Hydro-Probe Orbiter (Rotating Mounted) User Guide
Contents
1. Ensure the ceramic face plate is facing upwards and is completely clean and dry 2 Connect the Autocal Dongle to the sensor body and cable as shown in Figure 30 The Autocal Dongle should begin flashing red bright dim bright for 30 seconds 3 After 30 seconds the Autocal Dongle should start flashing on off on At this stage it is important to keep away from the ceramic faceplate 4 After approximately 20 seconds the Autocal Dongle should illuminate constantly The calibration is finished and the Hydro Probe Orbiter is ready to be fitted back into the mixer Disconnect the Autocal Dongle and reattach the cable for normal use If the Autocal Dongle continues to flash on off on as in stage 3 then the calibration was unsuccessful due to variation during its measurement stage stage 4 If this is the case disconnect the Autocal Dongle from the sensor body and cable and repeat steps 1 4 HYDRO PROBE ORBITER USER GUIDE 42 HD0256 REV 1 1 0 7 2 2 Air and water calibration Using any of the available Hydronix configuration utilities Hydro Link HydroNet View Hydro Com The calibration is performed by making separate readings in air and water With the sensor connected to a computer see section 4 4 the Hydronix PC based utility can be used to make the measurements and update the sensor in the configuration section The air reading should be made with the face plate clean dry and free from obstructions On the appropriate tab o2. sseeeeeeess 14 24 1 Height adjustment ore e acc Her he Fe Re ar het ec aal aeda 14 2 4 2 Sensing head angle adjustment for optimum performance eessssss 14 MA DLS Moh RO EE AAA 17 O dudes 17 3 1 Type A rotating connector assembly eerie rente toe e re etude donee Meee 18 3 1 1 Suitable applications ee 18 3 1 2 Mountings idee tio 18 CNET QOMMECWONS PEE 18 3 1 4 Threaded Adapters ssssssssssssssssssseesseeeeen nennen enne enne nenne emen nennen renis 18 3 1 5 A ette nte netto ots ok Bae cet 20 3 1 6 Fitting with good clearance aire ben Ee eo eee alaalia ila P e E asi 20 3 1 7 Fitting where minimal clearance eXiSts 2 2 ccccceeeeeeeeessnecteeeeeeeeeeedenenseeeeeeeeneenenes 21 3 1 8 Fitting rotating connector type A and connecting sensor cable to Mercotac 21 3 2 Type B rotating connector assembly rrnneseannenuntanaaeneennannatannananaeena nnn 23 3 2 1 Suitable applications A a enn E E e REB ea Sd 24 m2 Routing or cables anaana dust Ra aE incita bash rds tita talade Lois dris 24 3 2 3 Fitting rotating connector type B and connecting the sensor cable to the Mercotac 25 3 3 Type C rotating connector assembly essen nennen inet n nnn 26 3 3 1 Suitable applications sse eem eene mener nnns 26 CROP MERI PME 26 3 3 3 Fitting rotating connector type C and connecting sensor cable to
3. The cabling arrangements will be different for each type of mixer Therefore the intention of this manual is to conceptually cover the three different types of mixer applications The routing and fixing of the cable in the mixer together with the fixing of the rotating connector might require a certain amount of improvisation Rotating connector Plant cable assembly gt Rotating sensor Figure 12 Connecting the Hydro Probe Orbiter to the rotating connector Three different types of rotating connector assemblies referred to as types A B or C are available to suit different types of mixer The connection details for the plant cabling to the terminal blocks inside the rotating connector assembly are the same in all cases but are dependant on whether a 4 pole or 6 pole rotating connector is used HYDRO PROBE ORBITER USER GUIDE HD0256 REV 1 1 0 17 3 1 Type A rotating connector assembly 3 1 1 Suitable applications Suitable for mixers with a hollow central shaft through the gearbox where the motor is not positioned centrally i e planetary mixers such as OMG Rotating connector assembly Connection through the hollow shaft Figure 13 Connection to the rotating connector using a hollow shaft through the gearbox 3 1 2 Mounting Mounts directly on the top of the mixer using a nylon mounting flange 3 1 3 Connections Connects directly to the mixer central hollow shaft by means of thr
4. HYDRO PROBE ORBITER USER GUIDE 44 HD0256 REV 1 1 0 Chapter 8 8 Troubleshooting tips These tips are intended as suggestions for troubleshooting when problems occur with the water control system 8 1 Installation e Fit the sensor with a 50 mm gap between the bottom of the Hydro Probe Orbiter and the mixer floor e Fit away from the water cement and aggregate inlets e If the Hydro Probe Orbiter performance is suspect if possible compare the signal from the sensor using Hydro Com or Hydro Link to the calculated moisture content This will identify if the problem is with the Hydro Probe Orbiter or the control system 8 2 Electrical e Ensure that the cable is of suitable quality the minimum specification is twisted pairs of 22 AWG 0 35mm conductors screened with aluminium polyester foil and 65 minimum coverage braid Belden 8303 or equivalent e When using the analogue output it is advisable to take the RS485 cable back into the control cabin This can be particularly useful over the life of the equipment for diagnostic purposes and takes the minimum of effort and cost at the time of installation e Route the signal cable away from power cables in particular the mixer power supply e Check the mixer is properly grounded e The signal cable should only be grounded at the mixer end e Ensure the cable shield is not connected at the control cabin end e Ensure there is continuity of the shield through any junction boxe
5. cable Check clearance Rotating arms Figure 15 Checking the clearance between the revolving arm and the ceiling of the mixer 3 1 6 Fitting with good clearance The clearance should be sufficient to ensure the rotating arms do not snag the protective hose EB Pd t Securing Points i Optional A 32mm ID H fits over threaded 90 bend protective e can be screwed into hose e gearbox shaft with hose clip Figure 16 Fitting the cable with good clearance HYDRO PROBE ORBITER USER GUIDE 20 HD0256 REV 1 1 0 e The cable is sheathed with 32mm internal diameter rubber hose e Rubber hose fits over the boss covering the connector on the Hydro Probe Orbiter electronics body and is secured by a hose clip e Metal straps to be welded or bolted as appropriate to provide securing points for the rubber hose and cable Suggested details in Figure 16 3 1 7 Fitting where minimal clearance exists One suggested method of fitting the cable when there is very small clearance is by using a small thin plate that can be fixed in place using the existing blanking bolt in the ceiling of the mixer If the head of the bolt is drilled the cable can be passed through and up the gearbox shaft The plate is used to protect the cable near to the centre of the mixer where planetary blades run a risk of hitting the cable Metal plate to lt 4 protect and secure cable N Rubber tube secured to Head of blanking bolt
