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Hydro-Control V User Guide

1. 7 CHAPTER 1 INTRODUCTION pnt I IRR PH UR ei ER 9 CHAPTER 2 OPERATION ipeo a Eq asd eia sits 11 BASIC OPERATION OVERVIEW sess cs oe dede repetito eei e e e no tia er detegere e frere es 11 SETTINGMIX TIMES 13 EDITING RECIPES 2 2 nn ERN 14 MIX CONTROE MODES ea eea te une riii kat eine sine 14 PRESET MODE 4 408 15 ere e o eU Ade eu I eU qute een sieh ate on 17 AUTOMODE CONTROL PARAMETERS dienten iba lente breathe be de oie tte 20 CALCMODE EE 22 CHAPTER 3 MENU DESCRIPTION E E E en Brain Rama re 27 MENU TREE assise Acte ets at re e ee e o d ege e in e E RR RO est E iet 27 START MENU AREAS 28 SELECT RECIPE pe Ete ee RR RERO e EE toc E 30 EDIT RECIPE nhe rdiet dede ae t dut et dede eee des 31 jani 36 SYSTEM AUTOMATIC PAUSE AND ALARM nee enne enne tne tree tree tree ete es 37 TRIM AND oin et rt OPER CE re RP OREL ER EOS ent EO IRRE 38 MIX TSG see 39 SETUPS YSTEMS e IR OR ten en aot D be SEIDEL anal tete 45 SENSOR CONFIGURATION 2 ipee o n 8 pain e e ye e an cuentas idee aides 54 CHAPTER RS232INTEBREAG
2. 80 Hydro Control V User Guide HD0193 Issue 2 5 0 Password 10 1 Pause R eset eet ons Plus Tolerance esee N iui Proportional 49 95 1 Recipe Default Parameters 46 Reading Parameters 60 61 Remote Selection DOL OCUING 30 Setting Parameters 59 Remote Commands Remote Recipe Selection Resonator Menu Connections iiec ann e de Port Settings zn Ai PSA BS nn een Samples 5 uote etait ee Selecting Recipe 30 Sensor Configuration sensor Cable ite Sensor Calibration Configuration Hardware Sensor Configuration 50 2 222222 Setup SYSIEM tege da odes 106 Hydro Control V User Guide HD0193 Issue 2 5 0 Setup Menu BAQNOSUCS eripe 50 Hardware e 51 Monitor 22 2 ee 53 52 SIZING Valves na 86 Slew Rate en ln 55 stand By nannte 73 Start Menu 28 Auto Mode
3. 22 93 38 40 Calib Mode 33 Start Menu 2 2 2 29 Calibration nn 41 46 2 ci n MM T 24 34 Auto Mode 17 Calc 22 93 Hardware Menu 51 Mix Control 14 MiX LOQ rere 43 Mix Times 13 inre Mc n 22 Sensor Configuration 54 Temperature Compensation 26 Trim and Update 38 34 Water Information 41 With Admix eec 24 Without Admix 23 Calibration 34 Cement Gall ees 73 Cement In eene 73 74 Cement 37 6 s 90 Coarse Water 74 Connecting Ancillary Equipment 69 Control Algorithm 93 Control Method 28 36 40 48 Gut ii see 68 Cycle Loops ae 90 32 Default Recipe Parameters 46 Derivative 90 Diagnostics Menu 50 52 53 Displayed Moisture Value
4. amp MIS MIS amp amp Status calib Dev Reset Back Figure 19 Mix Log deviation information The deviations can be used as an indication of how stable the signal is at the end of each phase i e how homogeneous the mix is The deviation values are calculated by recording the difference between the maximum and minimum sensor readings over a period of time at the end of the first mix and final mix times the averaging time see control menu parameters Deviations should therefore be as close to zero as possible always less than 3 unscaled units Wet dev Average Wet CREER SEE Average Dry Averaging time Averaging time i Final mix i time First mix time Time Start Mix Complete Figure 20 Mix Log Deviations Trend display 42 Hydro Control V User Guide HD0193 Issue 2 5 0 Calibrating from the Mix Log When running in Calc mode as mentioned the recipe needs to be calibrated so that the controller will know the required moisture level This calibration can be done in two ways The first method is to use the Calib mode as described previously on page 28 The second method is to calibrate the recipe from a previous record in the mix log As with all calibrations it is essential to ensure that the moisture at the end of the first mix and the final mix times a
5. Final Wet 4 Discharge First Loading gt gt gt Inputs Water Meter Optional Cement In Coarse Water j Fine Water Mix Complete Status Start 1 Mix Final Wet Wet Mix Mix Complete Start Menu Menu Figure 34 Dry Mix Cycle no Pre Wet Hydro Control V User Guide 71 HD0193 Issue 2 5 0 Start Pre wet water added Moisture Busy mode Normal mix cycle 2 stage calibration mix cycle Water _ 72 Hydro Control V User Guide HD0193 Issue 2 5 0 Mix Complete First mix Final water Final mix time addition time 1 15 24 water Final mix water addition time addition Figure 35 Signal Mix Complete 2 stage calibration mix cycle 2 stage calibration mix cycle Explanation of mix cycle The mix cycle see previous figures can have the following phases START MENU System is waiting for START signal The mixer will normally be running and the aggregates will often be loaded or discharged with the Hydro Control V at the Start Menu PRE WET if required Following the addition of aggregates a START input either by pressing the front panel button or by the plant computer sending the input high will cause the system to add the amount of water defined in the recipe to the mixer before the cement is added The mix cycle will continue after the time defined
6. an O7 ON En cn cnp Status Select Defs Copy Edit Back Figure 10 Select Recipe Using the Select Recipe Menu The system is set up with 99 recipes Initially all the parameters of these recipes will be set to their default values see section Edit recipe parameters To select a recipe from the list use to move the cursor to the required or type the number of the required recipe e g enter D followed for 3 followed by 64 lt Defs gt F1 Set the selected recipe to the values defined by the Default Recipe see section Edit System Parameters lt Copy gt F2 Enables copying of recipes lt Edit gt F4 Edits the selected recipe Backs F5 Returns to the previous menu 30 Hydro Control V User Guide HD0193 Issue 2 5 0 Edit Recipe Rec Hatch 1 8 Edit Recipe water litz Pre wet target Pre set Fre wet mode Pre 7 Moisture Pre wet delay First mix time Cement timeout 15 Moisture target 6 3 Preset final lits 6 8 Final mix time Hore Inc Dec Back Figure 11 Edit Recipe 1 Page Using the Edit Recipe Menu To edit a recipe see next section for learning a new recipe select the parameters to be changed by scrolling through the parameter list using the up and down keys and then typing in the desired value c Enter the dig
7. 34 Dry Mix First Mix Cycle 71 Dry Weight use 34 Edit Recipe 31 SVSIBITI 46 nes 55 Fine 49 Fine Walter ae 74 First MIX een See Dry Mix First Mix en 33 Cr 20 49 Hardware Menu 51 Hydronix Password ts 99 VP ae 55 lu m 55 Input Module ae 69 jener 74 Interface Modules 87 Languages 46 Lightning Strikes 68 Lower Control Threshold 20 49 95 104 Meter Flow Pulse 46 TIMBOUL doe tits 46 Minus Tolerance 34 Mix Complete 73 74 Mix 73 Control Method 36 2 4600 18 Mix Extension 49 95 104 MIX m 34 39 40 Calibration ccccccececseeeecsseeeeeeeeeeee es 43 Downloading rastro ent ean 58 Mix Sequence Diagrams 70 Mix Times 13 Mixer Status Commands 63 Moisture Offset and Gain 34 Moisture Target 33 Monitor Menu 53 Output Module 69 ju 55 Variable 55 nd us 74 Panel
8. The large clear display ensures the principal information is readily visible without confusion Via a few easily accessed menus the user can define the mix cycle and the recipes as well as monitor the mixing cycle status recipe information sensor signal trend information and system diagnostics The Hydro Control V can be connected to a batch controller via an RS232 serial link to allow transfer of mix cycle information and remote recipe selection The RS232 port is also used to send software upgrades from a service computer The aim of this User Guide is to provide a simple operational overview follow by a more detailed screen by screen explanation of the system operation Hydro Control V User Guide 9 HD0193 Issue 2 5 0 Notes 10 Hydro Control V User Guide HD0193 Issue 2 5 0 Chapter 2 Operation Basic operation overview The Hydro Control V operation is based on a recipe system Up to 99 recipes can be defined Each recipe contains information for running the mix cycle Before running a mix cycle it is necessary to set up a recipe with the correct values to define the control mode and to control the mix cycle There are two basic mix cycles that can be defined Pre wet mix cycle The Pre wet mix cycle is used when an amount of water is to be added to the aggregates before cement addition the Final wet main water addition occurs after the First mix time often referred to as the dry mix time and is followed by the
9. 15 16 17 18 From the Start Menu press lt Recipe gt F2 Selected the desired recipe number From the recipe menu press Edit F4 Scroll to the bottom of the recipe menu to the parameter Calibration Type and select 2 point Enter the amount of pre wet water required in Pre wet water parameter If you do not require any pre wet set the Pre wet water and Pre wet target parameters to zero Enter the amount of final main water required in Preset Final parameter if you are unsure enter a value lower than that required A manual adjustment to a good mix can be performed at the end of the mix cycle so ensure that the discharge is set to manual Check that the First mix time and Final mix time parameters are correct Set the Dry weight parameter on page two of the recipe to that of your mix Check the Water limit parameter on page two of the recipe is correct Press Back F5 and then ED to save the changed values and return to the Recipe Menu Press lt Back gt F5 to return to the Start menu Press lt Mode gt F3 until Calib is displayed under the Recipe number Start the mix cycle from the batch controller or manually by pressing Start F1 On starting the mix an edit box appears which shows the current calibration water this will be the amount entered in the parameter Mes Water in the first and the Preset Final Calib Water in the second if this is greater than zero Type in the amount of water require
10. Averaging Time 16 Mix Extension Access mode Unlock Hore Inc Dec Back Figure 27 Control Menu first page NOTE INCORRECT VALUES MAY STOP THE SYSTEM FROM WORKING PROPERLY CHANGES SHOULD ONLY BE MADE BY COMPETENT OPERATORS The control algorithm used in Auto mode attempts to make a compromise between achieving the moisture target as quickly as possible and on the other hand not letting the moisture level overshoot the target level The factors that affect this compromise include How rapidly can your mixer make a homogeneous load How long after water addition starts will the moisture level near the sensor increase This depends upon sensor placement What is the flow rate of water through the coarse and fine valves What is the load size How quickly can you turn your valves on and off How often can you turn your valves on and off What variation in moisture content can you tolerate Adjusting the various control parameters permits optimisation to suit local conditions The Hydro Control V has been designed and configured so that most users will never need to know the details of the control method used and will not need to change the settings However if your mixer system is unusually fast or slow in its response and you are familiar with system control methods and theory you might be able to optimise your system response time by adjusting the default parameters 48 Hydro Cont
11. Q 19 ALARM E Me nom Outputs SN 8 MIXCOMPLETE S 7 MIX COMPLETE 6 PRE WET COMPLETE NS 5 PRE WET COMPLETE S 4 FINE WATER ae 59 3 FINE WATER Control K COARSE WATER Bn COARSE WATER Figure 37 System Interconnection Note The sensor cable screen is connected on Pin H of the Mil Spec connector ONLY 78 Hydro Control V User Guide HD0193 Issue 2 5 0 External 24VDC Note If only one valve is used connect to the Fine Valve output Hydro Mix Hydro Control V or Hydro Probe Orbiter Coarse Valve External Power Supply Relay or Volt Free Output Water Meter Figure 38 Wiring Schematic For Manual Plant Operation Hydro Control V User Guide 79 HD0193 Issue 2 5 0 Panel or Enclosure Cut out for Operator Terminal 232mm 9 14 in Figure 39 Panel cut out for Operator Terminal 171 Figure 40 Operator Panel Dimensions 80 Hydro Control V User Guide HD0193 Issue 2 5 0 190mm Remote Selection via If the Hydronix supplied PLC Hydronix part number 8102 is used for remote recipe selection the inputs to the PLC can be represented in one of three ways e BCD The recipe number is applied in Binary Coded Decimal form This allows all recipes 1 through 99 to be selected using eight inputs e BINARY The recipe number is applied in Binary form This allows all recipes 1 through 99
12. 32 Pre wet mode 0 auto 1 preset None 33 Cement weight Kg or lbs 2000 2000 34 Temperature or F 250 25 0 35 Temp Coeff 96 temp 200 0 2 36 Calibration Type 1 1 point 2 2 point None All the major recipe parameters can be written over the RS232 link The format and parameter list are similar to the read command i e to write the value of recipe parameter pp in recipe no nn send a message in the form Format Terminator Parameter Valid Period Response Range pp vv ASCII 13 nn 1 to 99 Active Standby if successful pp above All other recipes Anytime 1x if unsuccessful vv see above For example to set the final water target parameter 7 of recipe 5 to 8 5 e Send the ASCII string W 5 7 85 Do not forget to terminate with ASCII 13 carriage return 60 Hydro Control V User Guide HD0193 Issue 2 5 0 Reading and writing System Parameters Allthe system parameters including the default recipe parameters parameters 111 to 124 can be read and set over the RS232 link To read the value of system parameter pp send a message in the form Format Terminator Response Range ASCII 13 nn 0 See below pp see below 1xif unsuccessful System parameters can be read by specifying a recipe number of 0 and the parameter number 101 131 see table below Par
13. Corrected Moisture Target Moisture target Temperature Difference Temp Coeff Correction is applied for Calc or Auto mixes only there is no compensation during a Calib mix or if a Pre set amount of water is added Example Final Moisture 6 5 96 Temperature 20 0 100 9emoisture C If the current temperature measured is 25 0 C then the moisture target will become 7 0 If the current temperature measured is 15 0 C then the moisture target will become 6 0 26 Hydro Control V User Guide HD0193 Issue 2 5 0 Chapter 3 Menu Description Menu Tree Start Menu Mix Cycle Select Set up Mix Recipe System Log Edit Edit Display Input Sensor Configuration Output Keys Figure 8 Menu Tree In routine operation the user can operate the system using only the two highlighted menus shown above Mix Cycle amp Select Recipe However additional Set up and Diagnostic menus are provided to permit flexibility and complete control Hydro Control V User Guide 27 0193 Issue 2 5 0 Start Menu Start Menu Rec Hatch F m 4 15 litres Status Press Start when mix is loaded Start Recipe Mode Hore Figure 9 Start Menu After switching on the system a message stating Rom OK perform Ram test is displayed for 5 seconds Pressing will start the RAM test which ta
14. Moisture offset and gain Factors to convert sensor units into moisture units These parameters are used to convert the sensor s unscaled reading into a displayed moisture value The conversion performed is Displayed Moisture Unscaled x Moisture gain Moisture offset With default values the displayed moisture is not intended to be a true indication of the actual value It is possible to display actual moisture values by using the results of a bake out test to calculate correct Moisture offset and Moisture gain values Since Auto mode and Calc mode use the Moisture gain parameter in calculations changing these parameters will affect the control As a result it may be necessary to recalibrate recipes or change control parameter Typical values will be 0 to 5 for offset amp 0 1200 to 3 0000 for the gain If the parameters are changed all other moisture parameters in the recipe will be automatically re scaled Water trim An amount of water added or removed from the final water of a Calc mode mix cycle Cement weight The weight of cement in the mix This parameter is only used for calculating the water cement ratio which is displayed in the Mix log Temperature The base temperature used for temperature compensation in either degrees Centigrade Metric Mode or degrees Fahrenheit US Mode Temp Coeff The compensation factor used for temperature compensation in moisture per degrees temperature C or F If no compensation is
