Hydro-Mix VII User Guide
Contents
1. The sensor may be configured to output a linear value of between 0 100 unscaled units with a material or recipe calibration being performed in an external control system This is the preferred configuration for mixing applications Or internally calibrated using the Hydro Com sensor configuration and calibration software to output an absolute moisture percentage value 2 Sensor Calibration 2 1 2 2 2 2 1 Absolute moisture percentage calibration This method requires the user to ascertain the relationship between the unscaled values of the sensor and the material moisture percentage Figure 29 Detailed instructions on how to configure and calibrate the sensor are available in the Hydro Com user guide Good Moisture Calibration Data 12 10 e 8 LI O 8 6 4 IC B 2 a 0 7 T T T T T 1 0 20 40 60 80 100 120 Sensor Unscaled Output Calibrating in an external control system This configuration is recommended for mixing applications The sensor s averaging and or filtering and signal smoothing functions may be applied to the unscaled value and output directly to an external control system For many mixing applications the object of controlling the moisture addition is to ensure that a repeatable moisture target is achieved batch after batch Often this target point is derived through experience and monitoring the process In order to achieve repeatability it is not necessary to give the final moi2. 2 Analogue outputs Two DC current sources generate analogue signals proportional to separately selectable parameters e g filtered unscaled filtered moisture average moisture etc See Chapter 4 Configuration or the Hydro Com User Guide HD0273 for further details Using the Hydro Com or direct computer control the output may be selected to be e 4 20mA e 0 20 mA 0 10 V output can be achieved using the 500 Ohm resistor supplied with the sensor cable Hydro Mix VII User Guide HDO412 Rev 1 0 1 23 Chapter 3 Flectrical Installation and Communication Sensor cable Part no 0975 connections for new installations Twisted Pair MIL spec Sensor connections Cable colour SC ez A 530VDC o 30V 45 30VDC MOUSE Ce Jm Je Es me a CE CNE OO e f e EST TT aan CC e Cc ES GC 05 gt x lt 0975 twisted pair Sensor Cable Junction box Do not connect screen at control cabinet 500 Chm resistor for 0 10V BN cb 1 ene Run te ve E Digital A 1 R Output Input Supply 15 30V DC E DEE rn u EG Cortrol Room Wiring Input Figure 15 0975 Sensor cable connections Note The cable screen is grounded at the sensor It is important to ensure that the plant where the sensor is installed is properly grounded 24 Hydro Mix VII User Guide HD0412 Rev 1 0 1 Electrical Installation and Communication Chapter 3 A RS485 multi drop connection The RS485 serial interfa
3. Filtered unscaled Parameter Range options Analogue output configuration Output type Filtered unscaled 2 Average unscaled Output variable 2 High 0 100 20 00 N A Low 0 100 N A Moisture calibration Oa EE nm e e om es Signal processing configuration Smoothing time 1 0 2 5 5 0 7 5 10 7 5 sec Digital Signal Processing Very Light Light Medium 5 sec Heavy Very Heavy Unused Unused Unused Slew rate Light Medium Heavy None Light Slew rate Light Medium Heavy None Light Averaging configuration Average hold delay 0 0 0 5 1 0 1 5 2 0 5 0 0 0 sec Hydro Mix VII User Guide HDO412 Rev 1 0 1 55 Light Light 0 0 sec Appendix A Default parameters ze rs ama ee ms Im ms Input Output configuration Input Use 1 Input output Use 2 Measurement Mode Unused Average hold Moisture temp Unused Moisture temp Bin empty Data invalid Standard Mode V Mode E 1 1 1 Temperature Compensation Moisture temp Unused Standard Mode Standard Mode The temperature compensation settings are individual to the unit and set in the factory during manufacturing These should not be changed If needed the factory settings specific to that unit can be obtained by contacting Hydronix 56 Hydro Mix VII User Guide HDO412 Rev 1 0 1 Appendix B Document Cross Reference 1 Document Cross Reference This section lists all of the other
4. Wire correctly using specified cable in the technical specification Connect sensor to a PC and run Hydro Com Check analogue output on the diagnostics page Force the mA output to known value and check this with an ammeter Replace analogue input card Symptom Computer does not communicate with the sensor DC power at 15Vdc to 30Vdc junction box Action required on failure Locate fault in power supply wiring Check PC Com port settings Possible Com port number used is higher than 10 and therefore not selectable in the menu on Hydro Com Determine the Com Port number assigned to the actual port by looking at the PC device manager Sensor diagnostics Chapter 7 Com port number is The Com Port Renumber the Com Check sensor higher than 10 and assignments in the Port used for addresses is not available to PC s Device communication with use in Hydro Com Manager window the sensor to an unused port number between 1 and 10 More than one Connect to each Sensor is found at Try an alternative sensor has the same sensor individually an address RS485 RS232 USB address number Renumber this if available sensor and repeat for all the sensors on the network 1 4 Sensor output characteristics Filtered Unscaled Output values shown are approximate RS485 0 10 V Compatibility mode Sensor Sensor exposed to air to air mo om Ge e H SC CS Cu CE Hydro Mix VII User Guide HDO412 Rev 1 0
5. along with the 3 remaining lock nuts B to the Clamp Ring to push against the Fixing Plate 5 CHECK again to ensure that the sensor head is in the correct position using a steel rule and ensure that the mixer blades and scrapers clear the ceramic face by manually rotating the blades 6 Fully tighten the complete assembly including the lock nuts 7 Once the sensor has been correctly fitted and adjusted fill the gap around the sensor with silicone sealant preferred or compacted sand Figure 14 Adjustable Clamp Ring 0033 fitted to Fixing Plate 0021 and Hydro Mix VII 20 Hydro Mix VII User Guide HDO412 Rev 1 0 1 Mechanical Installation Chapter 2 3 3 3 4 3 5 3 6 Adjusting the sensor NEVER HIT THE CERAMIC THE CERAMIC IS VERY HARDWEARING BUT IS BRITTLE AND WILL CRACK IF STRUCK The ceramic face plate of the sensor is extremely resistant to abrasion The mixer wear plates will wear more rapidly than the ceramic Consequently from time to time it will be necessary to adjust the sensor so that it maintains the same relative position to the wear plates following this procedure a recalibration of the recipes may be required To move the sensor IN to the mixer Clean out compacted sand or silicone sealant from around the sensor Loosen the lock nuts B and screws A Tighten nuts C evenly max 50Nm or 37ft lb until the sensor is in the desired position Tighten screws A 20Nm or 15ft Ib Tighten lock nuts B 4
6. and suggestions relating to the product and this documentation ACKNOWLEDGEMENTS Hydronix Hydro Probe Hydro Mix Hydro View and Hydro Control are Registered Trade Marks of Hydronix Limited 2 Hydro Mix VII User Guide HDO412 Rev 1 0 1 Hydronix Offices UK Head Office Address 7 Riverside Business Centre Walnut Tree Close Guildford Surrey GU1 4UG Tel 44 1483 468900 Fax 44 1483 468919 Email support hydronix com sales hydronix com Website www hydronix com North American Office Covers North and South America US territories Spain and Portugal Address 692 West Conway Road Suite 24 Harbor Springs MI 47940 USA Tel 1 888 887 4884 Toll Free 1 231 439 5000 Fax 1 888 887 4822 Toll Free 1 231 439 5001 European Office Covers Central Europe Russia and South Africa Tel 49 2563 4858 Fax 49 2563 5016 Hydro Mix VII User Guide HDO412 Rev 1 0 1 3 4 Hydro Mix VII User Guide HD0412 Rev 1 0 1 Revision history Revision Software Description of Change No Version April 2010 Minor Format Change Hydro Mix VII User Guide HDO412 Rev 1 0 1 5 6 Hydro Mix VII User Guide HDO412 Rev 1 0 1 Table of Contents Ghapter IO dUCUO EES 11 WE eu dee iere EE 11 2 Measuring techniques ae eu 12 3 Sensor connection and confguraton ss 12 Ghapter 2 Mechanical Install ss a hoes 13 1 Generalto all applications dais 13 2 Positioning Bunter 14 Sa ne NS senso EE 18 4 Replacing the Ceramic Dec 21 C
7. fitted in an area where it is away from any possible collection of sitting water It is also necessary to monitor the position of the sensor over time as the mixer floor wears and adjust the sensor as necessary to maintain the recommendations above This is usually best done as part of the standard maintenance procedure at the site where the sensor is installed 14 Hydro Mix VII User Guide HD0412 Rev 1 0 1 Mechanical Installation Chapter 2 2 2 Turbo mixers The sensor may be positioned in the floor of turbo mixers Although possible it is not recommended to mount in the side wall as floor mounting means that the sensor has a better signal when the mixer is used with small batch sizes When the sensor is mounted in the floor it should be approximately 2 3 distance from the mixer centre to the side wall 4 Sidewall Mounted Floor Mounted Figure 5 Position of sensor in a turbo mixer If the sensor is mounted in the side wall it should be positioned approximately 60mm above the floor of the mixer Approximately 60mm 2 Ve inches Figure 6 Position of sensor in side wall of mixer Hydro Mix VII User Guide HDO412 Rev 1 0 1 15 Chapter 2 Mechanical Installation 2 3 Planetary mixers The sensor should be fitted in the base of the planetary mixer ideally in a position where the flow of material is smoothest away from the area of severe turbulence caused by the mixing action of the blades This is normally clo