6. between a signal proportional to moisture and a signal proportional to external material temperature Input Output Use 2 1 Unused default the status of the line is ignored 2 Moisture temperature Switch the analogue output between a signal proportional to moisture and a signal proportional to external material temperature Bin empty output Data invalid output Probe OK output NR HYDRO PROBE ORBITER USER GUIDE HD0256 REV 1 1 0 37 HYDRO PROBE ORBITER USER GUIDE 38 HD0256 REV 1 1 0 Chapter 6 6 Sensor care 6 1 Keeping the sensing head clean Ensure there is no permanent build up of material over the sensing head and arm If the angle of the face of the sensing head is correctly adjusted then the continual movement of fresh material against it should normally keep it clean At the end of the shift or if there is a significant gap in production it is advisable to hose or wipe the arm and head to ensure no hard build up occurs It is recommended that a high pressure water cleaning system is used to clean the sensor However although the Hydro Probe Orbiter is waterproof its seals will not prevent the ingress of water from high pressure equipment nozzles that are held in close proximity to the sensor Keep all high pressure water sprays at least 300mm away from the sensor and rotating connector CAUTION NEVER HIT THE SENSING ARM HYDRO PROBE ORBITER USER GUIDE HD0256 REV 1 1 0 39 Notes HYDRO PRO
7. hold Average hold Average filtered Moisture temp Unused Input output Use 2 Unused Unused Moisture temp Bin empty Data invalid Probe OK Temperature compensation Electronics temp coeff 0 002 Resonator temp coeff 0 0075 Table 4 Hydro Probe Orbiter default parameters Note When connected to a Hydro Control IV or Hydro View the output type should be set to compatibility HYDRO PROBE ORBITER USER GUIDE HD0256 REV 1 1 0 35 5 1 Calibration parameters The default calibration parameters in Table 4 are Hydronix standard sand calibration set These values will be used to convert the unscaled reading to a moisture reading according to the formula Moisture A x unscaled reading B x unscaled reading C The A B and C coefficients are only active when either e The analogue output is set to give Raw Filtered or Average moisture e Raw Filtered or Average moistures are read from the RS485 link The recommended analogue output type is Filtered Unscaled In this case the calibration parameters will have no effect NOTE The analogue and RS485 output work independently of each other Therefore if Raw Filtered or Average moisture levels are requested via the RS485 link the analogue output can still be set to give an unscaled output which will not use the A B and C values and visa versa 5 2 Average Hold Delay This parameter would only be used for applications where the Hydro Probe Orbiter is replacing
8. latest digital microwave techniques that provide a more sensitive measurement compared with other analogue techniques The frequency has been selected to provide the optimum compromise between penetration of measurement and accuracy The penetration of measurement is approximately 100mm in dry materials such as sand The output is linear for most materials with the ability to measure up to the point of saturation for the material concerned 1 5 Sensor output with rotating connector The standard 4 pole rotating connector will provide power to the sensor and a RS485 output only This is suitable for connecting directly to the Hydro Control V or direct to the control system using a RS232 converter Alternatively the RS485 capability may be sacrificed to provide an analogue output A 6 pole rotating connector can be used instead of the 4 pole to provide both the RS485 and analogue outputs 1 6 Sensor configuration As with other Hydronix digital microwave sensors the Hydro Probe Orbiter may be remotely configured using the Hydro Link or Hydro Com diagnostics software 1 7 Sensing arms The Hydro Probe Orbiter is available in various lengths Standard lengths are 560mm or 700mm note that this length refers to the overall height of the Hydro Probe Orbiter as shown in Figure 1 Other lengths can be made to order An additional feature with the longer 700mm sensing arm is a reinforcement collar that fits over the top of the arm see Fi
9. the Hydro Probe ll in high wear environments see HD0215 Hydro Probe Orbiter Manual Static Mounting Therefore in mixer applications this should be set to zero 0 for the Hydro Probe Orbiter 5 3 Smoothing time This defines the amount of filtering on the output signal The smoothing time defines the time taken to get 50 of the final value in response to a step input A value of 7 5 seconds is normal for most mixer situations 5 4 Slew rate and slew rate These slew rates are used to limit the effect of rapid transient signals due to mixing action There are three settings available Light Medium and Heavy which correspond to 5 2 5 and 1 25 unscaled units per second respectively 5 5 Temperature coefficient This parameter is used to correct for thermal drifts in the electronics when used in hot environments or with hot materials It should not normally be altered HYDRO PROBE ORBITER USER GUIDE 36 HD0256 REV 1 1 0 5 6 Digital input output The Hydro Probe Orbiter has two digital lines One line can be configured as an input and the other can be either an input or output Input Use 1 1 Unused the status of the line is ignored 2 Average hold default the readings are averaged and when switched the analogue output holds the average value 3 Average filtered the readings are averaged and when switched the analogue output returns to the filtered output 4 Moisture temperature switch the analogue output
10. 1 type RS232 port if the customer wishes to connect to a PC using a suitable cable RS485 line termination will not normally be required in applications with up to 300m of cable For longer lengths connect a resistor approximately 100 ohm in a series with a 1000 pF capacitor across each end of the cable It is recommended that the RS485 signals be run to the control room even if they are unlikely to be used This is because it will facilitate the use of diagnostic software should the need arise HYDRO PROBE ORBITER USER GUIDE HD0256 REV 1 1 0 33 RS485 RS232 RS485 A ED RS485 B Hydronix Part No 0049 e RS485 RS232 gt RS485 A P RS485 B Hydronix Part No 0049B 6 dipswitches control the configuration of the converter For both the 0049 and 0049B these should be set to Switch 1 ON Switch 3 ON Switch 5 OFF Switch 2 OFF Switch 4 OFF Switch 6 OFF Figure 27 RS232 485 converter connections KD485 STD Connect to PC serial port Connect to PC serial port Figure 28 Din rail mounting RS232 RS485 converter HYDRO PROBE ORBITER USER GUIDE 34 HD0256 REV 1 1 0 Hydronix Part No Hydro Probe Hydro Probe 0049A Orbiter Orbiter P1 P2 PC S 1 1 S F RS485 A F RS485 A or 9 way D Type PC Control System TURON S 2 2 S G RS485 B G RS485 B TX 4S5 318 RS232 2 H full
11. 2 0m e Keep the premix time as long as possible at the detriment of the wet mix time if necessary e The shortest mix time is generally obtained from this mix order Load aggregates including steel or rigid plastic fibres if used Load microsilica slurry if used Load cement just after aggregates start and after micro silica slurry if used Run cement and aggregates together and silica fume powder if used Finish cement before aggregates Allow sufficient dry mix time to obtain a good stable signal Measure moisture content Load water and admixtures Wet mix until the signal is stable 0000000 00 REMEMBER DO NOT HIT THE CERAMIC IT IS EXTREMELY WEAR RESISTANT BUT BRITTLE HYDRO PROBE ORBITER USER GUIDE HD0256 REV 1 1 0 47 Notes HYDRO PROBE ORBITER USER GUIDE 48 HD0256 REV 1 1 0 Chapter 9 9 Sensor performance The moisture reading from the sensor can only indicate what is happening in your 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 9 1 Adjustment of the blades e Ensure the mixer blades are regularly adjusted to comply with the manufacturers recommendations normally 2mm clear of the floor with the consequent benefits o Allthe residual mix is