15. of 3 seconds recommended Mixer valve Fine valve sie Flow rate On Off Moist Flow rate On Off Moist m3 L sec Time Increase L sec Time Increase 0 25 550 2 1 0 36 0 4 1 0 07 0 5 1100 4 1 0 36 0 75 1 0 07 1 0 2200 8 1 0 36 1 5 1 0 07 1 5 3300 12 1 0 36 2 25 1 0 07 2 0 4400 15 1 0 34 3 1 0 07 Mixer Coarse valve Fine valve Capacity Flow rate On Off Moist Flow rate On Off Moist ft Gal sec Time Increase Gal sec Time Increase sec 20 2800 1 2 1 0 36 0 25 1 0 07 40 5500 2 4 1 0 36 0 5 1 0 07 60 8300 3 6 1 0 36 0 75 1 0 07 80 11000 45 1 0 34 0 9 1 0 07 86 Hydro Control V User Guide HD0193 Issue 2 5 0 Chapter 7 Specifications Supply Voltage 24V DC 11W nominal power for Hydro Control V and sensor Recommended supply 24 V DC 1A minimum 24W Important If using 24V DC for inputs outputs valves etc use a separate 24V DC supply to that powering the Hydro Control V NOTE The power cable must be screened and the screen connected at the earth stud on the Operator Terminal only Keyboard Sheet keyboard with polyester overlay Graphical Display 120 mm x 90 mm 4 75 x 3 55 va VGA display with backlight Security Open access for operators Critical operations protected by two levels of pass codes supervisor amp engineer level Connections Sensor cable T
16. For a Preset mode mix cycle no value will be shown The moisture in unscaled or reached at the end of a mix cycle The water cement ratio reached at the end of the mix cycle This parameter will only be calculated if a cement weight is entered in the recipe The calculation uses the dry moisture reading together with the amount of water subsequently added therefore the accuracy depends on the calibration of the recipe and the accuracy of the dry reading Water Information Page Rec Batch 1 3 Mix Log Ho Pre Calc Tot L L L Pre set 6 G1F a u 7 357 05C 0 0 68 9 76 8 82 0 Moisture 35 050 70 6 78 0 38705C 250 2150 0 39 85C 2 0 38705C 8 0 1 10F 6 G1F al aiP 0 0 CCE us Hater Mix More Back Figure 17 Mix Log water information 40 Hydro Control V User Guide HD0193 Issue 2 5 0 water page of the Mix Log accessed by pressing lt Water gt F2 contains information about the water added for each mix cycle The water added will be shown in units selected by the Water mode parameter see section Setup System The above figure shows the Mix Log with the Water mode set to Metric Pre L The amount of water added to the mix during the pre wet phase Calc L The amount of water calculated during a Calc mode mix cycle The total amount of water added during the final wet phase s of a Calib mode mix cycle For Preset mode an
17. None English English French German Dutch Spanish ltalian Finnish Danish Busy mode None Water Water Admix All Max recipes None 10 1 99 Water mode Determines how the water is measured into the mixer If you have no water meter use Timed otherwise select US US Gallons lbs and degrees Fahrenheit or Metric litres kg and degrees Centigrade to match your system Meter flow pulse The quantity of water measured by each pulse of the water meter Meter timeout If no water pulses are received within this time after opening the valve then an alarm is generated and the system will pause Language Defines the language used for the information messages Busy mode This can be set to one of three values e Water Busy signal is high only during Pre wet and Final wet phases Admix Busy signal is high during the Final wet phase In a 2 stage calibration mix cycle the signal is high for the second Final wet phase only All Busy signal is high during entire mix cycle Max recipes Defines the number of recipes available Default recipe parameters Scrolling down to the Default recipe statement at the bottom of the list will display the first page of the Default recipe These parameters are identical to those in every other recipe and can be edited in the same way see section Edit Recipe 46 Hydro Control V User Guide HD0193 Issue 2 5 0 System Test lt Valve gt F1 lt HCV gt F2 M
18. Setting Mix Times Control Mode The Hydro Control V can operate in one of three control modes e Preset mode Pre where the entered amount of water is always added regardless of measured moisture e Auto mode Auto This mode adds a preset amount of water defined by Preset Water during the Pre Wet phase and then uses the sensor moisture readings to control the water addition up to the Moisture target see section Auto mode e Calculation mode Calc This mode adds a preset amount of water and then calculates the amount of water to add from a Calculated Moisture Target and the Dry Weight of the mix This mode will be disabled if no value of Dry weight has been entered or if there is no water meter present A Calib mode mix cycle must be performed in order to calibrate the recipe before this Control mode can be used see section Calc mode Plus tolerance Moisture 96 above target 96 at the end of the Final mix time at which the system will sound and output ALARM Disabled after mix complete Recipe Gain Used only in Auto mode A tuning factor for the control algorithm to provide accurate control for smaller batch sizes For a normal batch size this will be 1 0 For reduced batch sizes it will be a number between 0 0 and 1 0 The Recipe Gain would be set according to the following guidelines For example 34 Batch Recipe Gain 0 75 Ve Batch Recipe Gain 0 5 4 Batch Recipe Gain 0 25 In the case where an A
19. and output ALARM Top of display Water limit exceeded Status bar PAUSED Abort for Mix Complete Resumes F1 Overrides the Water limit and resumes the mix cycle The maximum amount of water that should be added to a recipe is defined on a per recipe basis by Water limit Plus tolerance Plus tolerance defines the level above the target moisture at which the moisture of the mix is recognised as being too high If the moisture at the end of the mix cycle exceeds this level the system will sound and output ALARM Disabled after mix complete Top of display IMoisture too high Status bar D to Ack amp Mix Complete Minus tolerance The Minus tolerance recipe parameter defines the level below the target moisture at which the moisture of the mix is recognised as being too dry If the moisture at the end of the mix cycle is below this level the system will sound and output ALARM Disabled after mix complete Top of display IMix too dry Status bar lt Abort gt F2 Allows the current mix to be aborted When pressed the option to generate MIX COMPLETE signal is prompted with the following Mix Complete Required Yes F2 and No If No is selected it will return to the Start Menu If Yes is selected the mix complete signal is generated and Reset F2 returns to the Start Menu and clears the MIX COMPLETE signal Trim Opens the FINE WATER valve all the time the key is depress
20. by the pre wet delay If no pre wet is required the Pre wet water and Pre wet target should be set to zero This will ensure that a dry mix cycle will be completed CEMENT CALL if required System will output a PRE WET DONE signal indicating the Pre wet is complete This signal can be used to initiate the addition of cement This phase terminates when either the CEMENT IN input is received or the System exceeds the maximum permitted waiting time for the CEMENT IN signal To avoid ambiguity the CEMENT IN signal may stay high until the Hydro Control V issues a MIX COMPLETE FIRST MIX Time allowed for aggregates and cement to blend before entering controlled water addition This is defined in the recipe menu FINAL WET Time during which the system will control the water addition to achieve the target moisture value FINAL MIX Time allowed for mix to achieve a homogeneous state following all water addition MIX COMPLETE If at the end of the wet mix the Hydro Control V outputs a MIX COMPLETE signal which may be used to initiate a discharge sequence START MENU After the RESET input either by pressing the front panel button or by the plant computer sending the input high the MIX COMPLETE signal is cancelled and the system goes back to the Start Menu The mix cycle will start as soon as another START input is received Hydro Control V User Guide 73 HD0193 Issue 2 5 0 Input and Output Functions Inputs START RESUME Minimu
21. in a new reference value using the keypad Once updated this will change the moisture target in the recipe Mix Log Rec Batch k Moisture Select final moisture X to cancel 4 to save Status Figure 22 Calibrating from mix log enter final moisture The next screen will enable the user to input a theoretical trim on the calibration This might be useful if the particular batch in the mix log was a little too wet or too dry Adding or subtracting a trim here will then adjust the calibration as if the batch was made with a different quantity of water For example a batch is made with 30 litres This is a little too wet by only about 2 5 Therefore using a trim of 2 5 litres would calculate the calibration as if 27 5 litres was used Rec Batch Fre set Moisture Trim Hater For Good Mix x to cancel A to save Figure 23 Calibrating from mix log enter trim water After this the calibration can be saved and the recipe will be updated with the new parameters 44 Hydro Control V User Guide HD0193 Issue 2 5 0 Setup System Rec Batch 1 3 Pre set Setup System Hydro Control U 25 00 Moisture Password Figure 24 Setup System Using the Setup System Menu The Setup System menu is accessed by pressing lt gt from the Start Menu and then lt Setup gt F1 The Setup System menu is displayed with a prom
22. interference Explanation of Symbols and Markings It is important to understand the meaning of the various symbols and markings on the Hydro Control V equipment as follows Caution refer to accompanying documents Caution risk of electric shock Ventilation Requirements is important to ensure that the Hydro Control V has adequate ventilation and that the side vents not restricted The recommended clearance for the sides of the enclosure is 100mm Hydro Control V User Guide 67 HD0193 Issue 2 5 0 Protection From Lightning Strikes You should give some consideration to protecting the Hydronix installation from damage caused by lightning and similar electrical disturbances Many installations will be in situations that are particularly prone to damage by lightning for example Tropical Regions Outdoor installations Long cable runs between the sensor and the control panel Tall electrically conductive constructions e g aggregate bins Although the Hydro Control V is fitted with Opto Isolation on the sensor input this will not prevent damage in all cases Precautions should still be taken to avoid damage by lightning in areas where there is a known risk We would recommend the installation of suitable lightning barriers to all conductors in the sensor extension cable Ideally these would be fitted at both ends of this cable to protect both the sensor and the Hydro Control V plus any other equipment co
23. laptop or PC for software upgrades The RS232 port settings should be set as follows Baud Rate 9600 Data Bits 8 Parity None Stop Bits 1 RS232 Connections on Operator Terminal The Hydro Control V is fitted with three multi way connectors of which terminals 21 22 and 23 are used for RS232 connection The connections to the remote device are shown in the table below Pin No Signal Name Description RS232 Rx RxD Receive data Input RS232 Tx TxD Transmit data Output RS232 Signal ground Sending Remote Commands This section describes the commands that the PLC batch controller must send to the Hydro Control V to instruct it to carry out the required operations Note Al commands are terminated with a Carriage Return code ASCII 13 Also note that the position of spaces between command characters is important In the next sections the character represents a space and must be used where shown To prevent accidental changes that may produce undesirable effects some commands are only valid during certain parts of the cycle These are shown below For example e Changing the active recipe can only be done when the Hydro Control V is in standby phase since changing a recipe in the middle of an active mix phase will probably produce an erroneous mix Response will be Not While Active if attempted during any other phase e Mix complete is only meaningful during the mix complete p
24. performance of your mixer Reduce your mix cycle time By optimising the performance of your mixer The speed with which any water control system can work is very much dependent on the time taken to obtain a meaningful reading The moisture reading from the sensor indicates what is happening in the mixer The speed of reading or the time taken to reach a steady reading when the materials are homogenous reflects the effectiveness of the mixer By taking some simple precautions the overall performance can be considerably improved and the cycle time reduced with consequent financial savings 1 Adjustment of the blades Ensure the mixer blades are regularly adjusted to comply with the manufacturers recommendations normally 2mm clear of the floor with the consequent benefits e All the residual mix is discharged when emptying the mix e Mixing action close to the floor of the mixer is improved thereby improving the reading of the sensor e Will reduce wear on mixer floor plates 2 Plastic blades over sensor face It is recommended that the blade or blades sweeping across the sensor face should be of the plastic synthetic type as this helps to keep the sensor clean and can sweep closer to the sensor with less risk of damage 3 Cement addition Mixing the fine cement particles in with the relatively coarse particular size of the sand and aggregates is a tough job When possible the cement addition should commence within a few se
25. required this should be set to 0 000 Calibration Type Determines whether the calibration will be a 1 point or 2 point calibration mix cycle when calibrating with admix refer to page 23 24 for more information 34 Hydro Control V User Guide HD0193 Issue 2 5 0 From the edit recipe page it is possible to complete parameters from to another Pressing F2 will display the copy recipe page as shown below Enter the recipe number to be copied in the From section using the numeric keypad and press ED Then enter the destination recipe number in the To section and press EP Rec Batch 4 1 Calc Select Recipe 1 Moisture x to cancel Run Time 5 wi to accept Status Select 1111 Figure 14 Recipe page Hydro Control V User Guide 35 HD0193 Issue 2 5 0 Mixing Rec Batch 4 17 Calc Start Menu Moisture Status first mix final wet final mix Pause Figure 15 Mix Cycle Mix cycle The current recipe number is displayed in the top box on the right of the screen along with the recipe control method and the batch number The mix run time is displayed in the bottom box on the right of the screen and along the bottom of the trend graph Also shown under the run time is a count down of the remaining time in mixing phases of the cycle first mix time or final mix time Throug
26. the Water limit parameter on page two of the recipe is correct Press Back F5 and then CD to save the changed values and return to the Select Recipe menu Press Backs F5 to return to the Start menu Press Mode F3 until Preset is displayed under the Recipe number Start the mix cycle from the batch controller or manually by pressing Start lt F1 gt As soon as WET MIX begins to flash press Pause F2 Observe the mix consistency or the quantity of water added and manually add water using lt Trim gt until the desired amount of water for the Final wet phase has been added If a water meter is fitted the quantity of water added will be displayed under the tap icons When the correct amount of water has been added press lt Update gt F4 Press E gt to confirm the update Press lt gt F1 to continue with the mix cycle At the end of the Final mix time a MIX COMPLETE signal is issued After the mixer is discharged press lt Reset gt F2 to return to the Start Menu Press Mode F3 until Auto is displayed under the recipe number The recipe is now ready to run in Auto mode 18 Hydro Control V User Guide HD0193 Issue 2 5 0 mix cycle paused at phase of the mix cycle by pressing lt gt F2 The following options will be available Resume F1 lt Abort gt F2 lt Trim gt F3 lt Update gt F5 Continues the cycle from the point wh
