

Figure 51: Sensor-Analogs

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Sensor-General-General

This screen provides the user and PSC service technicians with information about the hardware and
communications used by the frame sensor.

Precision: This allows the user to designate the number of digits after the decimal point, that measured
constituents will present in their displayed values.

Figure 52: Sensor-General

Sensor-Engineering-General
The parameters on this screen are not active for a frame mounted sensor.

Figure 53: Sensor- Engineering-General

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Sensor-Engineering-Constituents
This screen allows a PSC technician to review and alter the active sensor constituents. Settings should not be
adjusted as they will significantly influence the measurements made by the sensor.

Figure 54: Sensor-Engineering-Constituents

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Factory Settings

This selection tab is only available using a Factory Level password. The selection contains many parameters
that if altered will significantly influence the operation of the Guardian-HD Measurement System. They will
have been configured by the PSC factory and/or PSC commissioning engineers and should not be altered.

The screens illustrated in this section are for information purposes only.

Factory-Frame Hardware Settings: The parameters presented are all relevant to the correct operation of the
movement of the frame’s moving carriage.

Figure 55: Factory-Frame Settings

Frame Name: This is a where the frame name may be customized.

Frame Serial Number: This will present the serial number of the frame.
Frame Invert: This allows the frame firmware to invert the motor and idler ends of the frame for flexibility of
installation.
Cell over Run: This is a small distance that allows the sensor measurement beam to reach the edges of the
web even though the edge detection photocell as move past the edge of the web.
Virtual Motor and Idler Limits: These are firmware calculated safety scan limits to prevent the frame carriage
from inadvertently activating the motor and idler end limit switches.
Sample Multiplier: This is a factor that increases the number of readings the frame electronics take as it
traverses the web.
Polling Interval: This is a rate at which the Viewer Suite program will communicate with multiple frames and
static sensors.
Scan Mode-Auto: This indicates that the cross-web scanning will use the web edge detection photocells.
Scan Mode-Fixed: This indicates that the cross-web scanning will use fixed values for the motor edge and idler
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edge of the web.
Move & Park: This enables the Move and Park mode of operation.
Web Length Encoder Input: This function allows for a web speed input, you must know the encoder
circumference and pulses per revolution.

Factory-Frame Display Settings: This section allows you to display additional charts if the Guardian Sensor is
configured to measure more than one constituent.

Figure 56: Factory-Frame Display Settings

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Factory-TEC: This presents and allows setup of the thermo-electric cooling (TEC) system for the sensor’s NIR
light detector.

Figure 57: Factory-TEC

Factory-Filters: This lists the wavelengths of the filters installed in the sensor.

Figure 58: Factory-Filters

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Factory-AGC: This presents and allows changes to the detector pre-amp gain system used by the sensor.

Figure 59: Factory-AGC

Factory-Fault Mask: This allows any of the fault warning flags to be de-activated. For Example, when a sensor
or frame maintenance alarm is installed and only one or a few faults are wanted to trigger the alarm, the
unwanted faults may be masked.

Figure 60: Factory-Fault Mask

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On-Web Static Sensor Trend

Often it is useful or necessary for the cross web scanning sensor to monitor a particular place on the web to
check the operation of a spry nozzle or heater zone. This feature is available via the blue ‘trend’ icon on the
main profile display.

If the sensor is scanning across the web, click on the stop button when the sensor is close to the place on the
web for the sensor to monitor a fixed web location.

Then click on the blue trend icon. A jog screen will pop up allowing the sensor to be jogged to the exact
position needed.

Figure 61: Sensor Jog controls

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Static Sensor-Trend Graph: The profile display will switch to a down web trend graph with the same Y axis
scaling as used by the Profile display. The X axis has an adjustable time scale.

Figure 62: Static Sensor Trend Graph

Static Sensor-Trend Graph: Changes to the trend parameters are made by clicking the three buttons on the
top right of the graph.

Left-Right Arrows: This re-presents the jog controls so the sensor may be positioned at a different location.
House Symbol: This returns the display to the Profile Display

X Axis Time: This presents different time for the X axis of the trend graph.

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Move & Park Mode

To allow the Guardian-HD to make measurements on webs that have several stripes of coating applied, there
is a ‘Move and Park Mode’ available.
This mode allows the all or a selection of Recipes to be configured for the Move and Park Mode.
The mode moves the sensor to the position of the first coating stripe and the sensor parks there and makes a
time based average. After that time it will move to stripe position number two and make an average again.
This repeats with all the positions setup. After the last stripe position the sensor will ‘fly’ quickly back to the
motor edge of the web and repeat the move & park sequence.
Selecting the Move & Park Mode is made via Factory-Frame Settings (a Factory Password is required). Then
check the Move & Park Mode selector to activate this format.

Figure 63: Factory-Frame Settings

Activation of the Move & Park Mode will enable ALL Recipes to operate in that mode. Any recipe required to
operate in a full cross web scan mode may be disabled individually.

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Figure 64: Frame Recipe-Park & Move

To disable the Move & Park Mode for any Recipe un-check the Move & Park box.
Dwell Time: This is the time that the sensor will park at a given location and make a measurement average
over this time.