8. in different lengths Any extension cable required should be connected to the Hydronix sensor cable using a suitable screened junction box See Technical Specification Chapter 8 for cable details The Hydro Mix VIT is also directly backward compatible with older 0090A cables as used with the previous model Hydro Mix VI sensor When connecting to a 0090A cable it is not possible to use the 2 analogue output provided by the Hydro Mix VII For Hydro Mix VII installations using both Analogue Outputs it is necessary to use Sensor Cable part number 0975 It is recommended to allow the sensor to stabilise for 15 minutes after applying power before use 1 Installation guidelines Ensure that the cable is of a suitable quality see Technical specification Chapter 8 Ensure that the RS485 cable is taken back into the control panel This can be used for diagnostic purposes and takes the minimum of effort and cost to connect at the time of installation Route the signal cable away from any power cables in particular the mixer power supply Check that the mixer is properly grounded Note that there is an M4 threaded hole provided on the bottom of the Hydro Mix VII for a ground connection if required The sensor cable should only be grounded at the mixer Ensure that the cable screen is not connected at the control panel Ensure that there is continuity of the screen through any junction boxes Keep the number of cable joins to a minimum
9. input 15 30 V DC activation One configurable digital input output input specification 15 30 V DC output specification open collector output maximum current 500 mA over current protection required 50 Hydro Mix VII User Guide HDO412 Rev 1 0 1 asked questions Hydro Com doesn t detect any sensors when I press search If there are many sensors connected on the RS485 network ensure that each sensor is addressed differently Ensure the sensor is correctly connected that it is powered from a Suitable 15 30Vdc source and the RS485 wires are connected through a suitable RS232 485 or USB RS485 converter to the PC On Hydro Com ensure the correct COM port is selected What should set the analogue output variable to if want to monitor moisture in the mix It is recommended that the analogue output is set to Filtered Unscaled This variable is proportional to moisture and the moisture outputs from the sensor are calculated directly from this value The Filtered Unscaled output is a direct measurement from the microwave response which is scaled between 0 and 100 and filtered to reduce the noise on the signal Why does the sensor outout negative moisture when the mixer is empty The moisture output from the sensor is calculated using the Filtered Unscaled reading and the calibration coefficients in the sensor A B C and SSD such that moisture A US B US C SSD US unscaled These factors are normally u
10. it is flush to the inside radius of the mixer e Avoid areas of severe turbulence The best signal will be obtained where there is a smooth flow of material over the sensor e The sensor should be positioned where it will see a continuous sample of the flowing material and where the sweeping action of the blades ensures no build up of material on the face of the sensor e Position the sensor away from any electrical interference See Chapter 3 e Position the sensor so that it may be easily accessible for routine maintenance adjustment and cleaning Hydro Mix VII User Guide HDO412 Rev 1 0 1 13 Chapter 2 Mechanical Installation 2 Positioning the sensor The sensor may be installed into many types of mixer or application In most cases the sensor will work exceptionally well with the standard filtering parameters Some mixer types and certain applications may require further adjustments to the internal filtering parameters of the sensor For further information please contact your dealer or e mail Hydronix at support hydronix com 2 1 General mounting advice For installations in flat surfaces the top of the sensor must be flush with the floor of the mixer Figure 3 Mounting in flat surface When installing the sensor in curved surfaces ensure that the centre of the ceramic is flush with the radius of the mixer wall Figure 4 Mounting in a curved surface In all installations it is recommended that the sensor is
11. operator when the sensor is in air as the sensor s value goes to zero in air and can indicate a vessel empty state Data Invalid This output is energised if the unscaled value goes outside of any of the limits defined in the averaging section so it could be used to provide a high and low level alarm output ProbeOK This option is not used for this sensor An input is activated using 15 30V DC into the digital input connection The sensor power supply may be used as an excitation supply for this or alternatively an external source may be used as shown below C Yellow 0975 twisted pair Sensor twisted pair Cable Sensor Cable Figure 24 Internal external excitation of the digital input Hydro Mix VII User Guide HDO412 Rev 1 0 1 31 Chapter 4 Configuration 4 1 4 2 4 3 Filtering The default filtering parameters can be found on Page 55 or in Engineering Note EN0059 The raw unscaled reading which is measured 25 times per second contains a high level of noise due to irregularities in the signal from the mixer blades and pockets of air As a result this signal requires a certain amount of filtering to make it usable for moisture control The default filtering settings are suitable for most applications however they can be customised if required to suit the application It is not possible to have default filtering settings that are ideally suited to all mixers because every mixer has a different mixing a
12. the down stroke See guidance for installation in curved surfaces on page 14 Recommended up stroke position Alternative down stroke position Figure 9 Position of sensor in a twin shaft horizontal mixer Hydro Mix VII User Guide HDO412 Rev 1 0 1 17 Chapter 2 Mechanical Installation 3 Installing the sensor The Hydro Mix VII is fitted to the mixer using a Fixing Plate part no 0021 welded to the permanent floor or side wall of the mixer and the Adjustable Clamp Ring assembly part no 0033 which is supplied with the sensor The Adjustable Clamp Ring Assembly facilitates the correct positioning and subsequent height adjustment of the sensor 127mm 5 inch hole for Fixing Plate Fill gap with sand or silicon sealant MS Fixing Plate part no 0021 Mixer floor or wall em nn em mm Clamp Ring assembly part no 0033 7 d Figure 10 Sensor installation 3 1 Cutting hole in the mixer and fitting the Fixing Plate 0021 A hole should be cut into the mixer before welding the fixing plate The recommended cut out hole size is 127mm 5 inches to allow for tolerances in the hole The actual size of the sensor is 108mm 4 25 inches Having cut the hole in the mixer and checked the clearance for the sensor the fixing plate should be welded to the mixer Whilst welding the sensor must be removed to protect the electronic circuitry within it 18 Hydro Mix V
13. they are powder or liquid additives affect the measurement and as a result every different colour will require a different recipe and calibration If make regular half batches of a particular mix do need to have a separate recipe for this A variation in batch quantities can have a small effect on the amplitude of the output which may benefit from a separate recipe and calibration The sensor cannot discriminate when it is exposed to material or not Therefore in all cases when reduced batches are made and Hydro Mix VII User Guide HDO412 Rev 1 0 1 51 Chapter 9 moisture control is required it is very important to check if the sensor surface is continually covered by material by looking into the mixer during mixing As a rule the accuracy of the signal is not guaranteed if the batch is at or less than half the capacity of the mixer If change the ceramic on my sensor do I have to recalibrate the sensor A No the sensor will not need to be re calibrated but the recipe calibrations should be checked If there is any difference in consistence of the final mixes then the recipes will need to be recalibrated If have to exchange the sensor in my mixer do I have to recalibrate my recipes A It is prudent to check the recipe calibrations if your sensor has been moved or exchanged Q The sensor readings are changing erratically not consistent with the changes in moisture in the material Is there a reason for this A In th
14. 0Nm or 30 ft lb Fill the gap around the mixer with silicone sealant preferred or compacted sand SS St es A ee To move the sensor OUT of the mixer 1 Clean out compacted sand or silicone sealant from around the sensor 2 Loosen lock nuts B and nuts C 3 Tighten screws A evenly max 60Nm or 45ft lb until the sensor is in the desired position d Tighten nuts C 20Nm or 15ft lb 5 Tighten lock nuts B 40Nm or 30ft Ib 6 Fill the gap around the mixer with silicone sealant preferred or compacted sand Removal of the sensor Clean out compacted sand or silicone sealant from around the sensor Remove nuts C and carefully ease the sensor and clamp ring assembly from the mixer If the sensor is to be removed and the mixer used a sensor blanking plate part no 0035 can be used to seal the hole 4 Replacing the Ceramic Disc Should the ceramic face plate of the sensor become damaged it can easily be replaced It is advised that a replacement kit part no 0900 is held in reserve in case of this event Full instructions on replacing the ceramic can be found in the installation instructions accompanying the replacement kit or the Ceramic Disc Replacement Instructions HDO411 Hydro Mix VII User Guide HDO412 Rev 1 0 1 21 Chapter 2 Mechanical Installation 22 Hydro Mix VII User Guide HD0412 Rev 1 0 1 Electrical Installation and Communication Hydronix supplies cable 0975 for use with the Hydro Mix VII this is available