27. to be selected using seven inputs e DISCRETE Each input allows one recipe to be selected allowing recipes 1 through 10 to be used The selection method is configured by the state of inputs A and B on the PLC as defined in the table below Input A Input B Method ON OFF BCD Binary Note There has to be a recipe in the Hydro Control V to be able to select it If there is no recipe the selection remains as the last one selected Connecting the Hydronix supplied PLC for remote recipe selection The 9 pin connector on the IMO K 7 PLC user port uses a different pin out to a standard RS232 connector and the Hydro Control V must be connected to it according to the following diagram Hydro Control V PLC The PLC software is programmed to send a Recipe Select command via the RS232 port after the input selection is made the input selection must change from zero to the desired selection code according to the coding method as above BCD Binary or Discrete for more than 200ms then return to the Zero state Additionally the PLC will operate relay output P47 after a Recipe Select command the Hydro Control V requires that Recipe Selection is made during Start menu only this output may be used to delay the START signal to the Hydro Control V in case the Recipe Selection is made at the same instant as the plant Start signal in order to ensure the selection is registered The relay output P47 may also be used to origi
28. used by the Hydro Control V but available from sensor Output variable Determines which variable is available on the sensor analogue output e Filtered Unscaled reading filtered using the sensor filtering time and slew rates e Raw Unscaled reading with no filtering applied I P 1 Digital input to sensor that can be configured to e None status of input is ignored e M T switch analogue output between a signal proportional to moisture and a signal proportional to external material temperature 2 This parameter is not relevant to Hydro Control V and will always be set to None Ave hold delay Always set to 0 0 for mixer applications Filtering time Determines the filtering time in a sliding window averaging process Slew rate amp Slew rate These parameters are used by the sensor to limit the effect of rapid transient signals due to mixer blades or noise spikes on the electrical supply lines They set respectively the maximum positive and negative voltage change allowed between successive sensor readings Hydro Control V User Guide 55 HD0193 Issue 2 5 0 56 Hydro Control V User Guide HD0193 Issue 2 5 0 Chapter 4 RS232 Interface Hydro Control V can be connected to a remote device such as a programmable logic controller PLC for remote recipe selection or a batch control computer for remote recipe selection and reading of various parameters for logging purposes can also be connected to a
29. while mix active All replies are terminated with a carriage return ASCII code 13 Connecting to a PC Laptop The upgrade utility uses the Hydro Control V RS232 serial connections and you will need the appropriate connecting cable as described below Connect the COM port of the PC Laptop to the 5232 connections on the Hydro Control V using the following diagram Hydro Control V PC Laptop 9 pin DIN 64 Hydro Control V User Guide HD0193 Issue 2 5 0 Upgrading Software Due to Hydronix commitment to continuous improvement of their products upgraded versions of the system software may be released Any new software versions and the utility to upgrade the Hydro Control V are available on the Hydronix web site http www hydronix com Using the Hydro Control V Upgrade Utility An upgrade facility is available from Hydronix This utility is run from a PC using the RS232 serial port on the Hydro Control V This allows the ability to upgrade the Hydro Control V whilst on site Note that when upgrading the system parameters control parameters and recipe data will return to their default value The upgrade utility therefore has a backup and restore feature which will allow the parameters to be downloaded onto the computer then uploaded again so that the Hydro Control V will once more be fully functional Switching into Upgrade Mode e Switch off the Hydro Control V With the e key depressed switch on the
30. 1 133 Pre wet delay Seconds 10 10 134 Pre wet target 0 1 40 4 0 135 Pre wet mode 0 auto 1 preset None 136 Max recipes None 10 10 137 Access mode 0 unlock 1 lock None 138 Mix Extension Seconds 10 10 139 Cycle loops None 2 2 140 Cement weight Kg 2000 2000 141 Address 0 16 only None 5 5 142 Temperature 250 25 0 143 Temp temp 200 0 2 I 2 Both mene m T A 2 Both Mong 146 1 1 point 2 2 All major system parameters be written over the RS232 link The format and parameter list are similar to the read command i e to write a value vv to system parameter pp send a message in the form Parameter Format Terminator Response W nn pp vv ASCII 13 nn 0 if successful pp see above vv see above 1x if unsuccessful The response will be in the same format as the read command 62 Hydro Control V User Guide HD0193 Issue 2 5 0 Mixer Status Commands Four commands permit interrogation of the current status To read the current status parameter pp send a message in the form Format Terminator Parameter Response M nn pp ASCII 13 nn 0 See below pp see below 1x if unsuccessful Parameter Description Units RS232 Actual value value 6 Current active recipe None 1 1 12 Total water added at Mix Complete Litres or US Gallons 82 20 82 20 24 Time taken to reach Mix complete at Secon
31. 2 15 Kg 4 75 Ib 7 48 x 9 69 W 7 00 H x 9 14 W Front panel protected to IP65 Appendix Advanced Control Parameters Edit Control Batch 1 3 System mode Hormal Coarse upper thr Pre set Derivativerqain 1 8 2 Moisture Cucle zon off 3 8 mode Plant Samples s 8 1 Cycle Loops Address Inc Dec Back Figure 44 Edit Advanced Control Parameters Screen The Advanced Conirol Parameters are only used by the Auto mode mix cycle control To access the Advanced Control Parameters the Hydronix password must be entered at the System Setup menu see section Setup System Enter the edit system control parameters menu by pressing lt Control gt F3 and move the cursor lt down to More at the bottom of the menu Hydro Control V User Guide 89 0193 Issue 2 5 0 Advanced Control Parameters Parameter Units Default Oaseppertr fos 00 10 RS232 Mode Plant Screen 21 99 Cycle Loops None o ps ms System Mode This be set to one of two modes e Normal displays normal operating information only e Test setting this mode will display the internal control variables on the screen These are Average unscaled reading during dry mix averaging time Unscaled deviation max min readings during the dry mix averaging time Average unscaled reading d
32. 28 Calc Mode 28 Start Resume 74 secreted ber 9 63 System Control Parameters 90 im 46 es 45 Temperature Compensation 26 32 34 Start 28 45 Unpacking 67 Update 16 18 19 23 24 36 38 Upgrading Software 65 Upper Control Threshold 20 49 95 104 Valve 20 45 49 62 76 86 90 95 104 Cycle Time seen nee 90 On Off 20 49 95 104 SelectiOri eee cds 49 Ventilation anaso 67 Water 34 ere 46 Econ ene 34 Wet Mb het eid 73 Wet Mix 33 Wiring Connections 68
33. 68 Hydro Control V User Guide HD0193 Issue 2 5 0 Input Output Module Types Hydro Control V is fitted with plug in optically isolated input output modules manufactured by 22 A range of different input output modules is available Digital Input Module Types Hydronix OPTO 22 Description Part No Part No 0401 GAIDC5 10 32 VDC 0402 GAIAC5 90 140VAC 0403 GAIAC5BA 180 280VAC Digital Output Module Types Hydronix 22 Description Part No Part No 0404 G40DC5 5 60VDC 45 C 2A 70 C 0405 G40AC5 12 140VAC 45 C 2A 70 C 0406 G40ACBA 24 280VAC 45 C 2A 70 C Connecting Ancillary Equipment The Hydro Control V provides no operating voltage for any external equipment other than the Hydronix moisture sensor All external equipment valves water meter alarms relays etc must be provided with power from an external supply An example plant wiring schedule is shown in Fig 38 Hydro Control V User Guide 69 HD0193 Issue 2 5 0 Mix Sequence Diagrams Final Mix Final Wet Discharge Cement ia Pre Wet First Mix Time Water Meter Optional Cement Outputs Coarse Water Fine Water Pre Wet Done Mix Complete Status Mix Complete Figure 33 Pre Wet Mix Cycle 70 Hydro Control V User Guide HD0193 Issue 2 5 0 FinalMix
34. ART SIGNAL 8 0 440 4 83 FIGURE 43 REMOTE RECIPE PLC DIMENSIONS 0 2 0 4 4000 00 00 nne ee se esee nete nns sese reete nnne eren 84 FIGURE 44 EDIT ADVANCED CONTROL PARAMETERS 1 1 89 FIGURE 45 TEST MODE SCREEN scssssssccscosssssssssecceesossosssssseeseusocvcnssansenseucossssssanseescessessssseuscescesssssssssescescese 90 Hydro Control V User Guide 7 HD0193 Issue 2 5 0 Hydro Control User Guide HD0193 Issue 2 5 0 Chapter 1 Introduction Hydro Control V is an easy to use control system for controlling water addition during concrete mixing In conjunction with the Hydronix Hydro Mix V VI Hydro Probe Orbiter it is designed to precisely achieve the required moisture target without the need for metering the water although use of a water meter is preferred From software version HS0035 v 4 20 the Hydro Control V has temperature compensation which enables the control of water addition to achieve the required consistency throughout the year regardless of variation in material temperature It is simple to install and can be fitted to both new and existing plants It uses the latest Hitachi H8 microprocessor with SMD technology to achieve a compact and reliable unit The unit contains sophisticated control software to ensure the user can achieve the desired result with the minimum fuss
35. CE u 22 8 200228 eben epe edt ins ree eere tera fe 57 RS232 CONNECTIONS ON OPERATOR TERMINAL eee enne 57 SENDING REMOTE COMMANDS saine 2 00 Ba e de oce edge et 57 CONNECTINGTO A PEL APTOP nn a SI obtener beide GS a Ae ett 64 UPGRADING SOFTWARE 2 20 onte tee E reste tbe e rer dert tet e perti e 65 CHAPTERS INSTALLATION ire eee rece tree eter ann Rn A SI 67 SAFETY INSTRUCTIONS ae ete ee t dte e Rte Qr e iin ede eite ee 67 INSTALLING THE HYDRO CONTROL 68 WIRING CONNECTIONS ehe REO RO I SERERE RERO ree E Ere be RD UU e reU Erb E RO 68 EXPLANATION OF MIX CYCLE eti edd nee i demde eias 73 INPUT AND OUTPUT PUNGTIONS etiem tte 0 age te Pert anes E RUP Ee Th re Eee y tarte pert 74 REMOTE SELECTION VIA PEG eid ette eo e ba ao aaa ne ROREM 81 CHAPTER6 VALVES AND WATER FLOW RATES 85 CHAPTER T SPECIFICATION 22 2 2 2 0220 022220 heme deett 87 APPENDIX A ADVANCED CONTROL PARAMETERS 89 APPENDIX B BACKGROUND TO CONTROL METHODS 1 ns 93 Hydro Control V User Guide 5 HD0193 Issue 2 5 0 93 A ROI a aee 93 APPENDIX SYSTEM AND CONTROL PARAMETE
36. Final mix time also known as the wet mix time At the end of the Final mix time a MIX COMPLETE signal is issued from the Hydro Control V and the mixer can be discharged Moisture Pre Wet Final Mix i Fina 5 Ischarge Add 9 First Mix Time Figure 2 Pre Wet Mix Cycle Hydro Control V User Guide 11 0193 Issue 2 5 0 Dry Mix mix cycle The Dry Mix mix cycle is used when no pre wet is required The Final wet main water addition occurs after the First mix time and is followed by the Final mix time At the end of the Final mix time MIX COMPLETE signal is issued from the Hydro Control V and the mixer can be discharged Moisture Wet Mix 4 Discharge Final Wet First Mix Mixer Time Loading gt Figure 3 Dry Mix Mix Cycle The Hydro Control V can operate in one of three control modes The control mode to be used is defined by the recipe and may be different for each recipe Preset Mode A fixed amount of water defined by the recipe is added during both the pre wet if required and final wet phases of the mix cycle regardless of the current moisture reading this mode can also be operated without a sensor being connected Auto Mode An amount of water defined by the recipe is added during the pre wet phase if required and the sensor moisture reading is used to control the water addition up to a target defined by the selected recipe during the fi
37. GP type variable 1 fil urs Pre set IP 1 None Moisture IP 2 Hone Ave hold delay Filtering time 1 8 Slew rate None Slew rate Inc Dec Calihb Back Figure 32 Sensor Configuration Using the Sensor Configuration Menu The sensor configuration parameters can be viewed and edited here These should not be changed after commissioning as this could adversely affect system performance To change a parameter move the cursor lt to the parameter required using the up and down keys e Type the desired value using the numerical keypad or use the Inc F1 and Dec F2 keys to increment or decrement the value The Calib function shown above in F4 only appears when a Hydro Probe Orbiter is connected This is used to perform an Autocal which is used when a new sensing arm is connected to the sensor After completion of editing press Back F5 and then either of the following keys ED to save the changed values and return to the Diagnostics Menu to cancel return to the Diagnostics Menu Choosing this option will return any edited parameters to their original values 54 Hydro Control V User Guide HD0193 Issue 2 5 0 Sensor Configuration Parameters Parameter Units Default Range None None od Aveta delay Seconds 00 0005101520050 Seconds Output type Sets the analogue output characteristics of the sensor to the required type Not
38. Hydro Control V This will place the unit into upgrade mode Warning Whilst performing upgrade please ensure the power is stable for the complete duration The upgrade takes approximately 10 minutes If a problem with the power supply occurs at the end of this procedure it could cause the Hydro Control V to become inoperable and in such a situation would need to be repaired by Hydronix Hydro Control V User Guide 65 HD0193 Issue 2 5 0 66 Hydro Control V User Guide HD0193 Issue 2 5 0 Chapter5 Installation This chapter describes how to install the Hydro Control V including connection of the Hydronix moisture sensor and the RS485 RS232 communications link Unpacking the unit Remove the Hydro Control V from its packing and check for any transit damage or loose parts In the event of any problems contact Hydronix or your local supplier Safety Instructions The Hydro Control V has been designed in accordance with the recommendations of IEC 664 and has been supplied in safe condition This unit is suitable for indoor use only If the equipment is used in a manner not specified by the manufacturer the protection provided by the equipment might be impaired Precautions Disconnect from voltage supply before the unit is opened for any adjustment maintenance or repair work Ensure that only fuses of the correct type and rating are fitted Ensure that the Hydro Control V is mounted in an environment that will not cause electrical
39. Hydro Control V User Guide Hydronix Part no HD0193 Version 2 5 0 Revision date March 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 2003 Hydronix Limited 7 Riverside Business Centre Walnut Tree Close Guildford Surrey GU1 4UG United Kingdom All rights reserved CUSTOMER RESPONSIBILITY The customer applying the product described in this documentation accepts that the product 1 a programmable electronic system which is inherently complex and which 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 and suggestion
40. NG VALVES 47 FIGURE 27 CONTROL MENU FIRST 2 0 1 2 00000000000000000000000000000000000000000000000000 48 FIGURE 28 DIAGNOSTICS a nahe au ee CRU 50 FIGURE 29 HARDWARE ation iet ese tete i EDD SERERE CE 51 FIGURE 30 lt RESONATOR an an ken aeree voee ERR D 52 FIGURE 31 MONITOR SENSOR 5 0 040406 0 nete 53 FIGURE 32 SENSOR CONFIGURATION 2 2 2 2 1 0200000000000000000000000000200000 0 54 FIGURE 33 PRE WET MIX CYCLE iet ne en en ete nn Doe ine ae eire ore ee ee dete ae 70 FIGURE 34 DRY MIX CYCLE NO PRE WET 71 FIGURE 35 BUSY SIGNAL 32 FIGURE 36 SYSTEM BLOCK 4 11 006 001000000 enne enean ersten eren tiae TI FIGURE 37 SYSTEM INTERCONNECTION 78 FIGURE 38 EXAMPLE WIRING SCHEMATIC FOR MANUAL PLANT OPERATION esse 79 FIGURE 39 PANEL CUT OUT FOR OPERATOR 2 0446000 80 FIGURE 40 OPERATOR PANEL DIMENSIONS 2 000000 00 80 FIGURE 41 REMOTE RECIPE PLC 5 82 FIGURE 42 REMOTE RECIPE PLC ST
41. RS RECORD 95 APPENDIX D PASSWORDS ade ete OU dii Lena 97 APPENDIX IMPROVING THE PERFORMANCE OF YOUR MIXER 101 APPENDIX F DIAGNOSTICS RECORD u n nennen 103 INDEX ne nn He lee 105 Hydro Control User Guide HD0193 Issue 2 5 0 Table of Figures FIGURE 1 HYDRO CONTROL V FRONT 4 FIGURE 2 PRE WET MIX CYCLE 11 FIGURE 3 DRY MIX MIX CY CIEE a nn onde de e EHE ee 12 FIGURE 4 PRESET MODE MIX CYCLE iii a 15 FIGURE 5 AUTO MODE MIX 17 FIGURE 6 VALVE CONTROL IN 2 200400000000 21 FIGURE 7 CALC MODE MIX CYCLE 5 22 FIGURES MENU TREE 22 0 oran hd doe vances abe one 27 FIGURED START MENU A 28 0 rte creuset etui 30 FIGURE 11 EDIT RECIPE CE PAGE dens e aee Nee 31 FIGURE 12 EDIT RECIPE 2ND 0000000 0 0 ne sess easi sete nne sss easet e