Stripe Positions: When in the Move and Park Mode the Recipe Table has a second tab, Edit Measure Points.
On selecting this tab a data table will pop up for the user to insert the places on the web for the sensor to park
at. All measurements are made from the motor end edge of the web.

Figure 65: Frame Recipe-Edit Measure Points

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A Jog control is available to accurately place the sensor at each desired stripe location is entering locations
manually is not feasible.

Figure 66: Frame Recipe-Park & Move Jog Controls

The right and left arrows allow the sensor to be moved. The location position is indicated in the bottom left of
the screen and on clicking ‘Add New’ that value will be saved into the table and the sensor may then be jogged
to a second location. Repeating this sequence allows for all stripe positions to be entered.

Move & Park Display: The Move & Park display is similar to the cross web profile but each park/stripe location
is presented as a bar graph with a small gap between is bar. The bars will update at the end of each locations
dwell time.

Figure 67: Display-Park & Move

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4.2. “Essential” 12” OI Guardian-HD Scanning Frame

The OI based Guardian-HD scanning frame is comprised of the following main components:
• Automated Scanning Frame Assembly
• NIR MCT Transmitter
• Scan Controller Box with 12” OI and 3m Cables

4.2.1. Operation Modes

The Guardian-HD has two Operating Modes:

Standard: This mode offers full versatility in the setup of the profile display with respect to the ranges
measured, the out of target warnings, the scanner speed, the number of cross web zones to be displayed and
full access to the calibration and setup of the NIR sensor parameters.

Simple: This mode offers a simpler display-only mode with fixed display ranges, scan speeds, number of cross
web zones but no access to the NIR sensor setup parameters.

4.2.2. Product Recipes

The Setup and Selection of the user product that are to be measured is made using a series of Product
Recipes. Each Recipe is comprised of three components:
• The scaling of the profile display. Range, target, alert/alarm levels.
• The configuration of the scanner. Speed, park position and number of zones.
• The choice of the NIR sensor’s calibration for different products.

The setup of these Recipes is made by using different screens selectable on the 12” touch screen display.

4.2.3. Operator Interface Display Screens

Figure 52 below is a screen shot of the 12” O/I profile. This is for 1 constituent only.

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Figure 68: Profile Screen of 12” OI

Mode: Indicates that the format is in the Simple Mode.

Recipe: Shows the name of the recipe used for the current profile display. Touching the Blue recipe Name will
present a screen with a list of other Recipes that may be chosen for measuring on different products.

Target Symbol: When touched allows the user to enter the mid graph Target value. The Alert and Alarm levels
will automatically adjust around this Target.

SP: Set Point. When touched allows the user to make an adjustment to the sensor reading to correct the
measured value.

House: When touched allows the user to view several Setup and Diagnostic Screens.

Moisture: This is the live value of the sensors measured constituent. For Coat weight measurements the title
may be changed using the Supervisor password.

Average: This is the cross web average value. It will update at the end of each scan.

Position: This is an indication of the sensor position on the web. The value is measured from the motor end
limit switch. The units may be switched to Metric using the Supervisor password.

Figure 53 below is a screen shot of the target auto adjust.

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Figure 69: Target Adjust – 12” O/I

Touch C to Clear the displayed value, use the keypad to enter a new value. Touch ENT to apply.

In Figure 70 below is a screen shot of how to change the setpoint.

Figure 70: Setpoint – 12” O/I

Touch C to Clear the displayed value, use the keypad to enter a new value. Touch ENT to apply.

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Access to the Setup Menu is protected by a Password. The default (factory) Password is 0000. This may be set
to a different four digit number by using the Engineering password 2882.

Figure 71: Password Entry Page – 12” O/I

If the Password is still set to the factory default there is no need to type 0000, just touch ENT to access Setup.

Figure 72 shows the choice of selecting the Sensor menu or the Frame menu.

Figure 72: Select Sensor or Frame menu

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Figure 73 below shows the scan menu in a simple mode.

Figure 73: Scan Menu Simple Mode – 12” O/I

The Simple Mode allows the user to view the scanner diagnostics for verification of the correct operation of
the scanner and to view the various firmware versions loaded in the Guardian-HD 12.

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4.2.4. OI Based Guardian-HD Scanning Frame

Diagnostics – Page 1

Figure 74: Diagnostics page 1 – 12” O/I

Diagnostics Page 1: This presents to the user information on the operation of the scanner movement system.
When the scanner is moving the sensor symbol will move back and forth as the on machine sensor scans the
web.

On the top of the scanning frame illustration there are four warning LEDs.

Motor and Idler Limits. These will glow red if either of these limit switches have been triggered. In normal
scanning they should never be glowing.

Motor and Idler Cells. These two LEDs indicate the status of the web edge detection photocells. As each
photocell detects the edge of the web the LED will glow.

Scan Time: This indicates the time taken for each cross web scan.

Scan Speed: This indicates the speed of the sensor movement.

Scan Count: This is an indication of the number of measurement ‘samples’ that the sensor makes for every
cross web scan.

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Sensor Manual Jog System: The three lower buttons allow the user to stop the auto scan of the sensor and
then jog it left or right to a required fixed position.