15. 1 47 Chapter 7 Chapter 7Sensor diagnostics 48 Hydro Mix VII User Guide HDO412 Rev 1 0 1 Technical specification 1 Technical Specifications 1 1 1 2 1 3 1 4 1 5 1 6 1 6 1 1 6 2 1 7 Dimensions Diameter 108mm Length 125mm 200 including connector Fixing A 127mm diameter cut hole Construction Body Stainless steel Faceplate Ceramic Protection ring Hardened steel Penetration of field Approximately 75 100mm dependent upon material Operating temperature range 0 60 C 32 140 F The sensor will not work in frozen materials Power supply voltage 15 30 VDC 1 A minimum required for start up normal operating power is 4W Connections Sensor cable Six pairs twisted 12 cores total screened shielded cable with 22 AWG 0 35mm conductors Screen shield Braid with 65 minimum coverage plus aluminium polyester foil Recommended cable types Belden 8306 Alpha 6373 Maximum cable run 200m separate to any heavy equipment power cables Digital serial communications Opto isolated RS485 2 wire port for serial communications including changing operating parameters and sensor diagnostics Analogue outputs Two configurable O 20mA or 4 20mA current loop outputs available for moisture and temperature The sensor outputs may also be converted to 0 10 Vdc Hydro Mix VII User Guide HDO412 Rev 1 0 1 49 Chapter 8 18 Digital inputs One configurable digital
16. 2 Filters SEW TALC taria 32 FIXING SNE 18 Hole CUNO resia 18 A A 23 29 51 SKI EI 25 HNOT GISNIS ai iio 42 Installation ee 13 Curved Surface eeaenennennen 13 14 16 17 Serge WEE 23 Flat SUMACE EE 14 15 16 Side Wale cal 15 JUNCO BOX qn ee ende 25 HEET euer eden 13 Material SUIVI in iles 13 Measurement Technique 12 Alternative ee actu nt edit 35 Mix Times During Calibration oooncccnnncccccoonnnnns 43 A E EA 41 A O E et 18 FIOFIZONAl 2 ee 11 16 A ee en 11 16 RODOM acre secs ance ea 11 16 Rotating GT WEEN 11 Stale GT NEE 11 TUDO EE 11 15 RTE 17 MINI Se o 42 Mosture Temperature seen 31 Mounting ELE 14 UIP UTE be A A 29 ANdIOGUE een 23 Parameters e Un Te aan else 35 DOTAU EE 55 Low and Hab 30 Protection Ring Replacement dana 21 RaWiNWOISTUTO id ie 32 Raw Unscaled ani n 32 RS232 485 Converter 26 Sensor Adjustment netas 21 CONNECION Sisi aceso 12 POSINON zn ne 13 14 Sensor CADIS Ee Eug 24 Sensor Performance 41 Signal Stability ococoooccnnnnonccccononos 34 43 Slew Rate EE 32 SIUM sa cates ae See Consistency JA 41 Temperature cccoconcccccnnconccconononunnncnnnnnnnonnnnnnos 42 TUDO EEN 15 USB Sensor Interface Module 27 Water Addition oocooccoccnccnccncnnnonccncnnncnannnos 43 Workability ooooooooo See Consistency Hydro Mix VII User Guide HD0412 Rev 1 0 1 59
17. 3 1 0m3 is not as good as 3 x 2 0m3 Keep the dry mix time as long as possible It is possible to reduce the wet mix time if the final homogeneity is not as critical Control System Calibration and Integration There are several methods in which the sensor may used to control water addition in to a mixing process The Sensor Integration and Calibration Chapter on page 39 covers this topic in detail The suggestions below refer to the method of calculation based water addition only The calculation and control of the water addition may be either done by the Hydronix Hydro 42 Hydro Mix VII User Guide HDO412 Rev 1 0 1 Optimising Sensor and Process Performance Chapter 6 Control water controller or by a third party control system The advice below is based on generally accepted principles however third party control systems may differ in their approach and advice should be sought from the supplier Maximum repeatability of viscosity will be achieved by ensuring that the dry weight of materials in the mixer are correctly proportioned this may require weight correction on the weighed weights of materials that vary in moisture content to correct for moisture For this the Hydro Probe sensor is recommended When calculating the water to be added to the mix the accuracy of the calculation is affected by the total batch weight e g 2 different batch sizes of the same moisture content will require 2 different amounts of water to be added in o
18. Hydro Mix VII User Guide To re order quote part number HD0412 Revision 1 0 1 Revision date April 2010 Copyright Neither the whole or any part of the information contained in nor the product described in this documentation may be adapted or reproduced in any material form except with the prior written approval of Hydronix Limited hereinafter referred to as Hydronix 2010 Hydronix Limited 7 Riverside Business Centre Walnut Tree Close Guildford Surrey GU1 4UG United Kingdom All rights reserved CUSTOMER RESPONSIBILITY The customer in applying the product described in this documentation accepts that the product is a programmable electronic system which is inherently complex and which may not be completely free of errors In doing so the customer therefore undertakes responsibility to ensure that the product is properly installed commissioned operated and maintained by competent and suitably trained persons and in accordance with any instructions or safety precautions made available or good engineering practice and to thoroughly verify the use of the product in the particular application ERRORS IN DOCUMENTATION The product described in this documentation is subject to continuous development and improvement All information of a technical nature and particulars of the product and its use including the information and particulars contained in this documentation are given by Hydronix in good faith Hydronix welcomes comments
19. II User Guide HDO412 Rev 1 0 1 Mechanical Installation Chapter 2 3 2 Fitting the Adjustable Clamp Ring assembly to the sensor The Adjustable Clamp Ring comprises the following components A B QO mm oOo oO 3 x M8 screws 6 x M8 lock nuts Three shown 3 x M8 Nyloc nuts 3 x washers 2 x M6 screws 3 x M8 threaded stud Clamp Ring Figure 11 Adjustable Clamp Ring components Threaded studs F gt Lock nuts B gt W Fixing Plate part no 0021 Figure 12 Fixing Plate prepared for attaching Clamp Ring Screw the 3 threaded studs F to the Fixing Plate already welded to the mixer and tighten securely using 3 lock nuts B Fit the Clamp Ring G onto the sensor using the 2 x M6 screws E Position the Clamp Ring so that adjustment is possible with the ceramic head level with the mixer floor or side wall Fit the Clamp Ring and sensor assembly over the threaded studs of the Fixing Plate and use the Nyloc nuts C and washers D to position the sensor with the ceramic level with the mixer floor or side wall Hydro Mix VII User Guide HDO412 Rev 1 0 1 19 Chapter 2 Mechanical Installation 4 er 2 Ris i H j Be be A AA gt M8 screws A gt lt Clamp Ring G e M8 lock nuts B cb E d Washers D M8 Nyloc nuts C M6 screws E Figure 13 Adjustable Clamp Ring assembled and fitted to Fixing Plate 4 Fitthe three screws A
20. II User Guide HDO412 Rev 1 0 1 This is not applicable to a mixer application but may apply in chutes or other flush mount applications It is used to control the start and stop period for batch averaging When the input signal is activated the Filtered values unscaled and moisture start to Configuration Chapter 4 average after a delay period set by the Average Hold delay parameter When the input is then deactivated averaging is stopped and the average value is held constant so that it can be read by the batch controller PLC When the input signal is activated once again the average value is reset and averaging commences Moisture Temperature Allows the user to switch the analogue output between the unscaled or moisture whichever is set and temperature This is used when the temperature is required whilst still using only one analogue output With the input active the analogue output will indicate the appropriate moisture variable unscaled or moisture When the input is activated the analogue output will indicate the material temperature in degrees centigrade Temperature scaling on the analogue output is fixed zero scale 0 or 4mA corresponds to 0 C and full scale 20mA to 100 C The second digital input output can also be set to the following outputs Bin Empty This output is energised if the unscaled value goes below the Low Limits defined in the Averaging section This can be used to signal to an
21. ce allows up to 16 sensors to be connected together via a multi drop network Each sensor should be connected using a waterproof junction box C Yellow 0090A twisted pair Sensor Cable Junction box Do not connect screen at control cabinet other gt sensors Figure 16 RS485 multi drop connection 4 Hydro Control IV Hydro View connection To connect to a Hydro Control IV or Hydro View the Hydro Mix VII needs to be set to compatibility mode To operate in this mode the output type needs to be set to Compatibility using Hydro Com see Chapter 4 Configuration The 500 Ohm resistor supplied with the cable is required to convert the analogue current output to a voltage signal This should be fitted as shown in Figure 17 at the Hydro Control IV or Hydro View 0090A twisted pair Sensor Cable C Yellow Junction 500 Ohm resistor fro 0V gt Al ODIO Hydro Control IV HCO4 or RON Hydro View HV02 Connector Figure 17 Connecting to a Hydro Control IV or Hydro View Hydro Mix VII User Guide HD0412 Rev 1 0 1 25 Chapter 3 Flectrical Installation and Communication 5 Connecting to a PC A converter is required to connect the RS485 interface to a PC Up to 16 sensors may be connected at any time RS485 line termination will not normally be required in applications with up to 100 m of cable For longer lengths connect a resistor approximately 100 Ohm in series with a 1000pF capacitor across each end o