12. BE ORBITER USER GUIDE 40 HD0256 REV 1 1 0 7 Replaceable parts 7 1 Changing the sensing arm The sensing arm is a replaceable item The wear life ofthe arm is dependent on the materials in which it is used the mixer and of course on the amount of use Wear life may be extended by taking precautions as set out in the previous chapter However periodically either through accidental damage or excessive wear it may be necessary to replace the head and arm 7 1 1 Removing the sensing head and arm e Undo the clamp bolts securing the sensor body to the square support bar e Remove the entire sensor body and arm and take to a clean environment e Lay the sensing arm on a clean flat surface e Undo the arm clamp nuts on the sensor body and pull out the worn sensing arm e Attach the new sensing arm by following the installation instructions in this guide See section 2 1 7 1 2 Fitting the Hydro Probe Orbiter back into the mixer Follow the instructions in Chapter 2 ensuring both the height from the mixer floor and the angle of the sensing head are set correctly 7 2 Calibrating a new arm to the sensor electronics Recalibration is necessary after fitting a new arm to the sensor electronics For mixer applications a calibration called AUTOCAL is sufficient although there are other ways in case the customer has no facility for this 7 2 1 Autocal During any Autocal the ceramic face must be clean dry and free from obstruction This calib
13. Barrel tube Adapter 1 BSP to 14 BSP Adapter Connects directly to rotating tube Figure 22 Type C rotating connector assembly HYDRO PROBE ORBITER USER GUIDE HD0256 REV 1 1 0 27 3 3 3 Fitting rotating connector type C and connecting sensor cable to Mercotac The procedure for fitting the type C will be similar in principle to the type B except for connecting the threaded adapters and the 80mm rubber tube e Over the mixer rotating tube fit the 80mm rubber tube the spigot flange then the bearing holder plate e Screw on the brass adapters to the mixer rotating tube e With the Mercotac removed from the holder screw the Mercotac holder on top of the brass adapters e With the cable connected to the Hydro Probe Orbiter feed the cable up through the rotating tube and the Mercotac holder and cut to the correct length e Cut back the cable sheath and crimp on spade terminals At most 6 conductors are used so unused conductors can be cut back e Connect to Mercotac terminals See section 3 4 Mercotac wiring connections The static end of the Mercotac should be already connected to the terminal blocks e Ease the Mercotac back into the holder The retaining O ring may make this difficult so a small application of grease oil would make this easier e Fix the rotating connector body to the bearing holder plate and spigot flange e Tighten the thread adapters and slide over the 80mm rubber tube securing bot
14. D0256 REV 1 1 0 51
15. GUIDE 32 HD0256 REV 1 1 0 43 Compatibility mode Compatibility mode allows a Hydro Probe Orbiter to connect to a Hydro Control IV or Hydro View To operate in this mode the output type needs to be set to compatibility using Hydro Link or Hydro Com see section 5 The 500 ohm resistor is required to convert the analogue current output to a voltage signal This should be fitted as shown at the Hydro Control IV Hydro View The required connections are shown below in Figure 26 lt Cable 0090A 4m 1 2 3 4 5 6 7 8 9 500 Ohm resistor Hydro Control IV or Hydro View Connector O O O O O O O O O O O O Figure 26 Compatibility mode 4 4 Connecting to a PC An RS232 485 converter is required to connect one or more sensors to a PC There are three types of converter supplied by Hydronix All operate identically but come in a different package to suit a variety of connection types and applications For single sensor applications the twisted pair RS485 wires from the sensor can be either terminated in a 9 pin male D type converter part no 0049 or a terminal block connected converter part no 0049B These two converters are shown in Figure 27 For multi sensor applications it is recommended that a converter that has an external power supply is used such as the converter show in Figure 28 which is designed for industrial applications and is DIN rail mounted Note that this unit has an additional RJ 1
16. Hydro Probe Orbiter User Guide For model ORB1 rotating mounting This guide is for model ORB1 with rotating connector FOR ROTATING SENSOR IN STATIC PAN MIXERS Typical applications All turbo pan mixers such as Liebherr Pemat Rapid Teka Planetary type pan mixers with a hollow central shaft to the gearbox To re order quote part number HD0256 Revision 1 1 0 Revision date March 2004 Copyright Neither the whole or any part ofthe 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 2004 Hydronix Limited 7 Riverside Business Centre Walnut Tree Close Guildford Surrey GU1 4UG United Kingdom All rights reserved CUSTOMER RESPONSIBILITY The customer in applying the product described in this documentation accepts that the product is a programmable electronic system which is inherently complex and which may not be completely free of errors In doing so the customer therefore undertakes responsibility to ensure that the product is properly installed commissioned operated and maintained by competent and suitably trained persons and in accordance with any instructions or safety precautions made available or good engineering practice and to thoroughly verify the use of the product in the particular application ERRORS IN DOCUMENTATION The product describ
17. IN THE MIXER IF THIS IS NOT POSSIBLE A BATTERY MODEM IS RECOMMENDED 1 2 Typical Mixers e Turbo pan mixers such as Liebherr Pemat Rapid or Teka e Planetary mixers with hollow central shaft to the gearbox such as some OMG and Skako mixers 1 3 Description The Hydro Probe Orbiter is the most innovative sensor ever to reach the market With an easily replaceable sensing head that slices through the mix the Hydro Probe Orbiter provides a rapid and representative measurement of both moisture content and temperature of the material Utilising the latest digital technology the Hydro Probe Orbiter combines accuracy and speed to provide a meaningful reading that is unachievable with static mounted sensors The main sensor electronics are housed in the sensor body separate from the hard wearing replaceable sensing arm and head This provides many distinct advantages with the following key features and benefits e Small streamlined sensing head cuts cleanly and smoothly through the material without a build up providing a smooth and clean signal e Rapid response temperature measurement provided from a thermally insulated temperature sensor in the sensing head end plate e Easily replaceable sensing arm and hardened wear head with easy calibration procedure for matching new microwave sensing head and arm to main electronics HYDRO PROBE ORBITER USER GUIDE HD0256 REV 1 1 0 7 1 4 Measuring techniques The Hydro Probe Orbiter uses the very
18. ITER USER GUIDE 12 HD0256 REV 1 1 0 2 3 Fitting the square mounting bar A 25 35mm square bar should be very firmly welded to the appropriate scraper blade arm or alternative mixer arm depending on the mixer configuration It should be suitably reinforced to provide a rigid fixing that will withstand the thrust generated on the sensing head and arm whilst moving though the material Ensure that the bar is perpendicular to the floor in both planes It may be preferable such as in turbo mixers where each arm is sprung loaded to construct a separate arm fixed to the central part of the mixer Undo and remove the 4 bolts securing the pair of clamp blocks to the head unit for clamping the unit to the square bar and remove the pair of clamp blocks as shown in Figure 6 Depending on the configuration the clamp blocks may need to be rotated for either vertical or horizontal fixing to the square bar Figure 6 Removing the mounting bar clamp blocks ready for fitting to the mixer Figure 7 indicates how the square mounting bar may be welded to the scraper blade arm or an alternative arm Extra support bar welded Top view Figure 7 Square mounting bar welded to scraper blade arm HYDRO PROBE ORBITER USER GUIDE HD0256 REV 1 1 0 13 2 4 Mounting the sensor and final adjustments when running 2 4 1 Height adjustment The height may be adjusted by slackening the clamp blocks and sliding the body up and down the sgu