42. a full batch The Recipe gain parameter in the relevant recipe should be set to the batch size if a smaller batch is to be made 20 Hydro Control V User Guide HD0193 Issue 2 5 0 Moisture Valve output 100 always on pulsing First mix time Progressive Final water Final mix addition time moisture pulsing off gt Increase to reduce always on time Upper control threshold lt Decrease to extend always on time Increase to increase minimum flow typical 10 20 Lower control threshold lt Decrease to reduce minimum flow Figure 6 Valve Control in Auto Mode Hydro Control V User Guide 21 HD0193 Issue 2 5 0 Calc mode Calc mode uses the Dry weight parameter from the recipe and a Calculation target to calculate the amount of water required to achieve the Target moisture To achieve a correct calculation each recipe using Calc mode must be calibrated The dry reading used for the calculation must be very accurate and this usually requires the First mix time to be longer than is necessary for Auto mode control To achieve a very accurate dry reading the moisture signal is averaged for a time defined by the system parameter Averaging time It is critical that the moisture signal is stable before this averaging time starts in order to obtain a correct value The advantage of Calc mode is that the water is added in one shot which usually makes the Final we
43. ameter Description Units RS232 Actual value value 101 ined Mode 0 metric 1 US 2 102 Meter Flow Litres or US Gallons 200 0 200 103 Meter Timeout Seconds 20 20 Language 0 English 1 French 2 105 German 3 Dutch 4 Spanish 5 None Italian 6 Finnish 7 Danish 106 ae 0 All 1 Water 2 107 Pre wet water 22 72 150 108 First mix time Seconds 10 10 109 Cement timeout 1 sec 5 5 110 Moisture target 01 65 6 5 111 Preset final de 35 0 112 Final mix time Seconds 15 15 113 2 0 preset 1 auto None 114 Plus tolerance 0 1 10 1 0 115 Recipe gain None 10 1 0 116 Minus tolerance 0 1 3 0 3 117 Moisture Offset None 36364 8 6364 118 Moisture gain None 1817 0 1817 119 Dry weight Kg or lbs 2000 2000 120 Calc 0 1 60 6 0 121 Calibration Water Litres or US Gallons 500 50 0 122 Water limit Litres or US Gallons 1200 120 0 Hydro Control V User Guide 61 HD0193 Issue 2 5 0 Parameter Description Units RS232 Actual value value 123 Water trim Litres or US Gallons 50 5 0 124 Batch counter None 3 3 125 Gain None 20 20 126 Upper Control Threshold None 50 50 127 Lower Control Threshold None 50 50 128 Valve On Off Time Seconds 10 1 0 129 Fine Valve Tolerance Litres or US Gallons 20 20 130 In flight Litres or US Gallons 50 5 0 131 Averaging time Seconds 150 15 0 132 Samples Seconds 1 0
44. amount of water required if this is different and then press to accept At the end of the Final mix time a MIX COMPLETE signal is issued An edit box will appear which shows the final moisture reached for this mix You may accept this as the Moisture target or enter new value if appropriate NOTE Entering a new value of moisture only alters the displayed moisture figure the calibration is not effected Then press the accept button CD If the discharge is set to manual then the quantity of water may be manually adjusted by pressing Trim The quantity of water added will be displayed under the tap icons When the correct amount of water has been added press Update F4 followed by Discharge the mixer and press lt Reset gt F2 to return to the Start menu The recipe is now calibrated and Calc will be displayed under the recipe number indicating that the next mix cycle will be performed in Calc mode Hydro Control V User Guide 23 HD0193 Issue 2 5 0 Calibration with admix 2 stage calibration mix cycle When calibrating with admix there are two water addition phases and the mix cycle will complete with two final wet and two wet mix phases The Busy signal from the Hydro Control V will activate during the second water addition to add the admix In order for the Busy signal to operate correctly the Busy mode parameter must be set to Admix see section Setup System 1 2 10 11 12 13 14
45. anually test coarse and fine valves Checking valves F 4 litres seconds Status Reset Fine Coarse Rec Batch Fre set Moisture 1 3 Back Figure 26 Checking Valves lt Reset gt F1 box to zero lt Fine gt F2 lt Coarse gt F4 Backs F5 Returns to the Setup System Hydro Control V hardware tests Hydro Control V hardware tests Display F1 Generates a display test screen Input F2 View state of inputs Output Manually control state of outputs Use the up and down e keys to select output off F1 on F2 Keys F4 Resets the water added and the time elapsed shown in the display Activates the FINE WATER output all the time the key is depressed and will stop when the key is released The amount of water added and the time elapsed are shown in the display box Activates the COARSE WATER output all the time the key is depressed and will stop when the key is released The amount of water added and the time elapsed are shown in the display box menu turns selected output off turns selected output on Shows a mimic of the keypad and displays keys pressed Hydro Control V User Guide 47 HD0193 Issue 2 5 0 Edit Control Parameters Edit Control Rec Batch 1 3 Upper control thr uto Lower control thr 25 Moisture Valve onoff time 1 8 Fine delivery 20 0 In flight lits
46. as completed the current batch mix cycle Maintained high until RESET input received ALARM Output to indicate that the unit has entered an ALARM condition Intervention is normally required to clear the alarm 74 Hydro Control V User Guide HD0193 Issue 2 5 0 Basic Tests Sensor Testing The Hydro Control V uses RS485 serial communications interface to communicate with the Hydronix moisture sensor Once the sensor has been connected the Hydro Control V can be switched on The Hydro Control V will show a start up screen displaying the Firmware version for approximately 3 seconds After this period the Start Menu will be displayed and will search for the sensor A message in the Moisture display box will show Polling until the sensor is located If the current control mode is Auto the main display area will also show ALARM No response from sensor nn Where nn is the address the Hydro Control V is currently searching After a maximum of 15 seconds the display sensor should be located and the display will change to the standard Start Menu see section Start Menu displaying the current moisture value and the trend display 1 Press More F5 and then Setup F1 to access the Setup System menu 2 Enter the Advanced password see Appendix D press Diag F2 followed by Mons to display the Monitor page that shows the unscaled values being read from the sensor 3 With the mixer empty and the sensor
47. ate Moisture target but the water required is added in shot to the mixer Each recipe must first be calibrated see Section Calc Mode During a calibration mix cycle a fixed amount of water the Calib water for that recipe is added to a mix during the Final wet phase The system uses the Dry weight of the mix and the dry and wet values of moisture the moisture at the end of the First mix and Final mix respectively to calculate a calibration slope for that recipe relating the change in moisture of the mix to the amount of water added It is important to note that if additives are to be added to the mix these must be added after the calibration slope has been calculated To facilitate this water can be added to a calibration run in two stages see Section Calc Mode At the end of the mix two moisture targets are automatically defined for the recipe the Calc 96 and Moisture target The Calc 96 target is defined by the final moisture level generated by the water addition only and not by the effects of any mix additives The Calc 96 target is used to calculate the amount of water to be added to each subsequent Calc mode mix cycle The Moisture target is the final value of moisture reached at the end of the calibration run taking into account the moisture level generated by the water addition and any modifications to the moisture level generated by the addition of mix additives At the end of a calibration run the user will
48. ave been switched off The Fine Delivery and In flight parameters can now be adjusted to optimise the accuracy of the delivery see section Edit Control Parameters After the water meter has been calibrated the flow rate of the fine and coarse valves may be checked from the Checking valves menu by pressing Fine F2 or Coarse F4 and dividing the amount of water displayed by the amount of seconds displayed See Chapter Valves and Water Flow Rates for guidelines 76 Hydro Control V User Guide HD0193 Issue 2 5 0 Batch Control External Signals 24VDC 2 gt lt io 5 LU lt Binary BCD Discret PREWET DONE START RESUME ERI PAUSE RESET MIX COMPLETE Remote 24VDC Hydro Mix Recipe Select RS232 VNI PLC or 85485 If fitted Hydro Probe Orbiter N From Batch Computer Note If only one valve is used connect to the Fine Valve Coarse Fine Water output Valve Valve Meter optional optional Figure 36 System Block Diagram Hydro Control V User Guide TT HD0193 Issue 2 5 0 HYDRO CONTROL V External 24V DC SENSOR OV Hydro Mix V 24 DC PA i SENSOR 24V DC Connector BLK la A N RS485B RS485A RS232 RS232 GND E RS232 TX RS232 RX WATER METER WATER METER PAUSE RESET External PAUSE RESET START RESUME START RESUME CEMENT MIX LOADED CEMENT MIX LOADED S 12 Busy S 11 BUSY
49. be prompted to enter a final target value This value will allow the displayed final target moisture to be defined For example after a calibration run the final target moisture reading might be 6 3 If the user would prefer the final reading to be 8 0 then 8 0 should be entered when prompted The calculated and final target moisture targets for that recipe will then be automatically amended without altering the calibration Hydro Control V User Guide 93 HD0193 Issue 2 5 0 Notes 94 Hydro Control V User Guide HD0193 Issue 2 5 0 Appendix C System and Control Parameters Record System parameters This section should be used to record the System setup parameters Parameter Value Water mode Meter flow pulse Meter timeout Language Busy Mode Max recipes Control parameters This section should be used to record the System Control setup parameters Standard Advanced Gain System Mode Upper Control Threshold Coarse upper thr Lower Control Threshold Derivative gain Valve on off Time Cycle on off Fine delivery RS232 Mode In flight Samples Averaging Time Cycle Loops Mix Extension Address Access mode Valve Pre wet Valve Final wet Hydro Control V User Guide 95 0193 Issue 2 5 0 Notes 96 Hydro Control V User Guide HD0193 Issue 2 5 0 Appendix D Passwords Operator password Operators do not need a password Operator
50. clean and dry the unscaled value shown should read close to zero 0 Due to differences in installation the empty value may vary and acceptable values will be in the range 0 to 14 4 Get someone to place the palm of their hand on the sensor the unscaled value should now climb to a value of 70 85 over a period of approximately 30 seconds The value does not reach the final value instantly due to the rate limiting and smoothing filters in the sensor The above verifies that the sensor is working correctly and that the communications with the sensor is also working correctly Press Backs F5 three times to return to the Start Menu Hydro Control V User Guide 75 HD0193 Issue 2 5 0 Valve Testing 1 From the Start Menu press More F5 and then Setup F1 to access the Setup System menu 2 Enter the Advanced password see Appendix D 3 Press Test F4 to display the Test menu 4 Press Valve F2 to display the Checking valves menu 5 Press Reset F1 to reset the display 6 Press Fine F2 and keep pressed to ensure the fine valve activates correctly 7 Press Reset F1 to reset the display and repeat using lt Coarse gt F4 to check the coarse valve Water Meter Testing The water meter function is most easily tested by using a dummy recipe to deliver a set amount of water The actual amount of water delivered can then be checked against the amount displayed The system paramet
51. conds after the commencement of the addition of the sand and aggregates Folding in the materials together in this way will greatly assist the mixing process 4 Water addition To facilitate the mixing action the water should be sprayed in over as wide an area as possible rather than discharged at one point Remember excessively rapid water addition will increase the wet mix time required to reach homogeneity Hence there is an optimum rate of water addition for achieving minimum mix cycle time Commencement of water addition should only start after the cement has been substantially mixed in with the aggregates Cement powder lying on the surface of the aggregates will absorb the water turning into a wet paste which will be more difficult to disperse uniformly throughout the mix Hydro Control V User Guide 101 HD0193 Issue 2 5 0 Notes 102 Hydro Control V User Guide HD0193 Issue 2 5 0 Appendix F Diagnostics Record Log of Diagnostics for Customer Support A diagnostics utility is available from http www hydronix com This utility uses the RS232 port to interrogate the Hydro Control V see section Connecting to a PC Laptop and saves diagnostic information that can be emailed to our Customer Support Staff If for any reason the Diagnostics utility cannot be used please record the parameters and other details as indicated below It is important that you have this information ready to fax when you are speaking to our Customer S
52. d Auto mode mix cycles no value will be shown Tot L The total amount of water added during the mix cycle Trim L The value of the Water trim for a Calc mode mix cycle Mix Information Page Rec Batch 1 3 Pre set Mix Dry Gain Offset kg dHa BdlP 27 a 357 05C 118 1245 357050 113 1245 387 050 395 1245 39 85C 29 1245 387 050 196 1245 1 16P 7392 a 0 1P 32 a 1 01P 538 2 1P Moisture us Hater Mix More Back Figure 18 Mix Log mix information The third page of the Mix Log accessed by pressing lt Mix gt F3 contains the following information Mix s The total time taken to reach MIX COMPLETE Dry kg Dry weight from the recipe of the mix shown in units selected by Water mode Gain Moisture gain from the recipe Offset Moisture offset from the recipe The above figure shows the Mix Log with the Water mode set to Metric Hydro Control V User Guide 41 HD0193 Issue 2 5 0 Sensor Deviation information Pressing F2 will show the sensor readings available in moisture or sensor unscaled values at the end of the first mix time and the final mix time along with the deviation of the signal at the end of these phases Rec Batch 1 3 Pre set tr Final Het Dew a r ALP 395 990 3978302 387050 39 8930 38 8090 1 16P 60 81P 1 81P 2 1P Moisture mm xi en MIS MIS
53. d if this is different and then press e to accept the first and C to accept the second value At the end of the Final mix time a MIX COMPLETE signal is issued An edit box will appear which shows the final moisture reached for this mix You may accept this as the Moisture target or enter a new value if appropriate NOTE Entering a new value of moisture only alters the displayed moisture figure the calibration is not effected Then press the accept button If the discharge is set to manual then the quantity of water may be manually adjusted by pressing Trim The quantity of water added will be displayed under the tap icons When the correct amount of water has been added press Updates F4 followed by Discharge the mixer and press Reset F2 to return to the Start menu The recipe is now calibrated and Calc will be displayed under the recipe number indicating that the next mix cycle will be performed in Calc mode 24 Hydro Control V User Guide HD0193 Issue 2 5 0 A Calib mode mix cycle may be paused at any phase of the mix cycle by pressing Pause F2 The following options will be available Resumes F1 Continues the cycle from the point where it was paused lt Abort gt F2 Allows the current mix to be aborted When pressed the option to generate MIX COMPLETE signal is prompted with the following Mix Complete Required Yes F2 and No If No is selected it will return to