Moisture: This is the live value of the sensors measured constituent. For Coat weight measurements the title
may be changed using the Supervisor password.

Average: This is the cross web average value. It will update at the end of each scan.

Position: This is an indication of the sensor position on the web. The value is measured from the motor end
limit switch. The units may be switched to Metric using the Supervisor password.

Diagnostics – Page 2

Figure 75: Diagnostics page 1 – 12” O/I

Diagnostics Page 2. This presents a quick indication of the status of important parameters for the correct
operation of the scanning frame.

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Miscellaneous Page

Figure 76: Miscellaneous Page – 12” O/I

Miscellaneous Page: This lists the various firmware versions installed in the sensor, the scan controller and
Operator Interface.

Password: By touching the blue 0000 the default password may be changed to a new four digit number.
By touching the Firmware Version code the date of these versions will toggle.

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4.2.5. Sensor Parameters

Access to the sensor parameters is made by touching the Sensor button on the Select Device Screen.

User Parameters: The User Setup Screen shown in Figure 77 allows the user to make changes to some simple
sensor parameters.

Figure 77: User Sensor Parameters – 12” O/I

Adjust: This allows the user to adjust the sensor reading to make it match the value of the moisture or coat
weight of the measurement.

Damp: This adjusts the time response of the sensor. For accurate cross web measurements, it should be left
at 1.

Grab Time: This setting is not used by the Guardian-HD 12. It is only relevant to a static sensor on a conveyor
style installation.

Enter Setup: This allows the user to access the sensor setup parameters. As per with the Scanner Setup this
selection is password protected. The user default password is 0000.

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Sensor Select Menu:

The Select Menu will be presented. The select menu consists of two pages. Page 1 of the user menu is shown
in Figure 78 below and page 2 of the user menu is shown in Figure 799 below.

Figure 78: User Menu Page 1

Figure 79: User Menu Page 2

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Calibration Parameters

By touching the calibration parameters button, shown in Figure 60 above, you will access the Select Cal page
(shown in Figure 62 below). The display will present the product calibrations saved in the gauge.
You can simply select the product calibration by touching it. Touch the right arrow on the top right corner to
see the calibration parameters for the product being used as shown in Figure 15 below. Adding a new
product is made by touching the NEW blue button.

Figure 80: Calibration Parameters Page 1

Figure 81: Calibration Parameters Page 2

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Each Product Calibration has its individual span and zero settings.

To make a change to the values, touch the number, a numeric keypad will pop up. Type the new number and
touch the ENT key.

Alarms: Setting High and Low alarms levels to each constituent will cause that constituent’s reading to turn
RED when the high alarm is exceeded and YELLOW when the low alarm is exceeded.

Disable: this is used to disable one of the constituents for a given product.

Calibration Routine

The Calibration Routine is a linear regression routine that adjusts the gauge’s calibration parameters (span and
zero) so that the gauge’s readings match the actual lab moisture readings. This is done by using a series of
representative product sample with moisture contents covering the moisture range to be measured.

The objective of gauge calibration is to obtain a straight-line graphical relationship between the sensor’s
reading and the true moisture value of a series of samples as shown in Figure 16 below.

Figure 82: Calibration Graph

Calibration Routine Process:

1- Select one of the unused Product Calibrations in the gauge.

2- Make or collect from the process a series of sample (up to 25) with moisture contents covering the range
expected in the process.

3- Set the Span value to 25.0, the zero to -20 and the damp time to a value of 1.0.

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4- Present the lowest moisture sample to the sensor; adjust the zero setting to make the sensor’s reading
agree with the true moisture content of the sample. Note the reading.

5- Present all the samples to the sensor in turn, and make sure to note the sensor and actual lab readings
for each sample.

6- Tabulate the results as shown in Table 1 below:

Sensor Lab
3.7 3.7
4.5 5.2
7.6 8.3
9.5 10.3
8.2 8.9
Table 1: MCT vs Lab Readings

7- Select the Calibration Routine button in the main menu page (shown in Figure 78). Then select the
product you are working with and push the right-hand side arrow. This will take you to the calibration
page as shown in Figure 83 below.

Figure 83: Calibration Routine Page

8- Touch the Lab Value, displayed in blue on the LCD, and enter the true moisture value for the first sample.

9- Touch the MCT Value, displayed in blue on the LCD, and enter the gauge reading for the first sample.

10- Repeat this procedure for all the samples.

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11- When all sample pairs have been entered, touch the CALCULATE button. A window will pop up with the
regression statistics and the values of the zero and span setting that will correctly

calibrate the gauge. Touch SAVE to save the new calibration settings to the desired Product Calibration.

Please note that the up and down arrows are the page up and page down arrows. They are used to scroll the
page up and / or down.

Linear Regression Statistics

The gauge’s computer calculates several statistics during its calibration routine; these statistics give a
measure of the accuracy and quality of the calibration.

Correlation Coefficient: This is an expression of how well the sensor readings match the true moisture
values.
1 is perfect
Greater than 0.9 is acceptable
Less than 0.9 is not acceptable
Standard Error: This is an indication of the accuracy of the calibration. A perfect value is 0.0. Acceptable
values are in the 0.0 to 0.5 range depending on the moisture ranges being measured.