19. Mercotac 28 3 4 Mercotac wiring Connections viana ib 29 3 4 4 Wiring sensor cable to Mercotac 1eeesssesssseeeeee nennen nnne seeni 30 Chapter AN 31 A ANNO COMME CUOMS ERE o o OD ORDRE 31 4 1 Analogue Quipil cece Geet UU AA e babe ue Lan ts RARE NUR MAR A ER ba SAPERNE 31 4 2 RS485 multi drop connection sssssssssss ees 32 4 3 opere n 33 4 4 Connecting to a PG seii iiti ec ne ote Eae eese lelu Aceite ida t LOS 33 Chapter 5 uii er re a ED ROSE EXORTU ROSE E RAN RA RARE E E Uh d ERR OR RR RA AO END 35 5 e ler dete ta titudine kka tu Juta ahmi kana 35 5 1 Calibration paramieters x seit en tee ies 36 5 2 Average Hold Delay lola ista lads dau ceci din 36 5 3 eremi e 36 HYDRO PROBE ORBITER USER GUIDE HD0256 REV 1 1 0 3 5 4 Slew rate and slew rate a ea E a ae aA ea a a aa a aa ara aa Aa AAE aai e AA EE Adi akidai iaai 36 5 5 Temperature coefficient 0 nvnnenannnnnnnan ear anaannn anna nennen nnnm nnne en eren enses 36 5 6 Digital input oUtDUt 5 eret tere eee n ee er e e eae i a 37 lloc E 39 O Sensor Care odes eR RR ERE ERR OR RU EE Re EN RAE REI Bi Pn eR RE RARE RR ER AA RE INR nb AA ERN 39 6 1 Keeping the sensing head clean eese nter nnn nnnenn 39 Chapters fot ted eese c sa ON Un E PM Md e e M LEES 41 P Replaceable Parts tite ertet et e omn Pot tate rsen Fou ance rex Me abs 41 TA Changing the Sensing a FM v2 mE 41 7 1 4 Re
20. ORBITER USER GUIDE HD0256 REV 1 1 0 29 3 4 1 Wiring sensor cable to Mercotac The wiring instructions for the sensor cable are shown in table 2 below Please refer to Engineering Note EN0035 enclosed with the cable for full information The twisted pair numbers are referenced to the table in EN0035 and the Mercotac terminal numbers are as shown in Figure 23 If there is any doubt as to the terminal connections on the Mercotac check continuity using an electrical meter between the terminals at the bottom of the Mercotac rotating section and the screw terminal block in the rotating connector body 1 24V Red 3 3 1 OV Black 4 4 4 RS485 A White 1 1 4 RS485 B Black 2 2 3 Loop Blue 5 3 Loop Black 6 Table 2 Rotating connector sensor cable to Mercotac connections HYDRO PROBE ORBITER USER GUIDE 30 HD0256 REV 1 1 0 Chapter 4 4 Wiring connections The Hydro Probe Orbiter is connected using a 4 metre cable part no 0090A An extension cable twisted pairs from the rotating connector to the plant control room should be provided by the customer or agent installing the sensor Up to 3 twisted pairs may be required dependent on installation requirements It is recommended that a high quality cable with a good braid and foil screen is used to minimise electrical interference containing 22 AWG 0 35mm conductors Recommended cable types are Belden 8303 or Alpha 6374 The cable screen m
21. are support bar The recommended height for typical applications is 50mm above the floor of the mixer Figure 8 This height can be set using the angle aligner which has a width of 50mm The correct length of arm should be selected to allow the sensing head to sit a minimum of 50mm above the floor of the mixer and to ensure that the ceramic faceplate is in the full flow of the mix When adjusted to the desired height securely tighten the clamp block bolts to a torque of 60Nm 44Ib ft It is essential to ensure the Nordlock washers are fitted to the clamp bolts so that the sensor is securely retained on the square bar Sensing head Minimum level of material Ceramic faceplate 50mm Mixer floor Figure 8 Height setting of the sensing arm 2 4 2 Sensing head angle adjustment for optimum performance With the 4 arm clamp nuts loose the sensing arm can be rotated through an angle of approximately 300 Figure 9 The sensing arm is fitted with a mechanical stop to protect the internal cables from being over rotated If this stop prevents the faceplate from being adjusted properly then remount the Hydro Probe Orbiter main body on the square bar at a different angle This will then allow the arm to be adjusted correctly Figure 9 Adjusting the sensing head angle HYDRO PROBE ORBITER USER GUIDE 14 HD0256 REV 1 1 0 The angle ofthe sensing head face should be adjusted to provide consistent compaction of material agains
22. ction e Body stainless steel AISI 304 e Sensing head Hardened stainless steel wear resistant surface coating also available e Faceplate Alumina ceramic 10 3 Penetration of field e Approximately 75 100 mm dependent on the material 10 4 Operating temperature range e 0 60 C The sensor will not measure in frozen materials 10 5 Supply Voltage e 15V to 30 V DC 4 watt max 10 6 Connections 10 6 1 Sensor cable e 3 pairs twisted 6 cores total screened shielded cable with 22 AWG 0 35mm conductors e Screen shield Braid with 65 minimum coverage plus aluminium polyester foil e Recommended cable types Belden 8303 Alpha 6374 e Maximum cable run 100 m separate to any heavy equipment power cables 10 6 2 Digital serial communications e Opto isolated RS485 2 wire port for communications including changing operating parameters and sensor diagnostics 10 7 Analogue output e Two configurable outputs 0 20mA or 4 20mA current loop source available for moisture and temperature Also may be converted to 0 10 V DC 10 8 Digital inputs outputs e Two lines available for batch averaging start stop or temperature multiplexing One line may also be used as an output status flags indicating out of range bin empty or probe ok 10 9 Grounding e Ensure equipotential bonding of all exposed metalwork In areas of high lightning risk correct and adequate protection should be used HYDRO PROBE ORBITER USER GUIDE H
23. d and hence moisture content e Changes in ambient temperature also affect water demand 8 5 Workability e The Hydro Probe Orbiter measures moisture it does not measure workability or someone s perception of workability e Changes in many factors affect workability but these changes may not affect moisture content Aggregate grading Aggregate cement ratio Admixture dosage and dispersion Ambient temperature Coarse fine ratio Water cement ratio Ingredient temperatures 000000 0 8 6 Calibration e Leave out the admixtures when calibrating e If the wet mix time is shortened for production ensure the full time is used during calibration e Different batch recipes may be required for large variations in batch volume e Calibrate when conditions ingredients are typical e g not first thing in the morning when the aggregates are very wet or when the cement is hot e When using a calibration based water addition method obtaining a correct dry reading is essential o Signal must be stable o Dry mix time must be long enough to obtain signal stability o Good measurement requires time HYDRO PROBE ORBITER USER GUIDE 46 HD0256 REV 1 1 0 8 7 Mixing e Minimum mix times are a function of the mix design ingredients and mixer not just the mixer e Different mixes need different mix times e Keep batch sizes as consistent as possible e g three batches of 2 5m 2 5m 1 0m is not as good as 3 batches of