54. d the mix cycle will complete with one final wet and one wet mix phase The final mix time used during a calibration cycle is extended by the Mix extension time to ensure that a good final reading is obtained 1 2 10 11 12 13 14 15 16 From the Start Menu press lt Recipe gt F2 Select the desired recipe number Enter the amount of pre wet water required in Pre wet water parameter you do not require pre wet set the Pre wet water and Pre wet target parameters to zero Enter the amount of final main water required in Preset Final parameter if you are unsure enter a value lower than that required manual adjustment to a good mix can be performed at the end of the mix cycle so ensure that the discharge is set to manual Check that the First mix time and Final mix time parameters are correct Set the Dry weight parameter on page two of the recipe to that of your mix Check the Water limit parameter on page two of the recipe is correct Press lt Back gt F5 and then ED to save the changed values and return to the Recipe Menu Press Backs F5 to return to the Start menu Press Mode F3 until Calib is displayed under the Recipe number Start the mix cycle from the batch controller or manually by pressing Start F1 On starting the mix an edit box appears which shows the current calibration water this will be the amount entered in the parameter Preset Final Water Type in the
55. ds 140 140 Mix Complete 25 Status byte None 26 Moisture reading at mix complete 7 40 7 40 For example if system is at MIX COMPLETE e f water added was 43 1 L 0 12 will return 43 10 e f current recipe is 17 M 0 6 will return 17 e ftime taken to MIX COMPLETE was 48 secs M 0 24 will return 48 If system is notin MIX COMPLETE phase dependent values returned will be 0 00 The Status byte returns an indication of the current phase of the mix cycle Phase Returned value Standby 1 Pre Wet 2 call 4 First Mix 8 Final Wet 16 Wet Mix 32 Mix Complete 64 Paused 128 NOTE For example if the system is paused in the wet mix phase the command _0_25 will return 160 since the status value is 32 Wet Mix 128 Paused 160 Total Hydro Control V User Guide 63 HD0193 Issue 2 5 0 Command Acknowledgements The Hydro Control V will reply to valid remote commands in one of the following ways Code Meaning Value The data requested from a valid command Value may be in integer floating point or string format Message processed without error only issued if command returns no data The Hydro Control V replies to all invalid commands with one of the following responses Meaning 210 Invalid command 211 Parameter 1 out of range 212 Parameter 2 out of range 213 Parameter 3 out of range 214 Command not valid
56. e HD0193 Issue 2 5 0 Modes F3 Change the control mode of the current recipe Note until a Dry weight has been defined for the recipe the only control modes available will be Auto and Pre set Once a Dry weight is defined the Calib mode will be available After a Calib mode mix cycle has been carried out the Calc mode will also become available More F5 Displays further options as follows Setup F1 Displays the Setup System menu see section Setup System Log F2 Displays the Mix log see section Mix log Backs F5 Returns to the main menu with Start F1 Recipe F2 Mode and More F5 present Water trim parameter Calc mode only When Calc mode is the current the control mode Trim F4 will also be displayed below the moisture reading on the main page Trim F4 An edit box allows trim water to be added or removed from all subsequent calculation runs for the current recipe The numeric keys and Inc F1 Dec F2 and lt gt F3 may be used to set the value of trim water Alternatively the trim parameter can be edited using the Edit recipe menu Hydro Control V User Guide 29 HD0193 Issue 2 5 0 Select Recipe From the Start Menu pressing F2 will enter the Select Recipe menu Select Recipe Rec Hatch 1 8 Pre set Final Het Het Het Moisture amp mS mS Es TS S On P P C S
57. e valve used during Pre wet phase Can be set to Both default setting Fine only or Course only Valve Final wet Selects the valve used during Final wet phase Can be set to Both default setting Fine only or Course only Note When using only one valve for water input it is always recommended to connect to the Fine Valve output In such cases it is not necessary to change the above valve parameters to Fine as the default setting of Both will always work Hydro Control V User Guide 49 0193 Issue 2 5 0 Diagnostics Rec Batch 1 3 Auto Diagnostics Moisture HZH RES MOH CONF Back Figure 28 Diagnostics The Diagnostics screens are only used for troubleshooting and will normally only be accessed after instruction from Hydronix Using the Diagnostics Menu The diagnostics menu provides access to several screens that can be used to read test and configure the connected sensor e To read system information and test the Current Interface press H W F1 e To view a graphical display of the resonator press RES F2 e monitor the measurements made by the sensor press MON e configure the sensor press the CONF F4 key Press Backs F5 to return to the Setup System Menu 50 Hydro Control V User Guide HD0193 Issue 2 5 0 Hardware Hardware Rec Batch Current HEH lincompFreq 830 8 MHz Moisture Comp Freq 830 8 MH
58. ed allowing manual adjustment of the moisture level Hydro Control V User Guide 37 HD0193 Issue 2 5 0 Trim and Update Pressing lt gt F2 at any phase in the mix cycle will pause the cycle any water addition Messages showing the current status and at what phase the mix cycle has been paused will be shown for example Top of display Status bar Final wet PAUSED Abort for Mix complete The following options will be available Resumes F1 lt Abort gt F2 Trim Update F5 Continues the cycle from the point where it was paused Allows the current mix to be aborted When pressed the option to generate MIX COMPLETE signal is prompted with the following Mix Complete Required Yes F2 and No If No is selected it will return to the Start Menu If Yes is selected the mix complete signal is generated and Reset F2 returns to the Start Menu and clears the MIX COMPLETE signal Opens the FINE WATER valve all the time the key is depressed allowing manual adjustment of the moisture level Followed by current recipe saves the adjusted water amounts and moisture levels to the The availability and function of the Trim and Update keys depend on the control mode and phase of the mix cycle as shown in the table below The shaded cells indicate the phases for which Trim is available and the text indicates which recipe para
59. ensor moisture reading is used to add water up to the Pre wet target using Auto mode control Pre wet water is added using the same control algorithm and control parameters as used for Auto mode Final wet Auto mode control parameters that are optimised for final water addition where accuracy is required may produce a slower than desirable Pre wet where accuracy is not normally as important In the case where an Auto mode Pre wet is followed by a Calc mode Final wet the Recipe gain can be increased to improve the speed of the Pre wet water addition Temperature Compensation Temperature compensation can be used to correct for changes in ambient temperatures throughout the year and adjust the final moisture target to maintain mix consistencies Two recipe parameters are used for temperature compensation Temperature The is the base temperature from which the compensation will be calculated The temperature is measured by the sensor and displayed on the front page see Figure 9 At the time of setting up the recipe this value should be read from the front screen and the reading used in the recipe as the base temperature This value should not be adjusted following this reading Temp Coeff The temperature coefficient is the compensation factor in moisture Temperature i e how far the moisture target is anticipated to change per degree change in temperature From these two parameters the Moisture Target is then calculated by the following
60. erated indicating to the batch control system that the mixer is ready for discharging If discharge is set to manual and an automatic Reset is not received then the following options will be displayed Reset F2 Returns the unit to standby and clears the MIX COMPLETE signal NOTE Update is not available in Calc mode any adjustment should be performed using the Water trim parameter Water trim parameter Calc mode only When Calc mode is the current the control mode Trim F4 will be displayed in the Start Menu When Trim F4 is pressed an edit box appears allowing an amount of water to be added or removed from all subsequent Calc mode mix cycles for the current recipe The numeric keys and Inc F1 Dec F2 and lt gt F3 may be used to set the value of adjusted water Alternatively the Water trim parameter can be edited using the Edit recipe menu NOTE The Minus tolerance moisture alarm will be disabled if a negative adjustment is entered to prevent nuisance alarms Hydro Control V User Guide 25 HD0193 Issue 2 5 0 Pre Wet mix cycle The Hydro Control V can operate in one of two Pre wet mix cycle modes Pre set mode Pre The quantity of water defined by Pre Wet water is added regardless of measured moisture The speed and accuracy of the Pre wet water addition will be determined by the valves and the In flight and Fine delivery settings in the Edit Control menu Auto mode Auto The s
61. ere it was paused Allows the current mix to be aborted When pressed the option to generate MIX COMPLETE signal is prompted with the following Mix Complete Required Yes F2 and No If No is selected it will return to the Start Menu If Yes is selected the mix complete signal is generated and Reset F2 returns to the Start Menu and clears the MIX COMPLETE signal Opens the FINE WATER valve all the time the key is depressed allowing manual adjustment of the moisture level Followed by saves the adjusted water amounts and moisture levels to the current recipe Pressing Update F5 during Pre wet or First mix time phases of the mix cycle updates the Pre wet water and Pre wet target parameters Pressing Update F5 during Final wet or Final mix time phases of the mix cycle updates the Preset Final and the Target moisture parameters At the end of the Final mix time a MIX COMPLETE signal is generated indicating to the batch control system that the mixer is ready for discharging If discharge is set to manual and an automatic Reset is not received then the following options will be displayed Reset F2 Trim Update F5 Returns the unit to standby and clears the MIX COMPLETE signal Opens the FINE WATER valve all the time the key is depressed allowing manual adjustment of the moisture level Followed by C saves the adjusted water amounts and moisture levels to
62. ers Water mode Meter flow pulse and Meter timeout must be correctly set before performing any meter testing see section Edit System Parameters Arrange for the water delivered from both the coarse and fine valves to be diverted into a suitable container so that the actual amount of water delivered can be determined 1 From the Start Menu press Recipe F2 2 Select a recipe for the dummy recipe 3 Setthe Pre wet water parameter to zero 4 Enter the amount of water to be delivered in Preset Final parameter 5 Enteratime in First mix time that will allow you to reach the water delivery point 6 Check the Water limit parameter on page two of the recipe is greater than the Preset Final 7 Press Backs F5 followed by ED to save the changes to the recipe 8 Press Backs F5 again to return to the Start Menu 9 Press Mode until Preset is displayed under Recipe number 10 Press Start F1 to start the dummy recipe you will now have the amount of time defined by the First mix time to reach the area where the water is delivered to check the delivery 11 After the water turns off check the water amount shown on the display is consistent with the amount of water delivered The amount of water delivered and shown on the display ideally should be exactly the same as that requested by the Preset Final parameter In most installations this will not be the case as some water will continue to flow after the valves h
63. esonator Using the Resonator Menu The output from the resonator is displayed graphically Above the graph the values of the resonant frequency the amplitude of the resonance and the internal and outside temperatures C are shown e To view the 300MHz sweep press lt 300 gt F1 e To view the 40MHz sweep press lt 40 gt F2 e To view the 4MHz sweep press 4 e To view the reference signal press Ref F4 To return to the Diagnostics Menu press Back F5 52 Hydro Control V User Guide HD0193 Issue 2 5 0 Monitor Monitor Rec Batch Moisture Status Raw 2 secs Rawle Filz FiliB8 Hack Figure 31 Monitor Sensor Readings Using the Monitor Menu The Monitor Menu allows graphical display of the Raw or Filtered unscaled readings The current instantaneous value is shown numerically at the top centre of the graph Viewing options are To view the Raw readings with a 2 second time base press the lt Raw2 gt F1 key To view the Raw readings with 100 second time base press the lt Raw100 gt F2 key To view the Filtered readings with a 2 second time base press the lt Fil2 gt F3 key To view the Filtered readings with a 100 second time base press the lt Fil100 gt F4 key To return to the Diagnostics Menu press the Back F5 key Hydro Control V User Guide 53 HD0193 Issue 2 5 0 Sensor Configuration Rec Batch 1 3 Sensor Configuration
64. hase the parameter will return zero at all other phases NOTE During operation noise on the RS232 connection may be interpreted as characters by the Hydro Control V Sending a Carriage Return code ASCII 13 will clear the input buffer and generate a 10 response The Hydro Control V will now be ready for receiving valid remote commands Hydro Control V User Guide 57 HD0193 Issue 2 5 0 Selecting Recipes To select recipe No nn send a message in the form gt Ri nn ASCII 13 1 to 99 Stand By ASCII 13 For example to select recipe 10 e Send the ASCII string R1 10 Do not forget the ASCII 13 terminator e Note there are no spaces in this command Setting Dry Weight in Current Recipe Format Terminator Parameter Range Valid Response Response Period Terminator gt 01 ASCII13 Nnnnn 1 to Stand By ASCII 13 32000 Reading Current Moisture value The current moisture value can be read by sending a message in the form Format Terminator Parameter Range Valid Response Response Period Terminator 2 ASCII 13 Any ASCII 13 e g if the current moisture is 5 61 then the response to 2 will be 5 61 If the final moisture target achieved is required for record purposes then Mixer Status command should be used see later in this chapter Reading the software version string The software version identification string as used at start up can be accessed by se
65. hout the cycle the current moisture value is displayed both in the middle box on the right of the screen and on the trend graph Towards the end of the first mix and the final mix times the large sign flashes This is because the sensor is within its averaging time and at this point the moisture trace should be stable The middle box on the right of the screen also displays the amount of water to be added during the current phase of the mix cycle and the moisture target The mix cycle phases are displayed in the status bar with the name of each phase of the cycle flashing between CAPITALS and lowercase to indicate the phase of the cycle reached NOTE If no pre wet is required the Pre wet water recipe parameter should be set to zero This will ensure that a dry mix cycle will be used The cycle can be paused at any point by pressing Pause see section Trim and Update 36 Hydro Control V User Guide HD0193 Issue 2 5 0 System automatic pause and alarm Cement timeout If the system exceeds the maximum permitted waiting time for the CEMENT IN signal the system will sound and output ALARM Top of display Cement timeout Status bar PAUSED Resume to cont cycle Resumes F1 Overrides the Cement timeout and resumes the mix cycle The maximum permitted waiting time is defined on a per recipe basis by Cement timeout Water limit If Water limit is exceeded the system automatically pauses the mix cycle and the system will sound