22. ction The ideal filter is one that provides a smooth output with a rapid response The raw moisture and raw unscaled settings should not be used for control purposes The raw unscaled reading is processed by the filters in the following order first the slew rate filters limit any step changes in the signal then the Digital Signal Processing filters remove any high frequency noise from the signal and finally the smoothing filter set using the filtering time function smoothes the whole frequency range The Digital Signal Processing filter implements a sixth order low pass Butterworth filter that attenuates signals above a defined cut off frequency The advantage of this filter over smoothing is that the signals below the cut off frequency are allowed through for example the change of the moisture in the material but signals above the cut off frequency are attenuated The result of this is a smooth signal that responds rapidly to changes in moisture The smoothing filter applies to the whole of the frequency range of the signal and so as well as smoothing the noise in the signal it also smoothes the response to the changes in moisture This results in a signal that responds slowly to those changes in moisture The advantage is that where the mixer cycle itself introduces a low frequency noise on the signal the smoothing filter can remove this at the expense of the response time Slew rate filters These filters set rate limits for large
23. documents that are referred to in this User Guide You may find it beneficial to have a copy available when reading to this guide ENO059 Engineering Note Sensor Default Parameters ENO066 Engineering Note When to replace a Hydro Mix Ceramic Retaining Ring Hydro Mix VII User Guide HDO412 Rev 1 0 1 57 Appendix B Document Cross Reference 58 Hydro Mix VII User Guide HDO412 Rev 1 0 1 Adjustable Clamp Ring 18 19 Adjusting the Sensor 21 Admixtures uuussnennnennennnnennnnnne nennen enennnne nenn 51 Analogue Output 12 23 29 51 Average Moisture Ou 29 Average Hold A 30 Averaging Parameters een 35 Bali a 51 Batches Ve UE ainda 43 Ee 23 CaliDrallOnm WEE 51 Control SY SON EE 42 o PSE a ne 39 Cement AddOns ee ie 42 Temperature 42 43 Ceramic Garen ee ee 43 DISC Balearen 21 Disc replacement nenne 21 Camo RNO corae en 43 Adjustable EE 18 FNO A cheddar ns 19 20 GCompatblliiy EE 12 GOHIgUrallon Au 12 Connection MILITE Droits 25 PO esse era 26 Gonneellons men nn nine tune 12 Connector A seen 24 EISEN eeh 42 Converter Bee E 26 Digital IoputeiCOutput 30 Electrical Interference 13 Filtered Moisture ooooccccoccocconcconnoncnnnonanonns 29 Filtered Signal ccccccssseeeeeeceesseeseeeeeeeees 33 Filtered Unscaled 51 BUTS OL PP EE 32 DEIAaUl are 34 Filtering TIME nenne 3
24. e range required and that the sensor is not configured to be impractically overly sensitive In certain materials such as organic products the relationship between unscaled values and moisture means that a smaller change in unscaled values gives a large change in the moisture value when operating in Standard Mode This makes the sensor less precise and too sensitive which is undesirable If this were plotted with moisture on the Y axis and sensor unscaled values on the X axis the calibration line is very steep see Figure 29 Relationship of unscaled values to moisture The ability to select the fundamental measurement technique allows the user to choose the technique that most flattens the relationship between unscaled values and moisture see Figure 29 line B The mathematical algorithms employed in the sensor have been specially devised to respond in a different manner dependant on the material being measured All modes will all give a stable linear output however line B will give better precision and accuracy Modes V and E will also be less susceptible to density fluctuations Moisture percentage value 5 4 5 unscaled units 1 7 3 2 1 5 unscaled units 0 4 25 30 35 40 Sensor unscaled value 15 20 Figure 29 Relationship of unscaled values to moisture To determine which mode is the most appropriate it is recommend to run trials for a given material mixer type or application Before d
25. each a final set point What filter settings do need for this A Dribble feed systems do not need to have a stable signal at the end of a dry mixing time and so it should not be necessary to filter as much as you would if you were calculating a one off amount of water to add The sensor needs to respond as quickly as possible because the moisture reading has to keep up with the water going in otherwise too much water can be put in without being detected Recommended settings would be light for both slew rate filters with a minimum filtering time of 2 5 seconds maximum 7 5 seconds How can reduce my mix cycle times A There is no single simple answer to this The following could be considered e Look at how the mixer is charged with material Can the materials be loaded in a different sequence that will save some time e s it possible to wet the incoming aggregates with a large percentage of the total water at the instance material goes into the mixer This would reduce the dry mixing time e Are you continuing to mix the material for a long time after the moisture signal is stable If so you need only to mix up until you reach stability for 5 10 seconds 52 Hydro Mix VII User Guide HDO412 Rev 1 0 1 Frequently asked questions Chapter 9 e f you want to save time on the dry or the wet mixing times always maintain a long enough dry mixing time as this is the most important factor for determining the water e You can take out so
26. ensor Digital RS485 Digital RS485 incorrect to a PC using the connection is connection is not configuration Hydro Com working Correct the working Sensor software and a configuration should be returned suitable RS485 to Hydronix for converter repair Hydro Mix VII User Guide HDO412 Rev 1 0 1 45 Chapter 7 1 2 Sensor s analogue output is faulty PLC analogue input card is faulty 1 3 Possible explanation No power to sensor RS485 incorrectly wired into converter Incorrect serial Com Port selected on Hydro Com Wiring at the junction box and PLC Disconnect the analogue output from the PLC and measure with an ammeter Disconnect the analogue output from the PLC and measure the analogue output from the sensor using an ammeter Converter s wiring Instructions and A and B signals are the correct orientation Com Port menu on Hydro Com All available Com Ports are highlighted on the pull down menu 46 Hydro Mix VII User Guide HD0412 Rev 1 0 1 Chapter 7Sensor diagnostics Symptom Incorrect analogue output Possible Check Required result Action required on explanation failure Wiring problem Twisted pairs used for complete length of cable from sensor to PLC wired in correctly Milliamp reading within the normal range 0 20mA 4 20mA Milliamp reading within the normal range 0 20mA 4 20mA RS485 converter correctly wired Switch to the correct Com Port
27. er is not used if the output type is set to Compatibility 2 2 1 Filtered Unscaled The Filtered Unscaled represents a reading which is proportional to moisture and ranges from 0 100 An unscaled value of O is the reading in air and 100 would relate to a reading in water 2 2 2 Average Unscaled This is the Raw Unscaled variable processed for batch averaging using the averaging parameters To obtain an average reading the digital input must be configured to Average Hold When this digital input is switched to high the raw unscaled readings are averaged When the digital input is low this average value is held constant 2 2 3 Filtered Moisture If a moisture output is required the Filtered Moisture can be used which is scaled using the A B C and SSD coefficients and the Filtered Unscaled reading F U S such that Hydro Mix VII User Guide HDO412 Rev 1 0 1 29 Chapter 4 2 2 4 parameters Filtered Moisture A x F U S B x F U S C SSD These coefficients are derived solely from a material calibration and so the accuracy of the moisture output is dependent upon how good the calibration is The SSD coefficient is the Saturated Surface Dry offset water absorption value for the material in use and allows the displayed percentage moisture reading to be expressed in surface free moisture only Average Moisture This is the Raw Moisture variable processed for batch averagin
28. f the cable It is highly recommended that the RS485 signals be run to the control panel even if they are unlikely to be used as this will facilitate the use of diagnostic software should the need arise There are four types of converter supplied by Hydronix 5 1 RS232 to RS485 converter D type part no 0049B Manufactured by KK systems this RS232 to RS485 converter is suitable for connecting up to six sensors on a network The converter has a terminal block for connecting the twisted pair RS485 A and B wires and can then be connected directly in to the PC serial communication port Hydronix Part No 0049B RS485 RS232 gt RS485A Connect to PC serial RS485B port 6 dipswitches control the configuration of the converter For both the 0049 and 0049B these should be set to Switch 1 ON Switch 3 OFF Switch 5 OFF Switch 2 OFF Switch 4 ON Switch 6 OFF Figure 18 RS232 485 converter connections 0049B 5 2 RS232 to RS485 converter DIN rail mounting part no 0049A Manufactured by KK systems this powered RS232 to RS485 converter is suitable for connecting up to 16 sensors on a network The converter has a terminal block for connecting the twisted pair RS485 A and B wires and can then be connected to a PC serial communication port 26 Hydro Mix VII User Guide HD0412 Rev 1 0 1 Electrical Installation and Communication Chapter 3 KD485 STD Hydronix Part No 0049A Hydronix Hydronix Senso
29. ferred to as AUTO Mode when using the Hydronix Hydro Control water controller This method continuously adds water until a set target has been achieved Water addition rates and determination of stability at the target point should be considering in the control algorithm This method is less effected by variable batch sizes and varying ratios of ingredients in the mixer For further advice on any of these methods please contact the Hydronix support team support hydronix com 40 Hydro Mix VII User Guide HDO412 Rev 1 0 1 Optimising Sensor and Process Performance For most applications the default measurement mode filtering and signal smoothing settings of the sensor will be suitable A more desirable output may be achieved by adjusting the filtering and signal smoothing parameters in the sensor see Filtering Chapter 4 Selecting an alternative measurement mode see Alternative Measurement Techniques Chapter 5 may give a more desirable signal response but before doing so it is worth considering the application advice set out below It is also recommended that you contact the Hydronix support team support hydronix com For many applications it is also worth reviewing the application process The sensor itself is a precise instrument it s practical performance in a given application is largely a function of the application itself For example in a mixing application the sensor will output a stable signal once the material is homo