24. discharged when emptying the mix o Mixing action close to the floor of the mixer is improved thereby improving the reading of the sensor o Reduced wear on mixer floor plates 9 2 Cement addition e Mixing the fine cement particles in with the relatively coarse particle size of the sand and aggregates is a tough job When possible cement addition should commence a few seconds after the loading of the sand and aggregates Folding in the materials together in this way will greatly assist the mixing process 9 3 Water addition e 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 Therefore there is an optimum rate of water addition for achieving minimum mix cycle time e 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 PROBE ORBITER USER GUIDE HD0256 REV 1 1 0 49 Notes HYDRO PROBE ORBITER USER GUIDE 50 HD0256 REV 1 1 0 Chapter 10 10 Technical specification 10 1 Mechanical Dimensions e ORB1 Housing 156 x 225 mm e Sensing arm 104 5 x 34 mm length of arm to suit mixer usually 560 mm or 700mm 10 2 Constru
25. duplex Rx S 4 4 S 7 Host System ETE S A 5 QS 5 GND S 6 6 S Dip Switch Power supply Q 7 Settings 7 35V DC RJ11 Sls lo RS232 port 1234 5 Configuring the sensor The Hydro Probe Orbiter may be configured using the Hydro Link or Hydro Com software The complete set of default parameters is shown in the table below Parameter Hydro Probe Orbiter Standard Default Range options Moisture calibration A 0 0000 B 0 2857 C 4 0000 SSD 0 00 Signal processing configuration Smoothing time 7 5 sec 1 0 2 5 5 0 7 5 10 Slew rate Light Light Medium Heavy Unused Slew rate Light Light Medium Heavy Unused Averaging configuration Average hold delay 0 sec 0 0 0 5 1 0 1 5 2 0 5 0 High limit m 30 00 0 100 Low limit m 0 00 0 100 High limit us 100 00 0 100 Low limit us 0 00 0 100 Input output configuration Output type 0 20 mA 0 10V 0 20mA 4 20mA Compatibility Output variable 1 Filtered unscaled Filtered moisture Average moisture Raw moisture Raw unscaled filtered unscaled Average unscaled Material temperature Output variable 2 Material temperature Filtered moisture 96 Average moisture 96 Raw moisture Raw unscaled filtered unscaled Average unscaled Material temperature High 20 00 0 100 Low 96 0 00 0 100 Input Use 1 Average
26. e of the gearbox lid using a series of hooks as shown in Figure 21 This would provide a simpler way of both detaching and attaching the hose and cable during times of maintenance The hose can be squeezed into and out of the hook Cable e Rubber hose ee R Figure 21 Securing the cable Metal hook HYDRO PROBE ORBITER USER GUIDE 24 HD0256 REV 1 1 0 3 2 3 Fitting rotating connector type B and connecting the sensor cable to the Mercotac The procedure described below will be broadly similar in principle irrespective of the routing option selected e Drill or cut a central hole in top cover lid approximately 50mm diameter e Using the bearing holder plate as a template mark and drill the three fixing bolt holes e Fix flange bolts into place as indicated e Position the rotating connector over the hole easing spare cable back through the rubber hose and secure by tightening nuts on the three bolts e With the cable connected to the Hydro Probe Orbiter feed up through the Mercotac holder and cut to the correct length e Cut back the cable sheath and crimp on spade terminals At most 6 conductors are used so any unused conductors can be cut back e Connect to the Mercotac terminals See section 3 4 Mercotac wiring connections The static end of the Mercotac should be already connected to the terminal blocks e Ease the Mercotac back into the holder The retaining O ring may make this difficult so a sma
27. eaded adapters supplied 3 1 4 Threaded Adapters On some mixers threaded adapters enable the Mercotac holder to be directly attached to the gearbox shaft Two brass reducers are available depending on the type of mixer Oneisa 1 BSP male to 77 BSP male adapter and the other is a 1 BSP male to 3 4 male adapter The construction using either adapter is shown in Figure 14 HYDRO PROBE ORBITER USER GUIDE 18 HD0256 REV 1 1 0 Terminal block Earth connection Connection to plant cable through cable gland Rotating connector Mercotac retaining O body ring used only for 6 pole Mercotac Mercotac retaining O ring used only for 4 pole Mercotac Mercotac connector 4 pole shown or 6 pole Brass Mercotac Nylon mounting holder flange 1 BSP male to 44 BSP male brass adapter reducer or 1 BSP male to BSP male brass adapter reducer Connects directly to mixer threaded rotating shaft Figure 14 Type A rotating connector assembly HYDRO PROBE ORBITER USER GUIDE HD0256 REV 1 1 0 19 3 1 5 Cabling arrangements The routing of the cable and method of fixing it will be largely determined by the clearance between the underside of the gearbox and the highest point of the mixer blade arms as depicted below in Figure 15 The cable should be protected by feeding it through a length of 32mm ID rubber hose Hollow Rubber hose containing
28. ed 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 suggestions relating to the product and this documentation ACKNOWLEDGEMENTS Hydronix Hydro Probe Hydro Mix Hydro Skid Hydro View and Hydro Control are Registered Trade Marks of Hydronix Limited TABLE OF CONTENTS 94072 1 pied EE E Em 7 1 A lade EE EEEa AA dees EAREN a 7 1 1 Applications iii ER 7 1 2 TY vB Dci 7 1 3 B Telefon EET 7 1 4 MSASUrINGAEGAMIGUSSI e 8 1 5 Sensor output with rotating connector wwrrrrnrrtrrraea 8 1 6 Sensor config rati m sess eie bet mte ELE ii oaasi tess tutte otn en o ptis 8 1 Sensing ARMAS ec M HR 8 Pro pu 9 2 Installation process for mixers 10 nnvvnnnnennnennnenenennnennnnnnnnenenenenenenenenennnennenenneenenennane 9 2 1 Assembly of sensing arm and body wanaannnaenenennannnaannaneenennrentavaanaeneenet aenea 9 2 2 Selecting the best position for mounting the sensor rnennr 11 2 3 Fitting the square mounting Dar cuco a eon Pacte faded usas dela Pea set 13 24 Mounting the sensor and final adjustments when running
29. f the application software press the New Air or High button The software will make a new air measurement The water reading should be carried out in a bucket filled with a clean brine solution This solution should be made up from water with 0 596 by weight of salt e g 10 liters of water to be mixed with 50gm of salt The level of water needs to cover the ceramic face plate and at least 200mm of water is needed in front of the ceramic It is suggested that the sensor is held in the bucket offset to one side with the face towards the centre of the bucket see Figure 31 hence the measurement is carried out with a full bucket of water in front Press the New Water or Low button The software will make a new water measurement Once both readings are made the sensor can be updated by pressing the update button in the application software and it is then ready for use 200mm min gt Sensor in the water bath Sensor Minimum water depth 200mm Figure 31 Air water calibration IMPORTANT Once the alignment of the sensing arm is changed inside a mixer the resultant density change of material passing the sensing head will have an effect on the recipe This would apply when a new arm is fitted despite pointing the faceplate in the same approximate direction as the previous installed arm It is therefore advisable to recalibrate the recipes before continuing batching HYDRO PROBE ORBITER USER GUIDE HD0256 REV 1 1 0 43 Notes
