Hydro-Mix VI User Guide
Contents
1. ES 0 50 00 50 200 250 300 350 Time s o 1 o Figure 23 Graph showing raw signal during mix cycle HYDRO MIX VI USER GUIDE 30 HD0304 REV 1 2 0 CONFIGURATION CHAPTER 4 The two following graphs illustrate the effect of filtering the same raw data shown above Figure 28 shows the effect of using the following filter settings which create the Filtered Unscaled line on the graph Slew rate Light Slew rate Medium Filtering time 1 second Applying Filter Slew Rate Light Slew Rate Medium Filtering Time 1 second 3 2 iL s H S s S o a 2 350 Time s Figure 24 Filtering the RAW signal 1 Figure 29 shows the effect of the following settings Slew rate Light Slew rate Light Filtering time 7 5 seconds Applying Filter Slew Rate Light Slew Rate Light Filtering Time 7 5 seconds Unscaled Raw and Filtered 350 Time s Figure 25 Filtering the RAW signal 2 HYDRO MIX VI USER GUIDE HD0304 REV 1 2 0 31 CHAPTER 4 CONFIGURATION In Figure 29 it is clear that the signal at the dry phase of the mix cycle is more stable which is more advantageous when making the water calibration For most mixer applications the filter settings can be left at the default values which will adequately filter o2. 18 Figure 15 Sensor cable connections sise 22 Figure 16 RS485 multi drop connection ss 23 Figure 17 Connecting to a Hydro Control IV or Hydro View a 23 Figure 18 RS232 485 converter connections 1 25 Figure 19 RS232 485 converter connections 2 is 25 Figure 20 RS232 485 converter connections 3 25 Figure 21 Internal external excitation of the digital input 29 Figure 22 Typical moisture Curve iii 30 Figure 23 Graph showing raw signal during mix cycle 30 Figure 24 Filtering the RAW signal 1 iii 31 Figure 25 Filtering the RAW signal 2 iii 31 HYDRO MIX VI USER GUIDE 6 HD0304 REV 1 2 0 holds ceramic Removable Wear Ring disc 4 fixing screws Hydro Mix VI body houses __ sensitive electronics M 108mm 4 25 inch Electrical connector Ceramic disc 125mm 5 1 inch Clamp Ring PACKED CONTENTS Mil Spec _ HM06T Hydro Mix VI sensor 0033 Minimum accessories if ordered 0090A Sensor cable 4m 0021 Fixing plate Adjustable clamp ring Figure 1 The Hydro Mix VI and clamp ring Available accessories 0021 0033 0035 0090A 0090A 10m 0090A 25m 0116 0049A 0049B SIMO1A 0815 0830 0840 Fixing plate for welding to mixer Adjustable clamp ring supplied with sensor Additional rings can be ordered if required Blanking plate for blanking hole in the mixer when sensor is
3. E 5 5 o 5 ge 80 2 S c 2 S o 0 m m Qo m m m gt m c a x lt gt 0 u Q uo m lt 0090A twisted pair y Sensor Cable I l L ead au Junction box I lt oe e am em a s T 1 1 M eee m Do not connect screen at control cabinet escufensancsohensoncachancencelsonsensebonncaselossncasslssascusdoscnsses I I Le 500 Ohm resistor for 0 10V C3 i MIL NUI dE tcd a se A Lam Postive Retum J 2 m m Positive Retum T 1 OV HE DOE Dga 8 OA Digta 2 0x ul 2 Analogue Output Input 2 B 1 Analogue Output Input Supply 15 30V DC where available Output M ru u ss ce c 1 0 s us umo eme Control Room Wiring Note The cable screen Figure 15 Sensor cable connections is grounded at the sensor It is important to ensure that the plant where the sensor is installed is properly grounded HYDRO MIX VI USER GUIDE 22 HD0304 REV 1 2 0 ELECTRICAL INSTALLATION COMMUNICATION CHAPTER 3 RS485 multi drop connection The RS485 serial interface allows up to 16 sensors to be connected together via a multi drop network Each sensor should be connected using a waterproof junction box D Brown K Black J Green G Black F White D Blue E Black C Yellow B Black A Red zi 0090A twisted pair ba jo mE E His Junction