Diagnostics

All gauge diagnostic values may be viewed in this menu choice. To go to the diagnostics menu, touch the
DIAGNOSTICS blue button in the user menu shown in Figure 78 above. There are four pages of Diagnostic
parameters group, the first page is called Front end and is shown in Figure 84 below:

Figure 84: Diagnostics Menu – Page 1

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In the front end diagnostics page, the following are listed:

Sensor STATUS: This presents the operational status of the gauge. The sensor’s microprocessor continually
monitors up to 12 sensor parameters. If all are correct the status will indicate OK. If any one of the
parameters is out of range, then a warning message will be presented. A detailed SENSOR STATUS
diagnostics list is displayed on page 2 of the diagnostics.

Wheel Speed: This is the rotational speed of the filter wheel.

Internal Temperature: This is the internal temperature of the MCT460 gauge.

Filter Gain: This is the optical circuitry gain value.

Cooler Temperature: This is the actual detector’s temperature.

Page 2 of the diagnostics menu displays the status of a list of the MCT460 gauge components as shown in
Figure 85 below. The component tab is displayed in green when its status is ok and in red when something is
wrong.

Figure 85: Diagnostics Menu – Page 2

Page 3 of the diagnostics menu displays the main voltages used by the main circuit board of the MCT460 gauge
as shown in Figure 86 below. The value is displayed in green when status is ok and in red when status is not
ok.

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Figure 86: Diagnostics Menu – Page 3

Page 4 of the diagnostics menu displays the filter values, as shown in Figure 87 below, which are used to help
balance the MCT460 gauge.

This presents the detector signal levels for the six filters that may be fitted to the filter wheel in the MCT460
gauge. Values are given for both external and internal filters. A bar graph comparison for each filters INT and
EXT values may be presented by touching the F# of the filter.

The preamplifier gain value is also presented. This value is an indication of the amplification required to bring
the detector signals into the range required by the processing electronics.

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Figure 87: Diagnostics Menu – Page 4

Ranges of Diagnostic Parameters:

The following table gives the range of values for each of the diagnostic parameters:

Parameter Nominal Min. Value Max. Value Warning Message

Value

Internal Filters 2-4 0.5 5.0 Above 4.9 “High Signals”

External Filters. 2-4 0.5 5.0 Above 4.9 “High signals”

+5V 5.00 4.6 5.5 Outside Min/Max “VCC Fault”

+ 15 V 15.00 13.0 17.5 Outside Min/Max “VP Fault”

- 15 V 15.00 -16.0 16.0 Outside Min/Max “VN Fault”

Motor Speed 2000 950 3500 Outside Min/Max “High/Low Motor”

Filter Wheel Slot No slot switch input for > 400 ms “Motor Stopped”

Gain X1-X8 1 64 Above 64 “Low Signals”

Cooler Drive 15% 0.1% 100% Above 4V “Cooler Fault”

Pre-Gain 1 1 8 None

Cooler Temp 20 -10 30.0 Above 20 “Detector Fault”

Internal Temp 35 0.0 60..0 Above 65 “High Board Temperature”

Table 2: Diagnostics Parameters Ranges

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Miscellaneous

The Miscellaneous Menu, shown in Figure 88 below, provides access to change the password of the user
menu and the readings decimal places. It also lists the NIR MCT Transmitter gauge’s information such as the
sensor version, board type and the interface version.

Figure 88: Miscellaneous Page

Analogs

This menu selection is not used with the Guardian-HD as there are no analog outputs from the NIR MCT
Transmitter

Communications

This menu selection is not used with the Guardian-HD as there are no usable outputs digital communications
from the NIR MCT Transmitter.

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Operator Interface

Page 2 of the Sensor Select Menu presents further setup parameters. Touch the blue arrow at the top of the
screen to access page 2

The Operator Interface select menu shown in Figure 89 below allows access to settings related to the Scan
Controller Box and other important settings such as language, data logging, alarms, miscellaneous, analog,
and communications.

Figure 89: Operator Interface Select Menu

The operator interface functions are separated into six different sub menus and they are as follows:
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Alarms

This submenu helps the user configure the Scan Controller Box alarms when an alarm board is fitted in the
operator interface box of the MCT460 gauge. There is a total of 4 DC relay alarm outputs which can be linked
to any of the constituents used.

Language

This submenu allows the end user to select their language. The languages available are listed in figure 90
below.

Figure 90: Language - Operator Interface

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Data Logging

This submenu shown in Figure 91 allows the user to enable if installed the data logging using the USB port on
the side of the Scan Controller Box

Figure 91: Data Log – Scan Controller Box

Miscellaneous

The Miscellaneous submenu shown in Figure 92 lists the NIR MCT Transmitter firmware version, the board
type (and part #) and the serial # of the sensor.

Figure 92: Miscellaneous - Operator Interface

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1- Analog

This submenu is not used with the Guardian-HD

2- Communications – Operator Interface

This submenu is not used with the Guardian-HD

Photocells

This is a factory set page for the Guardian-HD so no parameters need to be adjusted.