30. gure 2 This is included to increase the strength of the arm CAUTION NEVER HIT THE SENSING ARM HYDRO PROBE ORBITER USER GUIDE 8 HD0256 REV 1 1 0 2 Installation process for mixers The Hydro Probe Orbiter may be clamped to a vertically or horizontally mounted 25 35mm sguare bar The bar should be supplied and suitably mounted by the customer or agent installing the sensor The installation involves the following processes e Assembly of sensing arm and body Section 2 1 e Selecting the best position for mounting the sensor Section 2 2 e Fitting of the square mounting bar Section 2 3 e Mounting the sensor and final adjustments when running Section 2 4 e Mounting rotating connector Chapter 3 2 1 Assembly of sensing arm and body The sensing arm and electronics body are shipped unattached They need to be connected before installation into the mixer e Lay the main electronics body on a clean flat surface e Loosen the 4 arm clamp bolts on the electronics body and remove the locking bolt A e Fit the two O rings These need to be located inside the clamp blocks up against the step as shown in Figure 2 e Ensure that the red mark on the electrical connector at the top of the sensing arm is on the same side of the arm as the ceramic faceplate The connector can easily be rotated by hand if required c Clamp block 4 bolts N Two O rings have to be installed to the end of the barrel S
31. h ends with hose clips e Wire plant cable to terminal block in rotating connector e Provide earth continuity wiring for rotating connector HYDRO PROBE ORBITER USER GUIDE 28 HD0256 REV 1 1 0 3 4 Mercotac wiring connections When connecting the Hydro Probe Orbiter to the rotating connector it is important to maintain the correct wiring to avoid possible damage to the sensor electronics The orientation of the terminals on the Mercotac for both the 4 pole and the 6 pole is illustrated in Figure 23 The top end marked on the side of the Mercotac with an arrow pointing upwards remains static and this should be already connected to a terminal block It is essential the Mercotac is mounted the correct way up The terminal block has pins that allow it to directly connect into a second terminal block mounted on the bracket in the rotating connector body Table 1 below shows the connections from the Mercotac to the terminal block using the pin referenced numbers in Figure 23 24V Red 3 3 OV Black 4 4 RS485 A White 1 1 RS485 B Violet 2 2 Analogue output Blue 5 Analogue output Green 6 Table 1 Rotating connector terminal block to Mercotac connections Note that these terminals are located nearer to the edge compared with their opposite terminals O eS 6 pole 1 4 6 oO N oO 4 pole Figure 23 Terminal configuration of the Mercotac connectors HYDRO PROBE
32. ightening nuts of the three bolts With the cable connected to the Hydro Probe Orbiter feed up through the rotating shaft and the Mercotac holder and cut to the correct length Ensure the cable and its protective hose do not interfere with the mixer arms Cut back the cable sheath and crimp on spade terminals At most 6 conductors are being used so unused conductors can be cut back Connect to the Mercotac terminals See 3 4 Mercotac wiring connections The static end of the Mercotac should already be connected to the terminal blocks Ease the Mercotac back into the holder gently pulling back any cable slack through the rotating shaft The retaining O ring may make this difficult so a small application of grease oil would make this easier Fix the rotating connector body to the mounting flange Wire plant cable to terminal block in the rotating connector Provide earth continuity wiring for the rotating connector HYDRO PROBE ORBITER USER GUIDE 22 HD0256 REV 1 1 0 3 2 Type B rotating connector assembly In this assembly the Mercotac holder is mounted in a bearing protected by a seal as shown in Figure 19 Cover screw Terminal block Earth terminal Connection to plant cable through cable Rotating gland connector body Mercotac retaining O ring used only for 6 pole Mercotac Mercotac connector 4 pole shown or 6 pole Mercotac retaining O ring used
33. ll application of grease oil would make this easier e Fix the rotating connector body to the bearing holder plate e Wire plant cable to terminal block in rotating connector e Provide earth continuity wiring for rotating connector HYDRO PROBE ORBITER USER GUIDE HD0256 REV 1 1 0 25 3 3 Type C rotating connector assembly This is almost identical to the type B rotating connector and will also provide a direct replacement for the HydroStop rotating connector 3 3 1 Suitable applications Suitable for some Skako Couvrot mixers with an 80mm metal tube mounting 3 3 2 Features The type C rotating connector is provided with a bottom spigot flange over which an 80mm rubber tube may be fitted thereby providing a sealed connection The arrangement for a type C connector also requires threaded adapters that enable the Mercotac holder to be directly attached to the mixer rotating tube that carries the cable from the sensor HYDRO PROBE ORBITER USER GUIDE 26 HD0256 REV 1 1 0 Cover screw Terminal block Earth terminal Connection to plant cable through cable gland Rotating connector Mercotac retaining O body ring used only for 6 pole Mercotac Mercotac connector 4 pole shown or 6 pole Mercotac retaining O ring used only for 4 pole Mercotac Bearing holder plate Bearing Brass Mercotac holder Seal Spigot flange Ps 9 1 BSP to 1 BSP brass nipple 80mm rubber 1
34. moving the sensing head and arm 2 ccccceeeeeeedeseeeneceeeeeeeeeeeeneeneeeeeeeeenensnanes 41 7 1 2 Fitting the Hydro Probe Orbiter back into the mixer oooooooooccnoccccnnccccccncnonannnnnncnccnananos 41 7 2 Calibrating a new arm to the sensor electronics nnnnnrrana 41 132241 SAUtOCal ito id tee E E CUL E E AE ena Gates 41 7T 2 2 Airand water calibration ae t d varad lan ee ee ad jaa a LR cR Sa 43 Cha pterG c EE 45 8 Troubleshooting UPS ere ei 45 8 1 InstallatiQn xt en ten been a tes rd e e V de EXE E RERO A es ee Rd RR duh 45 8 2 meg ECT 45 8 3 bcm DIM M 45 8 4 Ingredients garias mote E e e 46 8 5 Laon ccs e E 46 8 6 Calibration e etr RR CORR DER LX adds 46 8 7 VAIA eee a OA AAA ND ee pala vad aste it ad 47 urere D rr nM aaa jadade alad nadi aasad a eeku maa tati 49 9 Sensor performance utt tle diia 49 9 1 Acdjustmentorthe blades cocotte d arcte i erdt eee E a 49 9 2 Cement AI rc 49 9 3 Water addition vico A A A a a 49 eure LEE 51 10 Technical specificat OM e iiti ettet eret oct i oet reat orent Reo d a cbe pb d RR ER E RR d 51 HYDRO PROBE ORBITER USER GUIDE 4 HD0256 REV 1 1 0 TABLE OF FIGURES Figure 1 The Hydro Probe Orbiter with rotating connector mrrrmrrrs 6 Figure 2 Installation of sensing arm into sensor body wvnnrrnnnnmnrrrs 9 Figure 3 Fixing the sensor under the scraper blade a
35. naaanna 20 Figure 17 Fitting the cable where minimal clearance exists ssssee 21 Figure 18 Mounting the type A rotating connector esssseeesee e 22 Figure 19 Type B rotating connector assembly seeeeeeeeeeseennee tenentes 23 Figure 20 Routing the cable to the rotating connector for turbo type pan mixers 24 Figure 21 Securing th cable Pea Diae cosine Geek yen 24 Figure 22 Type C rotating connector assembly eeesseeeeeeeeenen nn 27 Figure 23 Terminal configuration of the Mercotac connectors 0 00 nennnnnrnn 29 Figure 24 Sensor cable 0090A CONNeCtiON cccccccconnnncconncncnnnnnnnnannnnnnnnnnnnnnnnnnnannnnnnnnnnnnnnnnnnnns 32 Figure 25 Multi drop Connection ercer sese Se tri oe kiskjate khanaat lilas 32 Figure 26 Compatibility MOUS riiin errem i roe recti bet gesendet cab da ta uu ed seit 33 Figure 27 RS232 485 converter connections 1 mwsevrttnanameetenennettanavaananenatedeaaaaan nte 34 Figure 28 Din rail mounting RS232 RS485 converter ssssssssseeeeenene 34 Figure 29 The Hydronix Autocal Dongle eananeetenenennnnnnannadaaeteetentanananaatatnatatanrannnaneee 42 Figure 30 Connecting the Hydronix Autocal Dongle for calibration merem 42 Figure 31 Air walter caliDFatior ii ctos oe oe oid