66. its ignoring the decimal point although with preceding zero if necessary Alternatively values can be increased or decreased by using the Inc F1 and Dec F2 keys these are also used for non numerical items which cycle through the valid entries in turn Example To change the Final mix time from 15s to 8s e Use a lt keys to move the cursor to the Final mix time parameter e Enter followed by on the keypad The value 085 will be displayed next to the Final mix time parameter After completion of editing press Back F5 and then either of the following keys CD to save the changed values and return to the Select Recipe menu to cancel and return to the Select Recipe menu Choosing this option will return any edited parameters to their original values Scrolling down to the More statement at the bottom of the list will display the second page of the Edit Recipe menu Hydro Control V User Guide 31 HD0193 Issue 2 5 0 Edit 1 1 1 Control method Pre set Plus tolerance x 1 0 gt Moisture Recipe gain 1 0 Minus tolerance Dru weight of mix kg Calib water lits Mater limit lits 126 8 Batch counter Hore Back Rec Batch Edit Recipe Rec Batch 1 8 Moisture offset Fre set Moisture gain 8 1817 Moisture Mater trim lits Cement weight kg a Temperature 20 0 Tem
67. kes approximately 60 seconds After the Ram test completes or 5 seconds has passed the Hydronix logo and firmware version is shown and is then replaced by the Start menu and trend moisture graph e The trend display is a scrolling moisture level graph which also shows the Target T and Alarm A levels for the chosen Recipe if in Auto or Calculation modes e Tap icons which show the Status Off 1 orOn ofthe FINE WATER and COARSE WATER valves Underneath the valves are number s showing how much water has been delivered If a water meter is used the total number of litres or gallons is shown If no water meter is used beneath each valve is the time that valve has been open in units of 0 1 seconds e Recipe number batch number and control method top right of display e Moisture readings and targets centre right of display Large number shows current moisture smaller numbers underneath show e The amount of water to be added during the current phase of the mix cycle e Moisture target of the current recipe e Trim water of the current recipe only in Calc mode e The temperature of the mixture in degrees Centigrade or Fahrenheit is also shown at the top right of the display just above the moisture axis of the trend graph lt Start gt F1 Manually starts the mix cycle Recipe F2 Displays the Select Recipe menu where recipes may be selected and edited 28 Hydro Control V User Guid
68. l parameter 5 Checkthat the First mix time and Final mix time parameters are correct 6 Check the Water limit parameter on page two of the recipe is correct 7 Press lt gt F5 and then ED to save the changed values and return to the Recipe Menu 8 Press lt Back gt F5 to return to the Start menu 9 Press Modes until Preset is displayed under the Recipe number 10 Start the mix cycle from the batch controller or manually by pressing Start lt F1 gt Hydro Control V User Guide 15 HD0193 Issue 2 5 0 mix cycle paused at phase of the mix cycle by pressing lt gt F2 The following options will be available Resume F1 lt Abort gt F2 lt Trim gt F3 lt Update gt F5 Continues the cycle from the point where it was paused Allows the current mix to be aborted When pressed the option to generate MIX COMPLETE signal is prompted with the following Mix Complete Required Yes F2 and No F3 If No is selected it will return to the Start Menu If Yes is selected the mix complete signal is generated and Reset F2 returns to the Start Menu and clears the MIX COMPLETE signal Opens the Fine Water valve all the time the key is depressed allowing manual adjustment of the moisture level Followed by ED saves the adjusted water amounts and moisture level to the current recipe Pressing Update F5 during Pre wet or First
69. lication Further notes are given in sections describing each Control Mode Hydro Control V User Guide 13 0193 Issue 2 5 0 Editing Recipes few seconds after switching the Hydro Control V on the Start Menu screen will appear see section Start Menu From this menu to select or edit a recipe press Recipe F2 For full details see sections Select recipe and Edit recipe Up to 99 recipes are available The number of recipes displayed is selectable see section Edit System Parameters Initially all the parameters of the recipes will be set to their default values see section Edit recipe parameters To select a recipe from the list use to move the cursor to the required recipe or type the number of the required recipe To edit the recipe press Edit F4 Select the parameters to be changed by using the and keys and then typing in the desired value Enter the digits ignoring the decimal point although with preceding zero if necessary Alternatively values can be increased or decreased by using the Inc F1 and Dec F2 keys these are also used for non numerical items which cycle through the valid entries in turn After completion of editing press Back F5 and then either of the following keys to save the changed values and return to the Recipe Menu ED to cancel and return to the Recipe Menu Choosing this option will return any edited parameters to their original va
70. llows screen dump of display bitmap Samples The number of seconds over which the readings from the sensor will be averaged to provide the moisture reading The Hydro Control V reads the moisture from the sensor 5 times per second during mix cycles Cycle Loops Sets the number of times the Hydro Control V will loop through the final wet and final mix phases of the mix cycle This is useful when performing linearity tests where the same amount of water needs to be added in steps As an example if a linearity test is to be performed and the water is added in 5 stages then the complete cycle would be with no prewet Cycle Loops 5 First Mix gt Final Wet gt Final Mix gt Final Wet Final Mix Final Wet gt Final Mix gt Final Wet Final Mix Final Wet gt gt Final Mix Address Allows sensor selection when more than one sensor is connected via RS485 Setting this to zero enables the Hydro Control V to communicate with all address numbers 1 16 whereas a non zero number will make the Hydro Control V only communicate with that specific sensor Hydro Control V User Guide HD0193 Issue 2 5 0 91 92 Hydro Control V User Guide HD0193 Issue 2 5 0 Appendix B Background to Control Methods Auto mode The Auto mode control algorithm the Hydro Control V used in the final wet phase of the mix cycle is a modified Proportional Differential PD algorithm In these types of algorithm the system first calculates
71. ls of the mixes including total time and the weight Back F5 Returns to the previous menu More F4 Displays the following additional menu items Calib F1 Enables a previous mix to be used to calibrate the recipe Dev F2 Displays the sensor readings from the dry and wet phases as in the sensor readings page and also the variation of the sensor readings deviation at the end of each phase They can be in unscaled or moisture values depending on which is set in the previous menu Reset F4 Clears the Mix Log confirmation by pressing is required before the Mix Log is cleared lt gt F5 Returns to the previous menu Hydro Control V User Guide 39 HD0193 Issue 2 5 0 Mix Log Parameters The first column in each of the three pages of the Mix Log is an identifier The identifier consists of the Batch number the Recipe number and the mix control mode with the following format Batch number gt lt Recipe number Control mode gt Where Control mode is P for Preset mode A for Auto mode C for Calc mode Q for Calib mode For example 04 010 is batch 4 recipe 1 Calib mode Sensor Readings Page The first page contains information about the sensor readings for each mix cycle Dry US Calc US Final US moisture unscaled reached at the end of the First mix time The target in unscaled or of an Auto mode Calc mode or Calib mode mix cycle
72. lues Scrolling down to the More statement at the bottom of the list will display the second page of the Edit Recipe Screen Mix control modes The control mode of each recipe can be selected using the Method parameter in the recipe Alternatively the control mode of the current recipe may be changed from the Start Menu by pressing Mode The Hydro Control V will cycle through the control modes available with successive presses of Mode NOTE Until the recipe s Dry Weight parameter has been defined for the recipe the only control modes available will be Pre set and Auto Once a dry weight is defined the Calib mode will be available and after a calibration cycle has been completed the Calc mode will also become available 14 Hydro Control V User Guide HD0193 Issue 2 5 0 Preset Mode This is the basic operating mode which simply adds preset amounts of water in both the Pre wet and the Final wet phases of the mix cycle Start Mix Complete Y Pre wet Y water First mix Preset final Moisture added ue Mater added Benz Mixer Loading Figure 4 Preset Mode Mix Cycle 1 From the Start Menu press lt Recipe gt F2 2 Select the desired recipe number 3 Enter the amount of pre wet water required in Pre wet water parameter If you do not require any pre wet set the Pre wet water and Pre wet target parameters to zero 4 Enter the amount of final main water required in Preset Fina
73. m 2005 pulse used to initiate the next mix cycle or to resume current mix cycle following a pause Event occurs on leading edge of pulse CEMENT IN Minimum 2005 pulse to indicate that cement addition to the mixer is complete Event occurs on leading edge of pulse PAUSE RESET Minimum 200mS pulse used to place the unit in a ready state for the next batch and remove the MIX COMPLETE signal Can also be used to pause the current mix cycle Event occurs on leading edge of pulse WATER METER Maximum 50 Hz input used for counting the amount of water added Water mode Meter flow pulse and Meter timeout are used for setting up the water meter input Count occurs on leading edge of pulse Outputs COARSE WATER Output used to switch on the coarse valve Maintained high while coarse water required FINE WATER Output used to switch on the fine valve Maintained high while fine water required BUSY Output used to signal that the system is busy either i during only the Pre wet and Final wet phases of the mix cycle ii during the final water addition phase only for use with admix or iii throughout the whole mix sequence selectable by Busy mode see System Settings PREWET DONE Output used to signal that the Pre wet phase Pre wet water addition and Pre wet delay has completed Maintained high until CEMENT IN received If Cement timeout is set to zero then this pulse will be momentary MIX COMPLETE Output to indicate that the unit h
74. me of 1 sec then water can only be added in 3 Gal steps With a full load 4800 Ibs then the smallest moisture step is approx 0 5 which is too coarse for adequate control If the same system was also fitted with a fine valve which had a flow rate of 0 3Gal sec and an on off time of 1 sec then using this valve would permit water addition in steps of approx 0 3Gal or 0 05 giving good control It is worth noting that a higher water flow rate should normally allow a shorter mix cycle time for an efficient mixer provided the valve is fast enough to control the dose on off time is short A slow flow rate and slow valve will provide the same dosing accuracy but will take longer to complete a mix Hydro Control V User Guide 85 HD0193 Issue 2 5 0 Guidelines For Sizing Valves amp Flow Rates e Fine valve flow rate multiplied by on off cycle time should be in the range 0 04 to 0 1 moisture increase e g into 1m 3512 mixer flow rate x on off time should be in the range 1 to 2 4L 0 26 to 0 63Gal e Coarse valve flow rate multiplied by on off cycle time should be in the range 0 25 to 0 5 moisture increase e g into 1m 3512 mixer flow rate x on off time should be in the range 6 to 12L 1 6 to 3 2Gal e Valve on off time if in doubt set it to one second then choose valve sizes to give suitable flow rate according to the chart below e Valve Cycle Time should be at least twice the Valve On Off Time with a minimum cycle time
75. meter pp in recipe no nn send a message in the form Format Terminator Parameter Range Valid Period Response _R_ nn pp ASCII 13 nn 1 to 99 Active recipe See below pp see below Standby 1x if All other recipes unsuccessful Anytime For example if the final water target parameter 7 of recipe 5 was 8 596 e Sendthe ASCII string R 5 7 Do not forget to terminate with ASCII 13 carriage return e Receive 85 NOTE It is important to include the spaces as shown Recipe parameters can be read by specifying the recipe number 1 99 and the parameter number see table below Hydro Control V User Guide 59 HD0193 Issue 2 5 0 Parameter Description Units RS232 Actual value value First mix time Seconds 10 10 Cement timeout Seconds 10 10 6 Pre wet water or 250 25 0 7 Moisture target 0 1 65 6 5 8 Preset final 30 0 13 Final mix time Seconds 15 15 14 Plus tolerance 0 1 10 1 0 15 Minus tolerance 0 1 3 0 3 17 Recipe gain None 10 1 0 19 Moisture Offset None 36364 3 6364 20 Moisture gain None 1817 0 1817 23 0 1 auto 2 None 24 Dry weight Kg or Ibs 2000 2000 25 Calc 0 1 60 6 0 26 Calibration Water Litres or US Gallons 500 50 0 27 Water limit Litres or US Gallons 1200 120 0 28 Water trim Litres or US Gallons 50 5 0 29 Batch counter None 3 3 30 Pre wet delay Sec 10 10 31 Pre wet target 0 1 40 4 5
76. meters are updated when Update is pressed Pre wet First Mix Final wet Wet Mix Mix complete Auto Pre wet water Pre wet water Moisture and Pre wet and Pre wet Moisture target Moisture target target target target Pre wet water Pre wet water Moisture target Moisture target and Pre wet and Pre wet uen target geh target Preset final Calibration Moisture target Final water amp Calc Calculation Pre wet water Pre wet water No Update and Pre wet and Pre wet see Water Ne target target trim 38 Hydro Control V User Guide HD0193 Issue 2 5 0 Mix Log Rec Batch 1 3 Pre set 5 n n Final dal alP 35 783C 3978302 387 050 39 8930 387830 1 16P 60 81P 1 81P 2 1P Moisture EURO NE J i eG LL us Hater Mix More Back Figure 16 Mix Log sensor readings Using the Mix Log menu The Mix Log contains information on the last 99 mix cycles On entering the Mix Log the most recent mix cycles are displayed Previous mix cycles may be viewed by using the up and down keys US F1 Displays the sensor readings in unscaled values for the mixes Repeated key presses will cycle between displaying units and unscaled values lt Water gt F2 Displays the actual water and target water for the mixes Mix F3 Displays detai
77. mix time phases of the mix cycle updates the Pre wet water and Pre wet target parameters Pressing Update F5 during Final wet or Final mix time phases of the mix cycle updates the Preset Final and the Target moisture parameters At the end of the Final mix time a MIX COMPLETE signal is generated indicating to the batch control system that the mixer is ready for discharging If discharge is set to manual and an automatic Reset is not received then the following options will be displayed Reset F2 Trim Update F5 Returns the unit to standby and clears the MIX COMPLETE signal Opens the Fine Water valve all the time the key is depressed allowing manual adjustment of the moisture level Followed by CP saves the adjusted water amounts and moisture levels to the current recipe Preset Final and Target moisture parameters are updated 16 Hydro Control V User Guide HD0193 Issue 2 5 0 Auto Mode Auto mode uses an algorithm to progressively add water to the mixer until the Moisture target is achieved As the control only relies on the Current moisture value and a Moisture target value no calibration is required and a relatively short First mix time can be used Sufficient Final mix time should be allowed to let the mix become homogeneous and the moisture stabilise before discharge A preset amount of water may also be added in the pre wet phase of the mix cycle if required Start Mix Complete y Pre wet P