Alarms

This menu is not used with the Guardian-HD as there are no alarms installed in the NIR MCT
Transmitter

Dirty Window

This submenu of the user menu allows the user to configure the dirty window alarm. Please see figure 93
below for more information.

Figure 93: Dirty Window – User Menu

Dirty Window can be enabled by pressing the enable button shown in figure 93 above. Push the Set Clean
Window when window is clean, and transmission is 100. The alarm could be set to trigger between 0 and
100. It is normally set to 50!
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4.2.6. Scanner Settings

By using the Engineering Password 2882 while in the Simple Mode, or with the User Password in Standard
Mode, access to more detailed Setup Parameters is permitted.
Scanner Setup

Figure 94: Scanner Setup page – 12” O/I

The Engineering password 2882 provides more selections in the Scanner Menu.

Recipe Setup

Figure 95: Recipe Setup page – 12” O/I

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The first Recipe Select Screen allows the user to:

New: Add a new recipe to the list. Touching the screen will present a new default “New Recipe” name to the
list

Delete: A Recipe name can be deleted. Touch the Recipe to be deleted and then touch the Delete button.

Rename: The default Recipe name may be customized to make the name more relevant to the user’s product.

Figure 96: New Recipe page – 12” O/I

Figure 97: Scan Setup page – 12” O/I

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Link: The Recipe Name must be ‘linked’ to a sensor product calibration; so that when that recipe is selected on
the profile screen, the correct sensor calibration is used.
Touch the desired sensor calibration name and then touch Save. The display will flash momentarily indicating
that the link has taken place.

Touch the Return Symbol in the top right to return to the Recipe Select Screen to verify the link was
successfully completed.

Display Setup

Figure 98: Recipe Display page – 12” O/I

In the Simple Mode this page is not used.

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4.2.7. Scan Settings – OI Based Guardian-HD Scanning

Frame Scan Settings

Figure 99: Recipe Setup / Scan Settings – 12” O/I

Three scanning parameters may be set in this page.

Park Pos: This is the park or garage position of the sensor. The value is the distance measured in inches or mm
from the motor end limit switch.
Motor Speed: This is the speed of the scanner carriage. The value is a relative number with a range of 0.1 to
5.0. It is not a true speed in inches or mm per second.

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Format – Page 1

Figure 100: Scan Settings Frame 1 page – 12” O/I

These parameters are ones that apply to all Recipes and the general format of the profile display.
Measurement Units: Selection is made between inches and metric by touching the blue button.

Display Last Scan: When enabled this will place a white line, which indicates the zone average value of the last
scan, on top of the current zone bars.

Display Chart Values: When enabled this will add the zone average value above each zone bar.

Scan Mode: This allows the scanner to operate in different scan formats.

Automatic: This allows the scanner to be used with edge detection photocells.

Fixed: This allows the scanner to operate without edge detection photocells and to scan using the motor and
idler length settings that will become active on the Scan Settings screen.

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Figure 101: Profile Display – 12” O/I

This screen shows the profile display with both last scan and chart values active

Format – Page 2

Figure 102: Auto Scan Limits Page – 12” O/I

Virtual Scan Limits: These Scan limits are virtual web edge widths that allow the edge detection photocells to
ignore machine covers either side of the web. The photocells will only be ‘active’ to the scanner while the
sensor is between these two limits.

Display Second Profile: This activates the second profile.

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Second Profile Source: This allows you to select what additional constituent if enabled to display on the
second profile. Choices are as follows:

Moisture (Constituent 0)
Constituent 1
Constituent 2
Temperature

Diagnostics and Miscellaneous

These two selections are the same as available in the User Level.

Analogs.

Figure 103: Sensor Outputs – 12” O/I

Analog outputs may be installed in a choice of three locations. The data sheet supplied with the OI base
Guardian-HD Scanning Frame will indicate where the analog outputs will be located for a particular system.
Normally the analog outputs will be installed in the Scan Controller enclosure located on the motor end of the
frame.

Select the Scanner Outputs to setup these outputs.

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Scanner Outputs

Figure 104: Scanner Analogs page – 12” O/I

The scan controller may be fitted with up to three analog output modules.
There is a choice of ‘data’ that may be used as the source for these outputs.
Use the Up arrow to select Analog 1, 2 or 3
Touch the Constituent listed in blue next to the Source name. Each touch will scroll the source through the
available Constituents. The sources are:
Moisture (Constituent 0)
Constituent 1
Constituent 2
Temperature

Analog Range. The scaling of the analog signal may also be set using the Hi and Lo values. The Hi value is the
value in engineering units that will give a 20mA output. The Lo value is the value in engineering units that will
give a 4 mA output.
Analog Mode: This may be toggled between 4-20mA and 0-20mA.

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Analog Calibration

Figure 105: Calibration of Scanner Analogs – 12” O/I

Tuning the Analog Output signals

The accuracy of the mA signal may be ‘tuned’ by using the Fix mA buttons and the Adjust
button.

Instructions:

 Touch the Fix 2 mA button.