36. o kamandab lk we uds 43 HYDRO PROBE ORBITER USER GUIDE HD0256 REV 1 1 0 5 Hose clamp tube Cable 25 35mm square mounting bar provided by customer Protective hose for cable lt Clamp block Sensor body Arm clamp Replaceable sensing arm Rotating connector assembly Ceramic face plate Sensing head Rapid response temperature sensor Two lengths of arm are available Overall length 560mm or 700mm Figure 1 The Hydro Probe Orbiter with rotating connector HYDRO PROBE ORBITER USER GUIDE 6 HD0256 REV 1 1 0 1 Introduction 1 1 Applications The Hydro Probe Orbiter may be used for three different types of application 1 For static mounting of the Hydro Probe Orbiter sensor ORB1 in rotating mixers or for conveyor belts or material in free fall applications 2 For a rotating mounting in static pan mixers using a rotating connector for connecting the cable to the Hydro Probe Orbiter 3 Also for a rotating mounting using a battery powered sensor ORB1MB with radio modem communication This is for applications where it is not possible to electrically connect the sensor to the outside of the mixer via a rotating connector This manual is written for Application type 2 FOR A ROTATING SENSOR IN STATIC PAN MIXERS THAT CAN BE CONNECTED TO A CABLE USING A ROTATING CONNECTOR A ROTATING CONNECTOR CAN BE USED WHERE THE MIXER HAS CABLE ACCESS TO AND FROM A CENTRAL POINT
37. only for Bearing holder 4 pole Mercotac plate Mercotac Seal Bearing holder 1 BSP thread 32mm ID hose fitted over end of Mercotac holder with hose clip or attachments can be used Figure 19 Type B rotating connector assembly HYDRO PROBE ORBITER USER GUIDE HD0256 REV 1 1 0 23 3 2 1 Suitable applications Suitable for turbo pan mixers where the motor is fitted to the underside of the mixer The cable is taken through a central hole in the top lid of the mixer Several options exist for routing the cable but the important requirement is the ability to remove the cover lid to the gearbox for maintenance and blade adjustment 3 2 2 Routing of cable These are suggested options only and fitting must be customized to suit each installation The cable should be routed through the protective 32mm internal diameter rubber hose and should connect directly onto the Mercotac holder As mentioned above it is important to be able to remove the cover lid to the gearbox so a longer length of cable is advised which can be wrapped with enough length to still remove the cover whilst connected A suggested method may be to secure the hose along the top inside edges of the blades as shown in Figure 20 Rotating connector A assembly Securing points Figure 20 Routing the cable to the rotating connector for turbo type pan mixers Rubber hose Alternatively the hose can be wrapped around the edg
38. onnections Applies to analogue and multi drop connections HYDRO PROBE ORBITER USER GUIDE HD0256 REV 1 1 0 31 DK J G F D E CB A i brown blk green blk white blue blk yellow blk red i i bl p Junction box e AE ES LO O a Ea k di si n SUM m TA TES UR OQOOOOQOOOQOOQ Prcestiad AR Ms m mm al m amp control cabinet OA dE MR 100 kr __ i mu NOI PNE E QUEE Ro EE SR Ko e 500R resistor for ee ee cabales aoe ee a 0 10V L I Positive Reum D B A Pose Reim Di Ww E a ll FO m eg 25 4 ll 2 Analogue Output 2 Digital RS485 1 Analogue Output f Digital Supply 15 30V DC i Input Input Control Room Wiring Figure 24 Sensor cable 0090A connection NOTE The cable screen is grounded at the sensor and therefore should not be connected at the control system end It is important to ensure that the plant where the sensor is installed is properly grounded If there is any doubt a connection from the cable screen to ground should be provided at the junction box 4 2 RS485 multi drop connection The RS485 serial interface allows up to 16 sensors to be connected together via a multi drop network Each sensor is connected using a waterproof junction box The control system is generally connected to the nearest junction box Cable 0090A 4m From other To PC or plant sensors control device Figure 25 Multi drop connection HYDRO PROBE ORBITER USER
39. plate with hose clip drilled to pass cable Figure 17 Fitting the cable where minimal clearance exists 3 1 8 Fitting rotating connector type A and connecting sensor cable to Mercotac e Remove blanking bolts from both ends of the gearbox shaft e Remove the Mercotac holder from the rotating connector and using the correct brass thread adapter screw into the end of the shaft e Remove the wide mounting flange from the rotating connector e Remove the bolts only securing the cover plate to the gearbox Generally there are a number of bolts around the cover plate but two would be sufficient to fix the rotating connector nylon mounting flange e Drill holes in the nylon mounting flange to match the cover plate bolt holes e If there is a grease nipple in the top of the gearbox that will obstruct the nylon flange drill a large hole in the nylon mounting flange e Mount the flange on top of the cover plate replacing the removed cover bolts with longer studs Ensure the captive bolts for securing the rotating connector are in place See figure 18 HYDRO PROBE ORBITER USER GUIDE HD0256 REV 1 1 0 21 Rotating connector housing Mercotac Holder Bolt Stud Thread adapter Nylon flange Gearbox lid Gearbox lid Rotating mixer shaft Figure 18 Mounting the type A rotating connector Position the rotating connector over the hole easing spare cable back though the rubber hose and secure by t
40. ration can be performed in three ways e Using Hydro Com PC utility The sensor should be connected to a computer see section 4 4 running a suitable Hydronix PC utility such as Hydro Com The configuration section of these programs has an Autocal facility Once selected the Autocal will be completed in approximately 60 seconds and the sensor is ready for use in the mixer Note that Hydro Link does not have Autocal feature e Using the Hydro Control V The Hydro Control V has the capability to perform an Autocal calibration in the sensor configuration page From the main window this can be accessed by the following MORE gt SETUP gt enter pass code 3737 gt DIAG gt CONF gt CALIB Note this feature is only available on Hydro Control V firmware versions 4 1 and later and Autocal will only work for the Hydro Probe Orbiter no other Hydronix sensors HYDRO PROBE ORBITER USER GUIDE HD0256 REV 1 1 0 41 e Using the Hydronix Autocal Dongle The Autocal Dongle as shown in Figure 29 has been designed for applications where there is no RS485 serial link and the customer is using the analogue output from the sensor This calibration is completed by connecting the dongle in line between the cable and the sensor body as shown in Figure 30 Figure 29 The Hydronix Autocal Dongle Sensor body Figure 30 Connecting the Hydronix Autocal Dongle for calibration The simple procedure outlined below should take less than one minute to complete