78. nal wet phase of the mix Calc Mode An amount of water is added during the pre wet if required and then the system calculates the amount of water to add during the final wet phase from a Calculated Moisture Target and recipe Dry weight parameter NOTE This mode requires a Calib mode calibration cycle to be completed before a Calc Mode cycle can be made This mode will be disabled if no value of Dry weight has been entered or if there is no water meter present 12 Hydro Control V User Guide HD0193 Issue 2 5 0 Setting Mix Times Setting the mix times correctly is critical to achieve the best from your Hydro Control V system The value of the mix times will vary dependant on the type of mixer the product to be made and the control mode that is used The First mix time needs to be sufficiently long to allow the dry aggregates the cement and any pre wet if selected to mix so that a reasonable reading for the average moisture content can be obtained Similarly the Final mix time needs to be long enough to allow Final wet to mix with the aggregates and cement so that a good consistency and reasonable reading for the average moisture content is obtained Both these times may be established by observing the moisture trend on the Hydro Control V during a mix cycle Sufficient mixing has occurred when the moisture trend shows reasonable stability i e a flat line before the Final wet and MIX COMPLETE phases are reached respectivel
79. nate a START signal upon receipt of a Select Recipe command For example different remote plant stations may invoke a START signal simply by sending a Recipe Select which may be unique to each station The batching plant must still load the mixer of course The following figure shows connections to the IMO K7 PLC terminals Hydro Control V User Guide 81 HD0193 Issue 2 5 0 Input contacts 1 3 5 7 2 4 6 8 Mode switch Coding selection 00 02 P04 6 8 COMO P01 P05 P07 P09 24G 24V AC 100 240V P44 P46 FG P45 P47 965669696666 965666066666 Optional delay contact for START input N Note Relay output rated to 24VDC 2A Hydro Control V AC Power connections 240 2 RS232 interface Figure 41 Remote Recipe PLC Connections 82 Hydro Control V User Guide HD0193 Issue 2 5 0 Plant Start output Hydro Control V START input a Normal Start connection no PLC AC 100 240V P44 P46 CONG P45 P47 Plant Start output Hydro Control V START input b Plant generated START signal delayed by PLC Note Relay output rated to 24VDC 2A AC 100 240V P44 P46 P45 P47 240AC 2A Hydro Control V START input c PLC generated START signal Figure 42 Remote Recipe PLC Start Signal Options Hydro Control V User Guide 83 HD0193 Issue 2 5 0 Dimensions mm E m m MN Figure 43 Remote Recipe PLC Dimensions 84 H
80. nding a message in the form Format Terminator Parameter Valid Response Response Range Period Terminator 3 ASCII 13 Any Hydro Control V v 1 10 ASCII 13 The reply is the ASCII version string displayed at start up Downloading the mix log The mix log can be downloaded by sending a message in the form Format Terminator Parameter Valid Response Response Period Terminator 4 ASCII 13 All current mix Each log logs ASCII 13 58 Hydro Control V User Guide HD0193 Issue 2 5 0 Reading current Temperature value The current temperature value C or F be read by sending a message in the form 5 ASCII 13 ASCII 13 e g If the current temperature is 25 0 then the response to 5 will be 25 0 C Reading sensor unscaled reading The sensor unscaled reading can be read by sending a message in the form Format Terminator Parameter Valid Response Response Period Terminator e g if the unscaled reading is 35 61 then the response to 7 will be 35 61 Download last batch from the mix log The last batch in the mix log can be downloaded by sending a message in the form Format Terminator Parameter Valid Response Response Period Terminator 8 ASCII 13 Any Last mix log ASCII 13 Reading and writing Recipe Parameters Allthe major recipe parameters can be set over the RS232 link To read the value of recipe para
81. nnected to it Installing the Hydro Control V The Hydro Control V is mounted in a control panel maximum thickness 10mm as described below Cut out an aperture in the panel 178 mm High x 232 mm Wide 7 01 in x 9 13 in e Remove the pair of mounting brackets from the Hydro Control V by releasing the screws and unhooking the brackets from the body of the unit e Insert the Hydro Control V through the prepared hole e Re fit the mounting brackets to the unit and tighten the screws to pull the fascia towards the control panel Do not over tighten as this may distort the fascia plate Wiring Connections The wiring connections for the Hydro Control V are shown in Figures 36 37 amp 38 The sensor must be connected using an extension cable made up from a suitable length of two pairs twisted 4 cores total screened shielded cable with 22 AWG 0 35mm conductors It is recommended that a high quality cable with good braid screen and also a foil screen is used in order to minimise the possibility of interference Recommended cable types are Belden 8302 or Alpha 6373 The cable screen must be connected at the sensor end only and therefore it is essential that the sensor body has a good connection to an electrical earth The cable run from the sensor to the control unit must be separate from any heavy equipment power cables particularly the power cable for the mixer Failure to separate the cable runs can lead to signal interference
82. nses aen 32 FIGURE 13 EDIT RECIPE 3RD PAGE sse nene emen ene emen e enne enne ee ee enne eese eese eese teen een 32 FIGURE 14 COPY RECIPE PAGE 1 40 35 FIGURE 15 MEX CY CB ict eite ta etait eo etd Heb t 36 FIGURE 16 MIX LOG SENSOR 5 1 242 0 2 0 0 00000000000000000000000000000000 00 000000000000 39 FIGURE 17 MIX LOG WATER 0 200000 20 0000000000000000000000000 rennen entere 40 FIGURE 18 2 121 20222002 000000000000000000000002000000000000020 41 FIGURE 19 MIX LOG DEVIATION INFORMATION 42 FIGURE 20 MIX LOG DEVIATIONS TREND 02 400404600000 0 42 FIGURE 21 CALIBRATING FROM MIX LOG ENTER DRY 0 0 0000 ener entren en 43 FIGURE 22 CALIBRATING FROM MIX LOG ENTER FINAL MOISTURE seen 44 FIGURE 23 CALIBRATING FROM MIX LOG ENTER TRIM 44 EIG RE24 SETUP SYSTEM iei eiie O rre ed etd Eee it 45 FIGURE 29 EDIT SYSTEM HH ern eme anne A ere ni ette eee Pete 46 FIGURE 26 5 CHECKI
83. om always on to pulsing A lower value will keep the valves in the always on state for longer only allowing the valves to pulse on and off closer to the Moisture target Values of 50 or 70 are typical for most applications if the Gain is set correctly Lower Control Threshold Determines the minimum flow rate that can be used by the progressive algorithm This parameter is used to prevent the water flow being too slow when the actual moisture is very close to the Moisture Target Typical values will be between 10 and 25 A higher value increases the minimum water flow near the Moisture Target Valve on off Time Determines how quickly the valve can be switched on and then immediately off again This parameter should be set as fast as practically possible for a pulse of water to be delivered Once set this parameter should not be altered Optimising the Auto mode control is a balance between the top three parameters It is suggested that starting from default values the parameters are altered in the following sequence 1 Setthe Gain parameter to achieve reasonable flow at the beginning of the Final wet phase 2 Increase the Lower Control Threshold so that the Moisture Target is reached at the maximum possible rate without excessive overshooting 3 Set the Upper Control Threshold to optimise when the valves switch from always on to pulsing NOTE Setting up the Auto mode control parameters should be performed with
84. p Coeff Calibration Type Dec Back Figure 12 Edit Recipe 2nd Page Parameter Pre wet water Units None Seconds Pre wet mode Pre wet delay Moisture target 96 Moisture Seconds Moisture Recipe gain None Moisture Kg or US pounds Litres or US Gals Water limit Litres or US Gals 120 0 Batch counter None Moisture offset None Water trim Litres or US Gals Cement Cement weight Kg or US pounds or US pounds ELI Degree LL or Fahrenheit Temp Coeff Moisture Temp Calibration Type None 32 Hydro Control V User Guide HD0193 Issue 2 5 0 Seconds Litres or US Gals Prewetargei 09 200 Cement timeout 159 Preset final Seconds Litres or US Gals Figure 13 Edit Recipe 3rd Page Default Range 0 0 0 0 999 9 0 0 99 9 Pre Pre Auto 0 0 999 0 999 0 999 6 5 0 0 99 9 0 0 0 0 999 9 30 0 0 999 Auto Pre Calc only if calibrated 1 0 0 0 99 9 10 0 0 0 10 0 0 2 0 0 9 9 0 0 99999 0 0 0 0 999 9 0 0 999 9 0 99 8 6364 99 9999 99 9999 0 1818 0 9 9999 0 0 999 9 999 9 0 99999 0 0 999 9 0 000 0 000 9 999 1 1 2 Pre wet waterThe quantity of water to add during the Pre wet phase of the mix cycle if the Pre wet mode is setto Pre set mode Pre wet target The moisture value to be reached during the Pre wet phase of the mix cycle if the Pre wet mode is
85. pt for a four digit password None of the function keys with the exception of Back F5 will operate until the correct password has been entered e Enter the password by typing the correct 4 digits The words Incorrect Correct or Advanced will then be displayed to confirm correct entry or warn of incorrect entry e incorrect password is entered then you must use the Back F5 key to return to the Start Menu e the standard password has been entered then the System F1 and Diag F2 function keys will be available e If the advanced password has been entered then the System F1 Diag F2 Control F3 and Valve F4 function keys will be available System F1 Edit the system parameters lt Diag gt F2 Enter sensor diagnostics lt Control gt F3 Edit the control parameters lt Test gt F4 Enter the system test menu Backs F5 To return to the Start Menu Hydro Control V User Guide 45 HD0193 Issue 2 5 0 Edit System Parameters Rec Batch 1 3 Auto Edit System Hater mode Meter flow pulse 1 986968 Meter timeout oM 5 Moisture Language English Busy mode Hater Max recipes 16 M E Default recipe Status Inc Dec Back Figure 25 Edit System Parameter Units Default Range Water mode None Timed US Metric Meter flow pulse 1 000000 0 9 999999 Meter timeout Seconds 5 0 99 Language
86. re stable and so this should be checked before any calibration is carried out Look at the deviations for both the first and final mix times These should be as close to zero as possible always less than 3 unscaled units To calibrate a recipe select the required recipe that provided a good mix in the mix log Then press Calib F1 from the More menu In order for that mix data to be used for calibration a number of checks are performed These are o Water must have been added to the mix If no water was used then the message Calibration failed No water added is shown o After the main water is added the sensor s unscaled reading must increase by at least 4 units If the difference between the unscaled reading in the final mix and first mix are less than 4 units then the message Calibration failed Low moisture variation is shown o There must be a dry weight in the recipe If no dry weight is present in the recipe it is possible to enter this weight at the beginning of this procedure The page will change to the following Enter the dry weight and press the ED to accept Rec Batch Fre set Moisture Enter Dry Height 1886 A to save Status Figure 21 Calibrating from mix log enter dry weight Hydro Control V User Guide 43 HD0193 Issue 2 5 0 next stage of the calibration procedure will be to enter the reference final moisture You select the figure displayed or type
87. rogressive Y Moisture water First mix Final water added time addition Final mix time Moisture target Figure 5 Auto Mode Mix Cycle It is usual to run the mix cycle in Preset mode for several cycles switching to Auto mode to establish mixing time water quantities and to ensure that good mix to mix moisture consistency is achieved The mix to mix consistency can be checked by pressing More F5 and then Log F2 where Final 96 values can be inspected It is suggested that the discharge is set to manual mode during Auto mode setup to prevent automatic discharge this enables manual correction to the mix after MIX COMPLETE Hydro Control V User Guide 17 HD0193 Issue 2 5 0 When running a recipe for the first time Auto mode the system needs to learn the target parameters required with a good mix 1 2 10 11 12 13 14 15 16 17 From the Start Menu press Recipe F2 Select the desired recipe number Enter the amount of pre wet water required in Pre wet water parameter If you do not require any pre wet set the Pre wet water and Pre wet target parameters to zero Enter the amount of final main water required in Preset Final parameter if you are unsure enter a value lower than that required A manual adjustment to a good mix can be performed during the mix cycle Check that the First mix time and Final mix time parameters are correct Check
88. rol V User Guide HD0193 Issue 2 5 0 Control parameters Parameter Units Default Range UperComwiTheshod 70 fps Lower GontrolThreshod fa pos 202 Uves Gafons seconds 0 0 998 _ Valve Final wet Both Both Fine Coarse Gain Upper Control Threshold Lower Control Threshold Valve on off Time See section Auto Mode Control Parameters Fine delivery When a fixed amount of water is being added to a mix the last fine delivery litres of the water will be added using the fine valve only NOTE Setting this parameter to be greater than 99 will ensure that only the fine valve is used for any mix cycle In flight The amount of water that continues to flow into the mixer after the valve output has been switched off Calc mode mix cycles require this value to be set correctly in order for calculations to be performed accurately Averaging time During the mix phases of any mode mix cycle the system will average the moisture values over this period of time Mix extension During a calibration run the system will extend the final mix time by the Mix extension time to ensure that a good final reading is obtained Access mode When set to Lock prevents editing of recipe parameters and allows user to change only between the current mix cycle mode and Preset mode In the case that signal is lost from the sensor it is still possible to run the recipe in preset mode Valve Pre wet Selects th
89. s can e Start stop pause amp abort the system e Create select amp edit recipes Supervisor password Supervisors can e Do everything operators can do e Access the top page of the system menu water meter settings timeouts supervisor password etc e Access the system diagnostics Advanced and Hydronix passwords The advanced and Hydronix passwords which permit access to the Hydro Control V control and advanced control parameters respectively are programmed into the Hydro Control V firmware and cannot be changed If the passwords become known to unauthorised people those people will have access to the system control parameters which if incorrectly set could make the system unstable Therefore these passwords should not be released The passwords are printed separately on the next page and can be removed to protect system security Hydro Control V User Guide 97 HD0193 Issue 2 5 0 Intentionally Blank 98 Hydro Control V User Guide HD0193 Issue 2 5 0 Advanced password The advanced password used to access the control parameters and valve test function is 3737 Hydronix password The Hydronix password used to access the advanced control parameters is 0336 NOTE You may wish to remove this page from the book to prevent unauthorised use of these passwords Hydro Control V User Guide 99 HD0193 Issue 2 5 0 Intentionally Blank 100 Hydro Control V User Guide HD0193 Issue 2 5 0 Appendix E Improving the
90. s relating to the product and this documentation This documentation is intended only to assist the reader in the use of the product and therefore Hydronix shall not be liable for any loss or damage howsoever arising from the use of information or particulars in or any error in or omission from this documentation ACKNOWLEDGEMENTS Hydronix Hydro Probe Hydro Skid Hydro Mix Hydro View and Hydro Control are Registered Trade Marks of Hydronix Limited 2 Hydro Control V User Guide HD0193 Issue 2 5 0 Revision History Issue No S W Version Date Changes 1 0 0 HS0035 May 01 Original 2 12 1 1 0 0035 01 Software upgrade Reference made to Hydro 3 0 Probe Orbiter 2 0 0 iod Oct 03 Software upgrade HS0035 Software upgrade Temperature Compensation 2 1 0 4 20 04 added Pre wet and Final wet valve selection added 2 2 0 50035 July 06 Software upgrade 5 00 2 3 0 March 07 Formatting Correction page 87 2 4 0 pne July 07 User Guide re indexed 24 1 HS0035 March 10 Modification to OPTO selection and maximum 5 05 flowmeter frequency Hydro Control V User Guide HD0193 Issue 2 5 0 3 Hydro Control V Start Menu Rec Batch 4 1 Calc Moisture 4a Status first mis final wet Figure 1 Hydro Control V Front Panel 4 Hydro Control V User Guide HD0193 Issue 2 5 0 Table of Contents TABLE OFFIGURES D ne RE EM