30. g using the averaging To obtain an average reading the digital input must be configured to Average Hold When this digital input is switched high the Raw Moisture readings are averaged When the digital input is low this average value is held constant Calibration inside sensor Averaging in the sensor using digital input Averaging in the sensor using digital input Filtered Moisture Filtered Unscaled Average Moisture Average Unscaled It would be advisable to average in the control system here Figure 23 Guidance for setting output variable 2 3 Low and High These two values set the moisture range when the output variable is set to Filtered Moisture NOTE These parameters are not used if the output type is set to Compatibility or Average Moisture The default values are 0 and 20 where These limits are set for the working range of the moisture and must be matched to the mA to 0 20mA OmA represents 0 and 20mA represents 20 4 20mA 4mA represents 0 and 20mA represents 20 moisture conversion in the batch controller 3 Digital inputs output setup The Hydro Mix VII has two digital inputs output the first can be configured as an input only The second can be either an input or output The first digital input can be set to the following Unused The status of the input is ignored Average Hold 30 Hydro Mix V
31. genous If the mixing equipment is not capable of achieving homogeneity or of achieving this in the allotted time the sensor signal will be conducive of the heterogeneity of the material usually a variable or undulating reading Other key factors worth considering are General to all Applications e Power Up It is recommended to allow the sensor to stabilise for 15 minutes after applying power before use e Positioning The sensor should be in contact with a representative sample of the material e Flow The sensor should be in contact with a consistent flow of material e Material If the ratio of ingredients or additives of the underlying material or blend changes this may effect the moisture reading e Material particle size If the particle size of the material being measured changes this may effect the rheology of the material for a given moisture content Increased fine material often leads to a stiffening of the material for a given moisture content This stiffening should not automatically be construed as a reduction in moisture The sensor will continue to measure moisture e Material build up Avoid material build up on the Ceramic Disc Mixing Applications The moisture reading from the sensor can only indicate what is happening in the material or mixer The speed of the reading or the time taken to reach a steady reading when the materials are homogeneous reflects the effectiveness of the mixer By taking s
32. hapter 3 Electrical Installation and Communication 23 Ne E leie Bal lee e EE 23 2 sev eet Ee e EE 23 3 RS485 m lti drop Connection ann 25 4 Hydro Control IV Hydro View CONNECTION ooocccccnccccccooonccnnnncnonononncnnnnnonononannnnnnnnnnnnnannennnnnnns 25 De GOME CUN oa Pl er eebe bebes 26 Onapler dG Omni qua ON TEURER 29 1 Gontiguing me SONS OM EE 29 2 ANalOQUE OUIPULSELWD DEEG 29 3 Digital e leo ene E e EE 30 A FEINO EE 32 5 Alternative Measurement Techniques sn 35 Chapter 5 Sensor Integration and CG albraton ss 39 TL Sensor MEGa an kein 39 alle e EE 39 Chapter 6 Optimising Sensor and Process Performance nennen 41 1 General to all Applications En 41 2 TE ie Te ele ee EE 41 S GOnCrete Migranten 42 G MR Die En Enter 43 Ghapler 7 Sensor Glagn slies rss 45 i Sensor Diagnostics eege deren een nel 45 Chapter 8 Technical speeification u ae Seed ebe ed 49 1 TECANICAL PEC A MAS des deeds 49 Chapter 9 Frequently asked questions iii 51 ADPENABE A Detault ee 55 DN A APP A tnt item nier ist 55 Appendix B Document Cross Reference iii 57 1 Document Gross Referenten 57 Hydro Mix VII User Guide HDO412 Rev 1 0 1 7 8 Hydro Mix VII User Guide HDO412 Rev 1 0 1 Table of Figures Figure 1 The Hydro Mix VII and Adjustable Clamp Ring 10 Figure 2 Connecting the sensor overview ooocccccccccoccnnnccononcnnnnonnnncnonononannnnnonnnnnnnnnonannnnnnnonannnnnnnnnnns 12 Figure 3 Mounting in flat eur
33. ime the Data Valid label changes to Data Invalid If the data falls below the lower limit the Bin Empty condition is activated for those sensors whose digital output can be configured to indicate this 5 Alternative Measurement Techniques The Hydro Mix VII has the option of selecting alternative measurement techniques There are three measurement modes supported by the HS0077 firmware Standard Mode Mode V and Mode E In most cases Standard Mode will give excellent results and the sensor parameters may be left in their factory settings 9 1 9 2 9 3 Standard Mode This is the standard measurement mode which is currently used in most Hydronix sensors It is best to use this mode if there are no reasons to choose one of the alternative modes This mode should work best for aggregates and concrete applications Standard Mode uses only the change in the resonant frequency of the sensor to measure changes in moisture Modes V and E Modes V and E combine the change in the resonant frequency with the change in the amplitude of the microwave resonator to determine the change in moisture The two modes respond differently to changes in moisture and density Either mode V or E may be more appropriate for certain materials or applications When to use an alternative mode is described below When to use alternative measurement techniques The most appropriate mode will be determined by the requirements of the user the app
34. is case the installation should be completely checked Is the ceramic cracked Is the sensor mounted flush and are the mixer blades adjusted as recommended in the routine maintenance section If the problem persists then check the output when reading only air and check also by placing sand over the sensor If the output is still erratic then the sensor could be faulty and you should contact your dealer or Hydronix for technical support If the readings are OK but appear erratic during mixing then try and connect to a PC and run Hydro Com to check the configuration filter settings Default settings can be found on Page 55 or in Engineering Note ENOO59 Q My sensor takes a very long time to detect the water that goes into the mixer Can speed this up A This could indicate that the mixer has a poor vertical mixing action Look at how the water goes into the mixer Try to spray the water into the mixer in as many places as practical Check the filter settings and if they are too high reduce the filtering time This should not be done to the detriment of the signal stability as unstable signals may affect the amount of water calculated and hence the quality of the final mix In some cases it has been found that the configuration of the paddles in the mixer has been misaligned Be sure to check the specifications on your mixer to be certain of the proper mixing action Q My water controller is a dribble feed system which progressively adds water to r
35. lication and the material being measured Precision stability and density fluctuations as well as the working moisture range are all factors that may determine the choice of measurement mode Standard Mode is often associated with flowing sand and aggregates and concrete mixer type applications Hydro Mix VII User Guide HDO412 Rev 1 0 1 35 Chapter 4 Configuration 9 4 Modes V and E are often associated with lower density materials such as grain or other organic materials They are also associated with any material that has a variable bulk density that correlates to moisture content Modes V and E may also be beneficial for high intensity mixing applications of high density material and for other mixing applications with distinct changes in density over time including aggregates and concrete The objective is to choose the technique that gives the most desirable often smoothest signal response and most accurate moisture determination Effects of selecting different modes Each mode will give a different relationship between the sensor s 0 100 unscaled values and the moisture percentage When measuring in any material it is usually beneficial that a large change in unscaled sensor readings equates to a small change in moisture levels This will give the most precise calibrated moisture reading see Figure 29 Relationship of unscaled values to moisture This assumes that the sensor remains capable of measuring across the full moistur
36. may also relevant to other mixing applications Ingredients If the aggregate masses are not corrected for high moisture contents then the aggregate cement ratio will change considerably having an adverse effect on consistency and concrete performance If the aggregates are very wet as may be the case at the beginning of the day due to water draining in the storage bin then there may be more water in the aggregates than the mix requires The moisture content of the aggregates should be above the saturated surface dry SSD Hot cement can affect consistency workability and thus water demand Changes in ambient temperature can affect water demand Where possible the cement addition should follow within a few seconds after the commencement of the addition of sand and aggregates Combining the materials together in this way will greatly assist the mixing process Consistency The Hydro Mix VII measures moisture not consistency Many factors affect consistency but may not affect moisture content These might include e Aggregate grading coarse fine ratio e Aggregate cement ratio e Admixture dosage dispersion e Ambient temperature e Water cement ratio e Ingredient temperature e Colours Mix Times and Batch Sizes Minimum mix times are a function of the mix design ingredients and mixer not just the mixer so different mix designs may require different mix times Keep batch sizes as consistent as possible e g 2 5m3 2 5m