 Measure the mA output of the gauge
 Touch the Adjust value to get the pop up numeric keypad. Enter the value measured in step
2. Touch the Enter key to correct the 2 mA reading.
 Touch the Fix 18 mA button.
 Measure the mA output of the gauge.
 Touch the Adjust value to get the pop up numeric keypad. Enter the value measured in step
5. Touch the Enter key to correct the 18 mA reading.
 Repeat step 2 and 5 to verify that the mA outputs are correct.

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Engineering Mode
Access to Engineering requires the Engineer Level password 2882. Making changes to the parameters in
Scanner Engineering and Sensor engineering can significantly influence the performance of the Guardian-
HD 12 System.

Figure 106: Select Menu Page – 12” O/I

Touch Engineering to enter the menu.

Figure 107: Engineering page – 12” O/I

Engineering has two choices. General and Fault Mask.

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Fault Mask is used to disable specific diagnostics status flags. One or more diagnostics flags could be disabled
at the same time.

General

Figure 108: General Engineering Page – 12” O/I

Frame Invert: This switches the software setup of the scanning frame so the frame may be operated in a
reverse direction but still use the settings entered for a standard frame.

Remember Limits:

Simple Mode: This toggle the frame and display system between the Simple and Standard Operating Mode.
When in the Simple mode the Alert, Alarm and range values will be automatically applied to any Target value
that is entered on the profile display. These values are +/- values above and below the target value.
When in the Standard Mode, these fixed +/- values are not used and different sets of these parameters may
be used in the display Setup.

Motor Offset: This is a value that allows the photocell overrun past the edge of the web on the motor side so
that the sensor light beam may move right to the edge of the web.

Idler Offset: This is a value that allows the photocell overrun past the edge of the web on the motor side so
that the sensor light beam may move right to the edge of the web.

Sample Multi: The NIR sensor and scanner system ‘samples’ the reflected light from the web up to a
maximum of 425 samples. When web widths are very long this maximum sample value may reach its limit.
When a Sample Count value reaches 400 then the Sample Multi value should be increased to X2 to allow the
software to make an average of adjacent sample values.

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General – Page 2

Figure 109: General Engineering Page 2 – 12” O/I

Motor Cell Name: This allows you to change the name of the Motor Cell label.

Idler Cell Name: This allows you to change the name of the Idler Cell label.

Zone Flip: This allows the Zones on the X axis in the profile screen to reverse.

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Chapter 5. Guardian-HD Scanning Frame Installation & Outputs

5.1. Siting the sensor

The optimum viewing distance is 200mm from the bottom of the sensor but any distance between 150 -
300mm is acceptable.

Due to the fact that most coatings on paper, textiles and films are reflective whether applied wet or dry, the
gauge head needs to be mounted at an angle of 15 ° to the horizontal to ensure that surface reflected light(
Specular reflectance) isn’t collected as this would interfere with the coat weight or moisture measurement.
The scanner support bracket is angled to account for this.

Once the gauge is positioned correctly on the scanner support bracket, gauge signal levels should be optimized
whilst the gauge is parked but viewing the dynamic product. This procedure should be carried out by a Process
Sensors engineer.

5.2. Vibration
As the measurement is optical, the scanning frame should be free from excessive vibration. Excessive vibration
will cause noisy measurement and may lead to misalignment or damage of components due to loosening.

5.3. Strong Light

Strong infrared light or direct sunlight should not be allowed to fall on the sensor window or erroneous
reading may occur.

5.4. Temperature and Environment

The Guardian-HD is rated for the following:

NIR MCT Transmitter

Temperature Operating Range: 0-50oC
Environmental Protection: IP00

Guardian-HD
Temperature Operating Range: 0-50oC
Environmental Protection: IP00

Scan Controller Box

Temperature Operating Range: 0-40oC
Environmental Protection: IP00

Environmental Specifications:
Indoor or Outdoor use: Indoor use only
Operating Altitude: 5000 ft Above Sea Level
Relative Humidity: 0-90% rh
Mains Supply Votage Fluctuations: EN61000-3-3
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Ventilation Requirements: N/A
Sound Level: N/A
Pollution Degree Rating: Pollution Degree II
Cleaning Instructions: Grease and other contaminants on the frame and on the sensor window
can be removed using a soft rag and Isopropyl Alcohol.

WARNING: Protection may be impaired if used in a manner not specified by the manufacturer.

5.5. Humidity and Dust – Window Air Purge

The head should be kept clear of excess humidity. It is important to prevent condensation on the sight
window. Normal atmospheric dust will not affect the sensor reading but similar to humidity, accumulation of
dust on the window will impair the sensor’s operation. The air purge attachment fitted to the sensor window
requires a 6mm tube with a supply of clean oil free dry air at a pressure not exceeding 10 psi. at approximately
2 liters per minute.

5.6. Reflections from Material Surface

It is essential to avoid specular reflections of the transmitted light from the product. Powdered and granular
products cause no problems and the sensor light beam may be mounted at any angle to the top surface of the
product. The closer the beam is to 90º from the surface the better the reflected signal strengths. Highly
reflective and shiny sheet materials require that the sensor be angled so that the light beam is at approx. 80º-
85º to the sheet surface.

5.7. AC Power Connections

The Guardian-HD Scanning Frame is powered using the 6-foot (2mtrs) power cord connected to the side of the
motor controller unit. The input is auto ranging 100-240VAC, 50/60Hz, 2 amps. This equipment must be
Earthed.