91. set to Auto mode Pre wet mode The Hydro Control V can operate in one of two pre wet modes e Pre set mode Pre The quantity of water defined by Pre wet water is added regardless of measured moisture Auto mode Auto The sensor moisture reading is used to add water up to the Pre wet target using Auto mode control see section Auto mode NOTE When the main Control Mode is set to Pre set or Calib mode the Hydro Control V will use Pre set mode for the Pre wet phase of the mix cycle regardless of the Pre wet mode setting Pre wet delay The delay between Pre wet phase completing and continuing the mix cycle Delays the Pre wet done signal allowing any Pre wet water to be mixed before cement is added First mix time The duration of the mix that follows the addition of any Pre wet water and the cement see Section Setting Mix Times Cement timeout Maximum time system will wait for CEMENT IN signal before beginning First mix time If the system exceeds the maximum permitted waiting time for the CEMENT IN signal the system will automatically pause the mix cycle sound and output ALARM If no CEMENT IN signal is to be used after a Pre wet phase set this parameter to zero Moisture target The moisture value to be reached during the final mix phase Preset final The amount of water to be added during the final wet phase of the mix cycle Final mix time The duration of the mix that follows the addition of the final water see Section
92. t phase quicker than would be the case with progressive water addition Fine Delivery determines the amount of water to be added with the fine valve only so that the calculated value of water is delivered accurately and without causing excessive overshoot Mix Complete Calculated Final water Y Moisture First mix addition Final mix time oneshot time Moisture target Dry reading used to calculate Final water Averaging Averaging time Mixer NE Loading Add Figure 7 Calc Mode Mix Cycle Calibrating a Recipe In order to run a recipe in Calc mode the recipe needs to be calibrated It is usual to run the mix cycle in Preset mode for several cycles before performing a calibration to establish mixing time water quantities and to ensure that good mix to mix moisture consistency is achieved The mix to mix consistency can be checked by pressing More F5 and then Log F2 where Final 9e values can be inspected It is suggested that the discharge is set to manual mode during calibration to prevent automatic discharge this enables manual correction to the mix after MIX COMPLETE A calibration run can be carried out in two ways depending on whether any admix is required 22 Hydro Control V User Guide HD0193 Issue 2 5 0 Calibration without admix When calibrating without admix or when the admix is added during the First mix time there is usually one water addition phase an
93. the current recipe Preset Final and Target moisture parameters are updated Hydro Control V User Guide 19 HD0193 Issue 2 5 0 Auto Mode Control Parameters The progressive algorithm used by Auto mode controls the effective water flow into the mixer The water flow rate is controlled by pulsing the water valves on and off As the moisture level approaches the moisture target the amount of on time compared to the amount of off time is reduced which reduces the average flow rate From the Start Menu pressing lt gt F5 followed by lt Setup gt F1 gives access to the system configuration menus It is necessary to enter the Advanced Password see Appendix D to access the Control Parameters after the password has been entered press Control F3 The following parameters are used to control the progressive water addition Gain Controls how fast water is put into the mixer A higher value will increase the rate at which water enters the mixer It is normal to start with a value of 20 Observe the trend line during a mix cycle to determine if the water is entering the mixer at the desired rate Increase the value initially by 5 to increase the water flow rate reduce the value to reduce the water flow rate A value of 20 40 is typical for moderate to good mixers with correctly sized water valves Slower acting mixers will use lower values Upper Control Threshold Controls the point when the water valves change fr
94. the Start Menu If Yes is selected the mix complete signal is generated and Reset F2 returns to the Start Menu and clears the MIX COMPLETE signal At the end of the Final mix time a MIX COMPLETE signal is generated indicating to the batch control system that the mixer is ready for discharging If discharge is set to manual and an automatic Reset is not received then the following options will be displayed Reset F2 Returns the unit to standby and clears the MIX COMPLETE signal Trim Opens the Fine Water valve all the time the key is depressed allowing manual trimming of the moisture level Update F5 Followed by ED saves the adjusted water amounts and moisture levels to the current recipe Preset Final and Target moisture parameters are updated A Calc mode mix cycle may be paused at any phase of the mix cycle by pressing Pause F2 The following options will be available Resumes F1 Continues the cycle from the point where it was paused lt Abort gt F2 Allows the current mix to be aborted When pressed the option to generate MIX COMPLETE signal is prompted with the following Mix Complete Required Yes F2 and No If No is selected it will return to the Start Menu If Yes is selected the mix complete signal is generated and Reset F2 returns to the Start Menu and clears the MIX COMPLETE signal At the end of the Final mix time a MIX COMPLETE signal is gen
95. the difference between the current value of moisture and the target value This difference is used in two stages to define an output level which can be considered as the percentage of time the water valves are open First the difference is multiplied by the proportional gain In this way as the current moisture value approaches the Moisture target the output drops and the likelihood of over shooting the target is reduced value of 20 40 is typical for moderate to good mixers Slower acting mixers should use lower values Secondly the rate of increase or decrease of the difference is calculated This is multiplied by the derivative gain and subtracted from the output level This parameter makes a correction for how quickly the moisture level is rising again an attempt to prevent overshooting the target The overall output level is calculated and constrained to be a number between 0 and 100 with large numbers representing the valve s being on for a greater percentage of time and zero meaning the valve is off In systems with both a coarse and a fine valve if the output level is greater than a certain value determined by Coarse upper thr in the Advanced Control Parameters then water is added using both the coarse and the fine valves If the output level is below this level only the fine valve is used Calc mode Calc mode calculates the amount of water required to achieve a moisture target In this way the user still achieves an accur
96. upport Staff UNIT SERIAL NUMBER as found on the back plate of the Hydro Control V PLANT PARAMETERS Mixer type i e Ribbon Twin shaft Turbo Planetary Mixer Manufacturer Mixer size Normal Load Minimum load Normal dry moisture NOMINAL RECIPE VALUES Pre wet water First Mix Time Final Moisture 96 Final Mix Time SYSTEM PARAMETERS Water mode Meter flow pulse Meter timeout Setup password Language Busy Mode Max recipes Hydro Control V User Guide HD0193 Issue 2 5 0 103 CONTROL PARAMETERS Standard and Advanced parameters Upper Control Threshold Lower Control Threshold Valve Time Fine delivery Averaging Time _ IMxExemo EE CS SytemWode Corser A E _ E pou pou Cycle on off RS232 Mode Cycle Loops 104 Hydro Control V User Guide HD0193 Issue 2 5 0 Address 90 fn nina 33 34 37 46 Auto Mode 12 14 29 32 33 38 40 0 17 Control Algorithm 93 Autocal eee 51 54 Ave Hold Delay 55 Averaging Time 49 Batch 34 Busy Modena 46 74 erii RER 60 61 Calc Mode 12 33
97. uring wet mix Unscaled deviation max min readings during the wet mix averaging time Number of water pulses received Sensors unscaled reading Mixing Pre set Rec Batch 1 5 a a n 70 Fre set 78 8 litres US 5 8 Average 3 7 Dry Deu 15 5 Wet Average 5 0 Wet Deu m Status Mix Complete 31 secs Rezet Trin Update Figure 45 Test mode screen Coarse upper threshold ratio together with the Upper control threshold this ratio defines the point at what the coarse valve is no longer used A lower value will keep the COARSE WATER output on for longer switching the FINE WATER output on closer to the Moisture target Derivative gain together with the Gain this ratio defines the Derivative gain This value attempts to compensate for how fast the moisture content is rising and slows the water addition if the moisture content is rising rapidly Cycle on off together with the Valve on off time this ratio defines the Valve cycle time This determines how often the valves are switched on and off It should not be less than twice the On Off time A shorter time will be faster and give more precise control if your mixer is fast enough to take advantage of it but will cycle the valves more often which could lead to wear 90 Hydro Control V User Guide HD0193 Issue 2 5 0 RS232 mode Determines how the serial port may be used e Plant RS232 communications with plant control e Screen a
98. uto mode Pre wet is followed by a Calc mode Final Wet the Recipe Gain can be increased up to a maximum value of 10 0 to improve the speed of the Pre wet water addition Hydro Control V User Guide 33 HD0193 Issue 2 5 0 Minus tolerance Moisture below target at the end of the Final mix time at which the system will sound and output ALARM In Auto mode if the moisture falls below this tolerance during the Final mix time the cycle will revert to Final wet and attempt to reach the Moisture target Disabled after mix complete Dry weight The total dry weight of the mix including all sand aggregates and cement Calib water The Preset final parameter defines the amount of water to be added during the final wet phase of a calibration mix cycle Setting the Calib water value to be less than the Preset Final allows the water to be added in two phases During the first phase of water addition when Calib water litres are added the calibration slope will be calculated and during the second phase of water addition when Preset final minus Calib water litres are added the admix is also added The Moisture target is then defined with any required admix present but the calibration slope is not effected Water limit The maximum amount of water that would ever need to be added for this recipe Batch counter A batch number to identify a mix in the mix log Default recipe values may be edited under Setup System see section Edit System Parameters
99. wo pairs twisted 4 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 8302 Alpha 6373 Maximum cable run 100m separate to any heavy equipment power cables Interface Modules Six output modules and four input modules are provided as standard For voltage options refer to Installation At least the FINE WATER output must be connected All other connections are optional and can be connected as appropriate for each configuration Hydro Control V User Guide 87 HD0193 Issue 2 5 0 Communications RS232 For connection to batch computer remote recipe module or remote operator terminal to permit the remote selection of recipes System Software can also be upgraded by connecting a PC to the RS232 port RS485 For communicating with the Hydronix moisture sensor including changing operating parameters and sensor diagnostics Simulator program also uses RS485 communications Operating Temperature Range 0 50 C 32 F 122 F Electromagnetic Compatibility Meets the requirements of Electromagnetic Compatibility Directive 89 336 EEC Mechanical Dimensions Fascia Panel Cut out Max Panel Thickness Depth Depth behind Fascia Weight Protection 88 Hydro Control V User Guide HD0193 Issue 2 5 0 190 mm H x 246 mm W 178 mm H x 232 mm W 12 mm 84 mm 3 54 78 mm 3 31
100. y During the mix phases of a Calc or Calib mode cycle the system averages the moisture values over the last Averaging time seconds defined by the system parameter Averaging time see section Edit Control Parameters of the mix time Therefore in Calc or Calib mode during the First mix and Final mix phases the system will mix for at least the amount of time defined by the Averaging time e g if the First mix time parameter is set to 10 seconds and the Averaging time is set to 20 seconds the first mix will last for 20 seconds however if the First mix time is set to 25 seconds and the Averaging time is set to 20 seconds the first mix will last for 25 seconds As it is critical that reasonable stability has been reached before averaging starts it is recommended that the First mix time and the Wet mix time parameters be set to be at least twice as long as the Averaging time Mix Time Guidelines Mixer Type Control Mode Averaging Time First Mix Wet Mix 5 5 Time s Single Star Planetary Auto N A 30 50 Calc 20 50 50 Two Star Planetary Auto N A 15 20 Calc 15 40 40 Twin Shaft Auto N A 15 20 Calc 15 40 40 Ribbon Auto N A 30 60 Calc 20 50 60 Turbo Auto N A 20 30 Calc 15 40 50 Mix times for Pre set mode should be the same as for the intended Control Mode The above is intended only as a guide for getting started Actual mixing times will vary and should be optimised for each app
101. ydro Control V User Guide 0193 Issue 2 5 0 Chapter 6 Valves and Water Flow Rates While the Hydro Control V can work with a single water control valve optimum performance fastest cycle times with least overshoot will probably only be achieved with e coarse valve to rapidly bring the moisture level near to target e Afine valve to trim up the moisture level to the target without overshoot It is essential that the valves are correctly sized and flow rates correctly adjusted with respect to the mixer capacity and efficiency Valves should be able to turn on and off rapidly the combined on off cycle time for a 50 mm 2 valve should be no more than 2 seconds and 19 mm 3 4 valves should have combined on off cycle time of no more than 1 second This permits precise water addition Example Metric units If a 1m mixer has only a coarse valve with a water flow rate through the valve is 10 L s and an on off cycle time of 1 sec then water can only be added in 10 L steps With a full load 2200 Kg then the smallest moisture step is approx 0 5 which is too coarse for adequate control If the same system was also fitted with a fine valve which had a flow rate of 1 L sec and an on off time of 1 sec then using this valve would permit water addition in steps of approx 1 L or 0 0596 giving good control US units If a 35 mixer has only a coarse valve with a water flow rate through the valve is 3 Gal s and an on off cycle ti
102. z Amplitude 673 si Sr Sensor SZ63CFR96 Firmware 1 HSOB63 v2 12 Temp C Min 11 3 Max 37 7 Run Pine Air 828 38 Water 784 30 Status Test Calih Back Figure 29 Hardware Using the Hardware Menu The Hardware Menu displays information about the connected sensor and allows the user to force the analogue output of the sensor and to autocal a Hydro Probe Orbiter To test the sensor analogue output select Test F3 This will force the current to the indicated value Use the numeric keypad or the lt Inc gt F1 and lt Dec gt F2 keys to vary the current between 0 20mA NOTE The current interface is not normally used when connected to a Hydro Control V The Calib function shown above in lt F4 gt only appears when a Hydro Probe Orbiter is connected This is used to perform an Autocal which is used when a new sensing arm is connected to the sensor The Hardware menu will also display the following information e Uncompensated and compensated frequency e Amplitude of frequency response e Sensor ID e Firmware Version e Min and Max temperatures recorded in the sensor e Factory calibration air and water readings Press the Back F5 key to return to the Diagnostics Menu Hydro Control V User Guide 51 HD0193 Issue 2 5 0 Resonator Rezonator Rec Batch Frey Amp T In T Out 542 85 579 30 7 38 8 Moisture Status 300 4 Ref Back Figure 30 R

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