37. me of the wet mixing time as this may be less important as the correct amount of water has already gone into the mixer if you do this then be aware that the final released mix may not be homogeneous e When running mixes using lightweight aggregates be certain to keep the lightweight as close to or above the SSD This will help reduce mixing time because less pre wet water is being used e When using a Hydro Control check also to see if there are timers being used after the mixer is charged prior to the start signal and after the mix complete prior to the mixer discharge These timers are not needed Is the mounting position of the sensor important A The mounting position of the sensor within the mixer is very important Refer to Chapter 3 Mechanical installation What is the maximum length of cable can use A See Chapter 8 Technical specification Hydro Mix VII User Guide HDO412 Rev 1 0 1 53 Chapter 9 Frequently asked questions 54 Hydro Mix VII User Guide HDO412 Rev 1 0 1 Appendix A Default parameters The complete set of default parameters are shown in the tables below This information is also listed in Engineering Note EN0059 available for download from www hydronix com 1 Parameters 1 1 Firmware version HS0077 Default Parameters Standard Compatibility Mode Mode 0 20mA 0 20 mA Compatibility 4 20mA Compatibility Output variable 1 Filtered moisture Filtered unscaled N A Average moisture
38. nennen nenne 31 Figure 25 Typical moisture curve ernennen 33 Figure 26 Graph showing raw signal during mix cycle nn 33 Figure 27 E le legt RAW SIGRAN N EE 34 Figure 28 Filtering the RAW signal A A A AAA A dt 34 Figure 29 Relationship of unscaled values to moisture nennen 36 Figure 30 Gradient of unscaled values to moisture percentage 4 40 Hydro Mix VII User Guide HDO412 Rev 1 0 1 9 Removable Protection Ring Ns 108mm 4 25 inch Ceramic Disc 4 fixing screws 125mm 5 1 inch Hydro Mix VII body houses sensitive electronics Clamp Ring PACKED CONTENTS HMO7T Hydro Mix VII sensor 0033 Adjustable Clamp Ring Mil Spec Electrical connector RECOMMENDED ACCESSORIES 0975 Sensor cable 4m 0021 Fixing Plate Figure 1 The Hydro Mix VII and Adjustable Clamp Ring Available accessories Part No Description 0021 Fixing Plate for welding to mixer 0033 Adjustable Clamp Ring supplied with sensor Additional rings can be ordered 0035 Blanking Plate for covering hole in the mixer when sensor is removed 0975 4m Sensor Cable 0975 10m 10m Sensor Cable 0975 25m 25m Sensor Cables 0116 Power Supply 30 Watt for up to 4 sensors 0049A RS232 485 converter DIN rail mounting 0049B RS232 485 converter 9 pin D type to terminal block SIMO1A USB Sensor Interface Module including cables and power supply EAKO1 Ethernet Adapter Kit including Power Supply EPKO1 Optional Ethernet Power Adapter Ki
39. nt and mixing times have to be set appropriately in accordance with the mixer due to the variation in efficiency of mixers The default filtering parameters can be found on Page 55 or in Engineering Note EN0059 34 Hydro Mix VII User Guide HDO412 Rev 1 0 1 Configuration Chapter 4 4 4 4 4 1 4 4 2 Averaging parameters These parameters determine how the data is processed for batch averaging when using the digital input or remote averaging They are not normally used for mixing applications or continuous processes Average hold delay When using the sensor to measure the moisture content of aggregates as they are discharged from a bin or silo there is frequently a short delay between the control signal issued to begin the batch and the material beginning to flow over the sensor Moisture readings during this time should be excluded from the batch average value as they are likely to be unrepresentative static measurements The Average Hold delay value sets the duration of this initial exclusion period For most applications 0 5 seconds will be adequate but it may be desirable to increase this value Options are 0 0 5 1 0 1 5 2 0 and 5 0 seconds High limit and low limit This refers to both moisture and unscaled units It is used to set the valid range for meaningful data whilst calculating the average value When the sensor reading falls outside these limits it is not included in the average calculation and at the same t
40. oing so it is recommend that you contact Hydronix to seek advice on our recommended settings for your given application Trials differ dependant on the application For a measurement taken over time it is recommended to record the sensor s output from each of the different measurement modes in the same process Data can easily be recorded using a PC and the Hydronix Hydro Com 36 Hydro Mix VII User Guide HDO412 Rev 1 0 1 Configuration Chapter 4 software these results may then be plotted in a spreadsheet When viewed in graph form it is often self evident which mode gives the desired performance characteristics For further analysis including sensor filtering analysis Hydronix can also offer advice as well as software to enable the experienced user to achieve the best possible settings for a sensor Hydro Com software and the user guide may be downloaded from www hydronix com When using the sensor to obtain an output signal that is calibrated to moisture an absolute moisture measurement it is recommended to calibrate using the different measurement modes and to compare results see Calibration page 39 For further information please contact the Hydronix support team at support hydronix com Hydro Mix VII User Guide HDO412 Rev 1 0 1 37 Chapter 4 Configuration 38 Hydro Mix VII User Guide HDO412 Rev 1 0 1 Sensor Integration and Calibration 1 Sensor Integration The sensor may be integrated into a process in one of two ways
41. ome simple precautions the overall performance can be considerably improved and the cycle time reduced with consequent financial savings Look at the mixing process Check how the water disperses If added water sits on top of the material for a time before dispersing then spray bars may be required to disperse the water into the mixer more quickly to shorten the mixing time Spray bars are more effective than single water inlets The wider the area the water sprays the faster it will mix into the material It is also possible to add water too quickly during a mixing process Adding water faster than the mixers ability to blend the added water into the mix may increase the overall mixing time Ensuring that a mixer is properly maintained with blade clearances as per the manufactures specifications will increase the efficiency of the mixer The user may also find it beneficial to understand the ability of a pan mixer to mix both horizontally and vertically A speed of the vertical mixing action which cannot be seen so easily by eye can be recorded by a floor mounted moisture sensor This is the difference in time Hydro Mix VII User Guide HD0412 Rev 1 0 1 41 Chapter 6 Optimising Sensor and Process Performance 3 1 3 2 3 3 3 4 between the time that the water addition was made and the time that the sensor registers an increase in moisture at or near the mixer floor Concrete Mixing This section is specific to concrete mixing but
42. on Chapter 4 Final mixing Water added Mixer Initial discharge mixing time Mixer loaded with material D O 7 gt D D i D LL Figure 25 Typical moisture curve The degree of stability at points and B can have a significant effect on accuracy and repeatability For example most automatic water controllers measure the dry moisture and calculate how much water to add to the mix based on a known final reference in a particular recipe Therefore it is vital to have a stable signal in the dry mix phase of the cycle at point A This enables the water controller to take a representative reading and make an accurate calculation of the water required For the same reasons stability at the wet end of the mix Point B will give a representative final reference indicating a good mix when calibrating a recipe Figure 25 shows an ideal representation of moisture over a cycle The output of this is the Filtered Unscaled reading The next graph Figure 26 shows raw data recorded from a sensor over an actual mix cycle clearly indicating the large spikes caused by the mixing action Raw Signal Raw Unscaled 0 50 100 150 200 250 300 350 Time s Figure 26 Graph showing raw signal during mix cycle The follo
43. on as the mixer blades paddles and floor wear The sensor will occasionally need to be adjusted downwards in the mixer as the mixer floor wears to maintain the correct position in relation to the mixer floor Additionally the blades will need to be adjusted to maintain the efficiency of the mixing action and cleanliness of the sensor faceplate If the sensor is allowed to protrude into the mixer it will be susceptible to damage from the mixer blades paddles as well as from aggregates becoming trapped between the paddles mixer floor and exposed side wall of the sensor NOTE Damage caused under these circumstances will not be covered by warranty For accurate and representative moisture measurement the sensor must be in contact with the moving stream of material It is equally important that no material can build up over the sensor face to obscure the sensor readings Follow the advice below for good sensor positioning e It is a good idea to provide a small inspection lid in the mixer cover so that during mixing and when the mixer is empty the sensor face may be observed without having to raise the main cover plate e If the floor is not level fit the sensor in the highest point in the floor e Ensure that the sensor is fitted away from the water cement and aggregate entry points e If the mixer surface is curved for example in a side wall or horizontal shaft mixer ensure that the sensor does not protrude to hit the blades and that