41. rm ssssseeeeee 11 Figure 4 Fixing the sensor above the scraper blade arm ooooccccccccocococoncccncccnnncnnnnnnnnnnncnononcnanananns 12 Figure 5 Protective roof placed over the sensor DOY ooooooccccccccccononononcncnncnnnnnnnnnnnnnononcnonnnnnnnnnnnns 12 Figure 6 Removing the mounting bar clamp blocks ready for fitting to the mixer 13 Figure 7 Square mounting bar welded to scraper blade arm sseeseeeeeee 13 Figure 8 Height setting of the sensing arm eeeseeseeeeee mener enne ntn nennen innen 14 Figure 9 Adjusting the sensing head angle ccccccccceenececteeeeeeeeeseenee sete seeeeseeeeneneeeeeeeetenesneces 14 Figure 10 Setting the sensor angle for optimum performance mmrarrea 15 Figure 11 The Hydronix angle aligner for sensor face alignment mennmn 15 Figure 12 Connecting the Hydro Probe Orbiter to the rotating connector 17 Figure 13 Connection to the rotating connector using a hollow shaft through the gearbox 18 Figure 14 Type A rotating connector assembly eeeeeeceeeeeeeeenetenee nne 19 Figure 15 Checking the clearance between the revolving arm and the ceiling of the mixer 20 Figure 16 Fitting the cable with good clearance nneneneneeenenennnnnananennenene
42. rom the sensor to the rotating connector e The sensing head should be positioned along the scraper blade arm where the flow of material is smoothest and as far as possible free from the turbulence created by the mixer blades e Asageneral rule the sensor should be attached along the scraper blade arm approximately 1 4 to 1 3 of the distance in from the wall of the mixer see Figure 10 The faceplate of the sensing head should be angled at 55 to the centre of the mixer which must be set using the aligner provided see Figure 11 for further information e The sensor body may be mounted underneath the scraper blade arm Figure 3 or above the scraper blade arm Figure 4 In both cases the body should be as far out of the mix as possible in order to keep it reasonably clean and minimise wear e The sensing arms are available in 2 lengths Figure 1 and the sensor should be mounted such that there is a 50mm gap between the underside of the sensing head and the mixer floor Figure 8 e A protective roof may be provided over the sensor body to protect the sensor from falling materials and prevent unnecessary build up of materials on the sensor body Figure 5 Figure 3 Fixing the sensor under the scraper blade arm HYDRO PROBE ORBITER USER GUIDE HD0256 REV 1 1 0 11 Figure 4 Fixing the sensor above the scraper blade arm Protective roof Figure 5 Protective roof placed over the sensor body HYDRO PROBE ORB
43. s e Keep the number of joints in the cable to a minimum Note that there is a M4 threaded hole provided on the back plate of the Hydro Probe Orbiter body for a ground connection 8 3 M Mixer e Look at the mixing process Check how the water disperses If water sits on top of the aggregates for a time before dispersing then spray bars will be required to get it into the mixer quicker to shorten the mix time e Spray bars are far better than single water inlets The greater the area of water inlet the faster it mixes in HYDRO PROBE ORBITER USER GUIDE HD0256 REV 1 1 0 45 8 4 Ingredients e Ifthe aggregate masses are not corrected for high moisture contents the aggregate cement ratio will change considerably having a bad effect on workability and concrete performance e If the aggregates are very wet then there may be more water in the aggregates than the mix requires This could be the case at the beginning of the day due to water drainage in the storage bin e The moisture content of the aggregates must be above their saturated surface dry SSD moisture content before loading into the mixer Microwave sensors measure moisture content accurately above the SSD value of a material because measurement loses linearity below SSD Mixing performance is also increased when the aggregates are above their SSD value upon loading as the cement can absorb free moisture prior to water addition e Beware of hot cement it can affect water deman
44. t the ceramic measuring face and at an angle that avoids build up of material on the sensing head Hydro Probe Orbiter A j Centre of D i mixer Direction of material flow 1 4 to 1 3 R Figure 10 Setting the sensor angle for optimum performance e Anangle of 55 generally provides good results Use the angle aligner provided to set the angle Figure 11 e Ensure all clamp bolts are tightened to a torque of 28Nm 21 Ib ft after adjustment Aligner positioned against face plate pointed towards the mixer centre Figure 11 The Hydronix angle aligner for sensor face alignment IMPORTANT Once the alignment of the sensing arm is changed inside a mixer the resultant density change of material passing the sensing head will have an effect on the measurement It is therefore advisable to recalibrate the recipes before continuing batching HYDRO PROBE ORBITER USER GUIDE HD0256 REV 1 1 0 15 Notes HYDRO PROBE ORBITER USER GUIDE 16 HD0256 REV 1 1 0 3 Cabling to the sensor The static plant cabling is connected to the rotating Hydro Probe Orbiter by means of a rotating connector assembly Electrical connectivity is achieved with the use of a high guality connector called a Mercotac Two versions of Mercotac are available e The standard 4 pole suitable for providing RS485 output only for example when interfaced to Hydro Control V e The 6 pole for providing both the RS485 and analogue outputs
45. trengthening Locking bolt A to collar be removed Figure 2 Installation of sensing arm into sensor body HYDRO PROBE ORBITER USER GUIDE HD0256 REV 1 1 0 9 e Lay the sensing arm on the same clean flat surface with the ceramic faceplate facing upwards aligned with the hole in the head unit e For ease of fitting apply a small amount of grease to the connector end of the arm or around the two O rings e Gently locate the connector at the top of the sensing arm in the hole in the head unit such that the connector lines up with its socket in the head unit Push the sensing head home into the main body unit e Tighten the arm clamp nuts up to a point where it is still possible to rotate the arm by hand these are not fully tightened until the sensing head has been aligned at the correct angle after the Hydro Probe Orbiter has been installed in the mixer e lf the arm is a replacement then a recalibration procedure will need to be carried out See section 7 2 Calibrating the new arm to the sensor electronics HYDRO PROBE ORBITER USER GUIDE 10 HD0256 REV 1 1 0 2 2 Selecting the best position for mounting the sensor The small stream lined sensing head needs to be positioned such that it cuts cleanly and smoothly through the material without build up thereby providing a smooth and clean signal In selecting the optimum position the following considerations need to be taken into account e The cabling arrangement f
46. ust 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 extension cable run from the rotating connector 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 4 1 Analogue output A DC current source generates an analogue signal proportional to any of a number of selectable parameters e g filtered unscaled filtered moisture average moisture etc See section 5 or Hydro Link manual for details Using Hydro Link Hydro Com or direct computer control the output may be selected to be e 4 20mA e 0 20mA This may be configured as a 0 10 V DC voltage output if a 500 ohm resistor is connected across the analogue output and return wires see Figure 24 NOTE If a 0 10V signal is required connect the resistor at the control room end Twisted Pair MIL spec Sensor connections Cable colour Number pins 1 A 15 30V DC Red 1 B OV Black 2 C 1 Digital input Yellow 2 Black Cut back 3 D 1 Analogue Positive Blue 3 E 1 Analogue Return Black 4 F RS485 A White 4 G RS485 B Black 5 J 2 Digital input Green 5 Black Cut back 6 D gm Analogue Positive Brown 6 K 2 Analogue Return Black H Screen Screen Table 3 Sensor cable 0090A c
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