5.8. Control & Communication Cables

The Guardian-HD Scanning Frame has 2 cables that connect the Frame to the Scan Controller Box the maximum
length of these cables is 3 meters.

5.9. Analog & Digital I/O Cable Connections

Customer data cables connect via a terminal strip inside the Scan Controller Box. Details of the respective
connectors in these connectors are given in the Appendices at the end of the manual.

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Appendix I

Automated Scanning Frame Assembly Overview Drawing and

Customer Sign off Sheet 1

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Appendix II

Guardian-HD Customer Sign off Sheet 2 – MCT Transmitter Mounting Options

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Appendix III

Guardian-HD Customer Sign off Sheet 3 – MCT Transmitter Mounting Options

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Appendix IV

Guardian-HD Customer Sign off Sheet 4 – MCT Transmitter Mounting Options

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Appendix V

Guardian-HD Customer Sign off Sheet 4 – MCT Transmitter Mounting Options

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APPENDIX VI

12” Scan Controller Box

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APPENDIX VII

Initial Startup Procedure (Optical Eye Version) using

12” Operator Interface or PC Software

The following is to be used as a one off startup procedure for new installations of Process Sensors Guardian-HD
Scanning Frames with Optical eyes fitted. It is assumed that the frame is installed and there is a web on the
machine, paper or film.

1. Power up the whole system and confirm that there is a green light coming out of the sensor.

2. Manually push the sensor to the middle of the web. You will see 2 yellow optical eyes either side of the
light tube. Using a small screwdriver rotate the potentiometer so that they are energized (orange light on).

3. Push sensor to edge of web Motor and Idler side, check to see that the optical eyes orange lights go out
when they are off the web. If they don’t adjust the potentiometer!

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4. Press Start on the 12” Operator Interface or PC Software so that the frame can find its length. After several
scans press Stop to stop the frame.

5. Change the Auto Scan Limits. Auto Scan limits are virtual web edge widths that allow the edge detection
photocells to ignore machine covers either side of the web. The photocells will only be ‘active’ to the scanner
while the sensor is between these two limits.

Procedure to get limit numbers:

- Press the House symbol at the top right of the front page
- Hit enter in password section
- Go to Diagnostics.
- Move the sensor using the left arrow, record the position where the left photo eye is off the web but
not looking at the machine cover.
- Do the same for the idler side using the right arrow to move the sensor.
- Go back to front page using the arrow button at the top right of the screen.
- Now to adjust the virtual scan limits press the House symbol and enter 2882 as the password, go into
Format and press right arrow once for the motor and idler limits enter the values you recorded in
diagnostics.

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6. Cell Offset for Motor and Idler

This is a value that allows the photocell overrun past the edge of the web to be adjusted so that the sensor
light beam may move right to the edge of the web. This adjustment is best made with the scanner moving.

To adjust enter Engineering mode by pressing the House symbol and enter 2882 as the password.

Select Frame Engineering and go into General, adjust the Motor and Idler cell offset to the desired distance
from the edge of the web. In the PC software goto Scanner Engineering and you will see Cell Over Run Motor
and Idler.

12” Operator Interface PC Software Page in frame engineering

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Initial Startup Procedure (Ultrasonic Version) using

12” Operator Interface or PC Software

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APPENDIX VIII

Calibration Check Standard

The Process Sensors Calibration Check Standard provides users of the Guardian-HD Scanning Frame with
a quick way of verifying that the sensor’s calibration has not altered over time.

The standard simulates moisture levels as follows:

Low Moisture
High Moisture

Connection of the Standard to the MCT Transmitter

Locate the standard on the light shroud. Make sure that the key on the Standard mates with the slot
on the light tube and then tighten the hand screw to ‘lock’ the standard in place.

How to Use the Calibration Check Standards

The Check Standards should be used on a periodic basis, daily, weekly or monthly, to check that the
sensor is remaining stable and thus giving the correct moisture values.

The standards may be used in two ways:

a) As a quick low/high check of the sensors’ reading. In this manner it allows users to gain
confidence in the stability of the sensor and in the accuracy of the initial calibration.

b) As a way of transferring the calibration from one sensor to another. In this manner a newly
purchased or repaired sensor can be quickly put into operation without the need for actual samples of
product.

Quick Calibration Check

Using the standards to check the stability of the MCT Transmitter requires that it be correctly calibrated
using samples of the product(s) on which it is measuring. As soon as the sensor is satisfactorily calibrated,
the reading of the low and high sides of the standard should to be noted.

1. Clip the standard onto the light tube.

2. Rotate the standard selector knob to the LOW position and tighten the locking nut.

3. With the MCT set on the same CAL Channel as used to measure the product, make a note of the
MCT reading

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4. Rotate the standard selector knob to the HIGH position and lock into place. Note the MCT
Transmitter reading.

At any time in the future, inserting the check standard, and selecting the respective reflectors, will give
the same values as previously noted above. If the MCT does not give the same readings to +/- 0.2, then
the calibration of the MCT Transmitter may be in error.