44. positive and negative changes in the raw signal It is possible to set limits for positive and negative changes separately The options for both the slew rate and the slew rate filters are None Light Medium and Heavy The heavier the setting the more the signal will be dampened and the slower the signal response Digital Signal Processing The signal is passed through a Digital Signal Processing filter This removes noise from the signal using an advanced algorithm Settings are None Very Light Light Medium Heavy and Very Heavy Filtering time This smoothes the signal after it has passed through the slew rate and Digital Signal Processing filters Standard times are 0 1 2 5 5 7 5 and 10 seconds although it is possible also to set this up to 100 seconds for specific applications A higher filtering time will slow the signal response Figure 25 is a typical moisture curve during a batching cycle of concrete The mixer starts empty and as soon as material is loaded the output rises to a stable value Point A Water is then added and again the signal stabilises at Point B at which point the batch is complete and the material is discharged The main points to note with this signal are the points of stability because these signify that all the materials aggregates cement colourings chemicals etc are completely mixed together i e the mix is homogeneous 32 Hydro Mix VII User Guide HDO412 Rev 1 0 1 Configurati
45. r Sensor S A F RS485 A 9 way D Type PC Control System SEET 8 B G RS485 B 3 nat Lea TX e S full duplex RX 8 Host System ae E Dip Switch Settings RJ11 RS232 port 12 3 4 Figure 19 RS232 485 converter connections 0049A 5 3 USB Sensor Interface Module part no SIMO1A Manufactured by Hydronix this USB RS485 converter is suitable for connecting up to 16 sensors on a network The converter has a terminal block for connecting the twisted pair RS485 A and B wires and then connects to a USB port The converter does not require external power although a power supply is supplied and can be connected providing power to the sensor See USB Sensor Interface Module User Guide HDO303 for further information Hydronix Part No SIMO1 Connect to PC USB port gt ee sensor connections Sensor A Interface ov Sensor power optional DS Module aw SC Connect to 24Vdc power supply optional The Sensor Interface Module is powered from the USB port The external 24V power supply can be used if sensor power is required See user guide HDO303 for further information Figure 20 RS232 485 converter connections SIMO1 A 5 4 Ethernet Adapter Kit part no EAKO1 Manufactured by Hydronix the Ethernet adapter is suitable for connecting up to 16 sensors to a standard Ethernet network An optional Ethernet Power Adapter Kit EPKO1 is also available which eliminates the need for additional expensive cables
46. rder to achieve the same moisture percentage Failure to correct for moisture in the aggregates leads to varying total batch weights and less accuracy in the calculation This also results in under yielding and is consequently an inefficient use of cement A different calibration may be required for large variations in batch weights e g half batches When performing a calibration it is advised that both the dry and wet mix times are extended to ensure that both are homogeneous Calibrate when conditions and ingredients are typical e g not first thing in the morning when the aggregates are very wet or when the cement is hot When using a calibration based water addition method it is essential to obtain a correct dry reading The dry mix time must be long enough to obtain stability of the signal 4 Routine maintenance Ensure the ceramic is always flush with the mixer wear plates Fit the adjustable clamp ring part no 0033 for ease of adjustment and extraction Keep the mixer blades adjusted to 0 2mm above the mixer floor This will have the following benefits All the residual mix is discharged when emptying the mix Mixing action close to the floor of the mixer is improved thereby improving the reading of the sensor Reduced cycle times will result in savings on power and wear REMEMBER DO NOT HIT THE CERAMIC Hydro Mix VII User Guide HDO412 Rev 1 0 1 43 Chapter 6 Optimising Sensor and Process Performance 44 H
47. s a number of internal parameters which can be used to optimise the sensor for a given application These settings are available to view and change using the Hydro Com software Information for all settings can be found in the Hydro Com User Guide HD0273 Both the Hydro Com software and the User Guide can be downloaded free of charge from www hydronix com All Hydronix sensors operate in the same way and use the same configuration parameters However not all the functions are used in mixer sensor applications Averaging parameters for example are typically used for batch processes 2 Analogue output setup The working range of the two current loop outputs can be configured to suit the equipment to which it is connected for example a PLC may require 4 20 mA or 0 10V DC etc The outputs can also be configured to represent different readings generated by the sensor e g moisture or temperature 2 1 Output type This defines the type of analogue outputs and has three options 0 20mA This is the factory default The addition of an external 500 Ohm precision resistor converts to 0 10V DC 4 20mA Compatibility This configuration must only be used if the sensor is to be connected to a Hydro Control IV or Hydro View A 500 Ohm precision resistor is required to convert to voltage 2 2 Output variable 1 and 2 These define which sensor readings the analogue output will represent and has 4 options NOTE This paramet
48. se to the side wall of the mixer Therefore it is generally recommended that the sensor be positioned with the inner edge approximately 10 cm to 15cm 4 6 inches from the side wall of the mixer The minimum distance should never be less than 5cm 2 inches See the advice for flat surface mounting on page 14 Approximately 10cm 4 ins Figure 7 Position of sensor in a planetary mixer 2 4 Single shaft horizontal and ribbon mixers The sensor is generally best positioned near the base of horizontal mixers 30 degrees above the base to prevent water pooling in the base covering the sensor face It should be placed approximately half way along the length of the mixer See guidance for mounting in curved surfaces on page 14 NOTE The sensor om should be on the up ZT stroke of the mixer Q Y A N ME x Wi 30 Figure 8 Position of sensor in a horizontal shaft or ribbon mixer 16 Hydro Mix VII User Guide HDO412 Rev 1 0 1 Mechanical Installation Chapter 2 2 5 Twin shaft horizontal mixers The best position on horizontal twin shaft mixers is half way along the length of the mixer near the base at approximately 30 degrees above the base to prevent water pooling in the base covering the sensor face The sensor should be mounted on the up stroke of the mixer If this is not possible for example when the mixer unloading doors obstruct this area then it should be positioned on the opposite side on
49. sed for bin applications with the Hydro Probe II but are used in the exactly the same way with the Hydro Mix VII With these factors unchanged A 0 B 0 2857 C 4 SSD 0 and the mixer empty air measurement 0 unscaled then it can be shown that the moisture is 4 What calibration is required for my Hydro Mix VII When using a mixer sensor for concrete production it is normal to connect the sensor to a batch controller or Hydro Control unit which manages the moisture during batching The sensor is not calibrated directly Instead a series of recipe calibrations within the batch controller are made for each different mix design each carrying their own reference to which concrete of the correct consistency can be made Each mix design should have its own recipe because each combination of materials has an effect on the microwave response Do Hydronix sensors have to be calibrated to an exact moisture percent Although possible for most applications exact moisture of the mix is not necessary All that is needed is a reference target that is known to product a good mix Therefore in the majority of situations the analogue output from the sensor is set for Filtered Unscaled 0 100 A set point is recorded at the end of each batch and stored in the recipe where it is used as the final target lf make a mix with the same quantities of dry materials but with different colours do need to have a different recipe Yes pigments whether
50. sture target a moisture percentage value in order to perform the water addition calculation or progressively add water to a set target Water addition is in one of two ways Calculation based water addition A moisture reading is taken in the homogenous dry material and a calculation is made of the amount of water required to achieve the required target This method requires a calibration routine to determine the ratio between a change in the sensor s unscaled values to a change in moisture percentage This effectively calculates a gradient of unscaled values to moisture percentage see Figure 30 Because the sensor s output are linear and fully temperature stable once this gradient is known the control system can calculate from any dry reading the water required to reach a given target for a known recipe The calculations and target are often calculated in terms of unscaled units only Hydro Mix VII User Guide HDO412 Rev 1 0 1 39 Chapter 5 2 2 2 Whilst it is possible to perform a moisture sample test on the final product to determine it s moisture content this is often impractical and the theoretical value or recipe design value is used Advice on controlling this process can be found in Chapter 6 Moisture Percentage Value 5 4 3 2 5 unscaled units 0 4 moisture 0 5 10 15 20 25 30 35 40 45 Sensor Unscaled Value Figure 30 Gradient of unscaled values to moisture percentage Progressive Water Feed Re
51. t 0900 Replacement Ceramic Kit Ceramic Disc Protection Ring and Ceramic Retaining Ring 0910 Replacement Ceramic Kit Ceramic and Protection Ring kit 0920 Replacement Ceramic Kit excluding Protection Ring 0930 Replacement Protection Ring including screws Hydro Com configuration and diagnostics software is available for free download from www hydronix com 10 Hydro Mix VII User Guide HDO412 Rev 1 0 1 Introduction Introduction The Hydro Mix VII digital microwave moisture sensor with integral signal processing provides a linear output both analogue and digital The sensor may be easily connected to any control system and is ideally suited to measure the moisture of materials in mixer applications as well as other process control environments The sensor reads at 25 times per second which enables rapid detection of changes in moisture content in the process including determination of homogeneity The sensor may be configured remotely when connected to a PC using dedicated Hydronix software A large number of parameters are selectable such as the type of output and the filtering characteristics The sensor is constructed to operate under the most arduous conditions with a wear life of many years The Hydro Mix VII should never be subjected to unnecessary impact damage as it houses sensitive electronics In particular the replaceable ceramic faceplate although extremely hardwearing is brittle and may crack if subjected to se
52. tace nennen nnnnnnnn nennen nennen nnnnnnnn nenne nennen 14 Figure4 Mounting in a CURVE Surface a ae 14 Figure 57 Position OrSensor ind turbo MIXED am eae Ae ee 15 Figure 6 Position of sensor in side wall of mixer ss 15 Figure 7 Position of sensor in a planetary mixer sn 16 Figure 8 Position of sensor in a horizontal shaft or ribbon mixer 16 Figure 9 Position of sensor in a twin Shaft horizontal mxer nennen een 17 Figure 10 Sensorinstallation sa ara I 18 Figure 11 Adjustable Clamp Ring components VV 19 Figure 12 Fixing Plate prepared for attaching Clamp Ring 19 Figure 13 Adjustable Clamp Ring assembled and fitted to Fixing Plate ernennen 20 Figure 14 Adjustable Clamp Ring 0033 fitted to Fixing Plate 0021 and Hydro Mix VII 20 Figure 15 0975 Sensor cable connections ss 24 Figure 16 RS485 multi drop connection siennes 25 Figure 17 Connecting to a Hydro Control IV or Hvdro View 0001nnnnno000nnnnnnnnnsnnnnnnnnnnnennnneensnnnnnnnnne 25 Figure 18 RS232 485 converter connections O04A0OP nn 26 Figure 19 RS232 485 converter connections OU4A0OA nennen nn 27 Figure 20 RS232 485 converter connections SIMOAA RR Rnnnnnnn ne nennnnnn nennen 27 Figure 21 Ethernet Adapter Connections EAROI 28 Figure 22 Ethernet Power Adapter Kit connections EPKO1 nennen 28 Figure 23 Guidance for setting output variable 30 Figure 24 Internal external excitation of the digital input nennen
53. to be run to a remote location which does not have local power If this is not used then the Ethernet adapter will require a local 24v power supply Hydro Mix VII User Guide HDO412 Rev 1 0 1 27 Chapter 3 Hydronix Part No EAKO1 Electrical Installation and Communication QODOCCODOOOAOATD EAO1 Ethernet Adaptor 10 100baseT o aler Cable to Sensor ACA PEDO de WY to Network LQOODODOOD Colour MILSPEC RS 485 A White F A RS 485B Black G EN OvDC Black B 24vDC Red A RS 485 A RS 485 A Figure 21 Ethernet Adapter Connections EAKO01 Hydronix Part No EPKO1 Control Room Cabinet IEC Mains Cable 100 240v 50 60Hz 10 100baseT CAT5e Ethernet to Network pai Lona 10 100baseT CAT5e Ethernet i ae to EPAO1 PR Junction box close to sensors 10 100baseT CAT5e Ethernet to EPIO1 EPAO1 Ethernet Power Adapter Foa Se OSA PFS PER IS PE PS E EAO1 Ethernet Adapter Cable To Sensor g Colour MILSPEC RS 485A White F RS 485B Black G Ov DC Black B 24v DC Red A 10 100baseT e CAT5e A linking EPAO1 and EAO1 Figure 22 Ethernet Power Adapter Kit connections EPKO01 28 Hydro Mix VII User Guide HDO412 Rev 1 0 1 Configuration 1 Configuring the Sensor The Hydro Mix VII ha
54. ved using the 500 Ohm resistor supplied with the sensor cable e Digital control an RS485 serial interface permits direct exchange of data and control information between the sensor and the plant control computer or Hydro Control system USB and Ethernet adapter options are also available e Compatibility mode this is a legacy mode which allows a Hydro Mix VII to connect to a Hydro Control IV or Hydro View unit The sensor may be configured to output a linear value of between 0 100 unscaled units with the recipe calibration being performed in the control system Alternatively it is also possible to internally calibrate the sensor to output a real moisture value Digital inputs output O O 3 RS485 serial communications T _ Figure 2 Connecting the sensor overview Power supply 15v 30v DC 1A min 2x Analogue outputs 0 20mA 4 20mA 0 10v 12 Hydro Mix VII User Guide HD0412 Rev 1 0 1 Mechanical Installation General to all applications A significant benefit of the Hydronix system is that only one sensor is required in the mixer However it is important that it is positioned correctly in relation to the mixer floor aggregate and water inlets and other moving parts such as blades and paddles Although paddles or scraper blades can be a useful mechanism to keep the sensor free from material build up they could cause damage to an incorrectly positioned sensor It will be necessary to periodically check the positi
55. vere impact CAUTION NEVER HIT THE CERAMIC Care should also be taken to ensure that the Hydro Mix VII has been correctly installed and in such a manner to ensure representative sampling of the material concerned Suitable applications The Hydro Mix VII microwave moisture measuring sensor may be successfully used in the following applications e Static pan mixers e Planetary mixers e Turbo mixers e Single and twin shaft horizontal mixers e Ribbon mixers e Flush mounted in chutes or similar applications NOTE For rotating pan mixers such as the Eirich and Croker liner mixers a static mounted Hydro Probe Orbiter is recommended Hydro Mix VII User Guide HD0412 Rev 1 0 1 11 Chapter 1 2 Measuring techniques The Hydro Mix VIT uses the unique Hydronix digital microwave technique that provides a more sensitive measurement compared to analogue techniques 3 Sensor connection and configuration As with other Hydronix digital microwave sensors the Hydro Mix VII may be remotely configured using a digital serial connection and a PC running Hydro Com sensor configuration and calibration software For communication with a PC Hydronix supply RS232 485 converters and a USB Sensor Interface Module See page 26 There are three basic configurations by which the Hydro Mix VII can be connected to a mixer control system e Analogue output A DC output is configurable to e 4 20mA e 0 20 mA e 0 10 V output can be achie
56. wing two graphs illustrate the effect of filtering the same raw data shown above Figure 27 shows the effect of using the following filter settings which create the Filtered Unscaled line on the graph Slew rate Medium Slew rate Light Filtering time 1 second Hydro Mix VII User Guide HD0412 Rev 1 0 1 33 Chapter 4 Configuration Applying Filter Slew Rate Light Slew Rate Medium Filtering Time 1 second CO o J CH D CH WA o ts o 3 D i e a z a E 3 2 a Z D CAN o 350 Time s Figure 27 Filtering the RAW signal 1 Figure 28 shows the effect of the following settings Slew rate Light Slew rate Light Filtering time 7 5 seconds Applying Filter Slew Rate Light Slew Rate Light Filtering Time 7 5 seconds CO CH D D o 50 ts CH Unscaled Raw and Filtered LAN o 350 Time s Figure 28 Filtering the RAW signal 2 In Figure 28 it is clear that the signal at the dry phase of the mix cycle is more stable which is more advantageous when making the water calibration For most mixer applications the filter settings can be left at the default values which will adequately filter out the noise with the aim of providing a smooth signal Should there be a requirement to change the filtering then the aim is to provide as fast a response as possible whilst maintaining signal integrity Signal stability is importa
57. ydro Mix VII User Guide HDO412 Rev 1 0 1 Chapter 7 Sensor diagnostics The following tables list the most common faults found when using the sensor If you are unable to diagnose the problem from this information please contact Hydronix technical support 1 Sensor Diagnostics 1 1 Symptom No output from sensor Possible Check Required result Action required on explanation failure Output is working Perform simple test Milliamp reading Power down and re but not correctly with hand on sensor within the normal power sensor range 0 20mA 4 20mA No power to sensor DC power at 15Vdc to 30Vdc Locate fault in junction box power supply wiring Sensor has Power down and re Sensor functions Check power temporarily locked power sensor correctly up No sensor output at Measure sensor Milliamp reading Check cabling back control system output current at within the normal to junction box control system range 0 20mA 4 20mA Varies with moisture content No sensor output at Measure sensor Milliamp reading Check sensor junction box output current at within the normal connector pins terminals in junction range 0 20mA 4 box 20mA Varies with moisture content Sensor MIL Spec Disconnect the Pins are bent and Check sensor connector pins are sensor cable and can be bent to configuration by damaged check if any pins normal to make connecting to a PC are damaged electrical contact Internal failure or Connect the s
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