Using the Check Standards with multiple calibration channels

When the MCT Transmitter is operating with multiple calibration codes, it is important to only use the
check standard on the same Cal Channel. The differences in the calibration coefficients for the various
products (zero & span) will give different readings for the check standards.

Users may wish to use a vacant Cal Channel as a designated ‘CAL CHECK CHANNEL’. Doing this will
allow two convenient values to be setup for the low and high standards.

To use this method, decide on a low reading for the low standard, say 2.0 and a high value for the high
standard, say 8.0.
Now use the calibration development routine to calculate the zero & span values that make the MCT
Transmitter read the 2.0 and 8.0 values. As the Cal Development routine requires 3 data pairs, one set
of values needs to be entered twice.
Finally store this zero & span value in the CAL CHECK CHANNEL, say # 9.

When using the standards make sure that this CAL CHECK CHANNEL is selected prior to inserting the
standards.

Calibration Transfer

Once the values given by the two standards are known for a specific product calibration, they can be
used as ‘stable samples’ for calibrating other sensors.

The known values for the standards should be used as the LAB values in the Cal Development routine.

1. For a new or repaired sensor set the span to 25.0.

2. Select the Low standard and note the MCT Transmitter reading.
3. Select the High standard and note the MCT Transmitter reading.
4. Select the CAL DEVELOPMENT routine.
5. Enter the data pairs of MCT reading and known standard values. Enter the High standard
twice to get the 3 data pairs.
6. Compute the zero and span values that will make the sensor read the values of the
standards.
7. Save these settings in the desired Cal Channel.

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APPENDIX IX

Customer Wiring Connections

The following diagrams show the standard configurations for the power, digital and analogs

POWER

Input
Terminal #
1
Live

2 Neutral

Gnd Symbol Ground

ANALOG Outputs – Inside Scan Controller Box on a Terminal Strip

Web Break In. Sensor goes to

park. Inputs are ‘dry’ contact
closure Voltage 0-24V

Analog 3 4-20mA 0-15V and GND

Analog 2 4-20mA 0-15V and GND
Analog 1 4-20mA 0-15V and GND

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Customer Wiring Connections

The following shows the exterior connections to the Scan Controller Box Exterior Connections

AC Analog and Web Motor Controller Sensor

Power Break Input Cable Cable

The following shows the exterior of the Guardian-HD Scanner on the motor end

Sensor
Cable

Motor Controller
Cable

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APPENDIX X

Data and Roll Report Logging

1. Front Page

2. Select “Settings”, “Application Settings”

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3. When prompted use 2882 as Password.

5. Choose “Data Logging” in Application Settings. Enable “Data Logging” and choose File
format to save. If a roll report is required also enable Roll Reports.
6. Decide on the type of file for the data log.
7. You can also change where the Default Logging Folder saves the file. Press “Close” to save
changes and start logging.

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5. In “Frame”, “General” choose “Hour” or “Day” to create a new file. Here you can also select what to save
“Zones” (Zone Averages) and “Average” (Scan Average).

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Viewing Log Files

Unless the default location is changed log files will be saved in the PC Documents/PSC Viewer Logs with a date
name.

Select the date file to be viewed and double click to open it.

A typical csv file is as below.

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Viewing Roll Reports

Go to Application Settings. To view, edit and print a Roll Report select the Roll Report tab. This will present a
list of saved Roll Reports by User Name. Double click to open the stored reports each with a different date and
Recipe name. Highlight any of the report names.

The page gives options to Edit, View and Delete the report.

If additional information needs to be added to the report select View. Any missing data may be added.

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Select View to see the complete report. Use the Windows print function to print the report.

The trend graph represents a time trend of the cross web averages for the number of scans saved in the
report.

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APPENDIX XI

Language Selection

Select Settings

Enter Password of 2882

Select the General tab

Select Displayed Language

Select the desired language

Confirm Yes to change the language. The Viewer Suite will close and automatically re-start to load the new
language. When the frame is found on the connect screen click on Connect to open the program in the new
language.

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APPENDIX XII

EU Declaration of Conformity

Equipment: Process Sensors Guardian-HD Web profiling system

The above equipment complies with the following European Directives

Low Voltage Directive: 2014/35/EU EN 61010-1: 2010 + A1: 2019 Safety requirements for electrical
equipment for measurement, control and laboratory use.

EMC Directive: 2014/30/EU

Emissions EN61326-1: 2013 Electrical equipment for measurement, control and laboratory use

EN 61000-6-3: 2007+A1:2011 Electromagnetic compatibility (EMC) Part 6-3: Generic standards -

Emissions for residential, commercial and industrial environments

Immunity EN61326-1: 2013 Electrical equipment for measurement, control and laboratory

EN 61000-6-1: 2007 Electromagnetic compatibility (EMC) Part 6-1 Generic standards: Immunity for
residential, commercial and industrial environments

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Process Sensors Corporation

113 Cedar Street
Milford, MA USA
Phone: (508) 473-9901
Fax: (508) 473-0715
www.processsensors.com
Email: [email protected]

Copyright © 2019 All rights reserved

PROCESS SENSORS CORPORATION is a registered trademark of Process Sensors Corporation.

Process Sensors Corporation is part of KPM Analytics.

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