4. addressed differently Ensure the sensor is correctly connected that it is powered from a suitable 15 30Vdc source and the RS485 wires are connected through a suitable RS232 485 or USB RS485 converter to the PC On Hydro Com ensure the correct COM port is selected Q What should set the analogue output variable to if want to monitor moisture in the mix A It is recommended that the analogue output is set to Filtered Unscaled This variable is proportional to moisture and the moisture outputs from the sensor are calculated directly from this value The Filtered Unscaled output is a direct measurement from the microwave response which is scaled between 0 and 100 and filtered to reduce the noise on the signal Q Why does the sensor output negative moisture when the mixer is empty A The moisture output from the sensor is calculated using the Filtered Unscaled reading and the calibration coefficients in the sensor A B C and SSD such that moisture A US B US C SSD US unscaled These factors are normally used for bin applications with the Hydro Probe II but are used in the exactly the same way with the Hydro Mix VI With these factors unchanged A 0 B 0 2857 C 4 SSD 0 and the mixer empty air measurement 0 unscaled then it can be shown that the moisture is 4 Q What calibration is required for my Hydro Mix VI A When using a mixer sensor for concrete production it is normal to connect the sensor to a ba
5. Analogue output Where available two configurable 0 20mA or 4 20mA current loop outputs available for moisture and temperature The sensor output may also be converted to 0 10 Vdc HYDRO MIX VI USER GUIDE HD0304 REV 1 2 0 41 CHAPTER 8 TECHNICAL SPECIFICATION Digital inputs e One configurable digital input 15 30 V DC activation e One configurable digital input output input specification 15 30 V DC output specification open collector output maximum current 500 mA over current protection required HYDRO MIX VI USER GUIDE 42 HD0304 REV 1 2 0 Appendix A Default parameters The complete set of default parameters are shown in the tables below This information is also listed in Engineering Note EN0027 available for download from www hydronix com Firmware versions HS0047 Version 1 25 or later Default Parameters Parameter Range options Standard Compatibility Mode Mode Analogue output configuration 0 20mA Output type 4 20mA 0 20 mA Compatibility Compatibility Filtered moisture 96 Average moisture Filtered DuIpUL Vallee Filtered unscaled unscaled WA Average unscaled High 0 100 20 00 N A Low 0 100 0 00 N A Moisture calibration A 0 0000 0 0000 B 0 2857 0 2857 C 4 0000 4 0000 SSD 0 0000 0 0000 Signal processing configuration Smoothing time 1 0 2 5 5 0 7 5 10 7 5 sec 7 5 sec Light Slew rate ree Light Light Unused Light Slew rate
6. be subjected to unnecessary impact damage as it houses sensitive electronics In particular the ceramic faceplate although extremely hardwearing is brittle and may crack if subjected to severe impact CAUTION NEVER HIT THE CERAMIC Care should also be taken to ensure that the Hydro Mix VI has been correctly installed and in such a manner to ensure representative sampling of the material concerned Suitable applications The Hydro Mix VI microwave moisture measuring sensor may be successfully used in the following applications e Static pan mixers e Planetary mixers e Turbo mixers e Single and twin shaft horizontal mixers e Ribbon mixers e Flush mounted in chutes or similar applications NOTE For rotating pan mixers such as the Eirich and Croker liner mixers a static mounted Hydro Probe Orbiter is recommended HYDRO MIX VI USER GUIDE HD0304 REV 1 2 0 9 CHAPTER 1 INTRODUCTION Measuring techniques The Hydro Mix VI uses the unique Hydronix digital microwave technique that provides a more sensitive measurement compared with analogue techniques Sensor connection and configuration As with other Hydronix digital microwave sensors the Hydro Mix VI may be remotely configured using a digital serial connection and a PC running Hydro Com diagnostics software For communication with a PC Hydronix supply RS232 485 converters and a USB Sensor Interface Module See page 26 There are three basic configurations by which the Hydr
7. box i Do not connect screen at control cabinet From b other l gt sensors control device Figure 16 RS485 multi drop connection Hydro Control IV Hydro View connection To connect to a Hydro Control IV or Hydro View the Hydro Mix VI needs to be set to compatibility mode To operate in this mode the output type needs to be set to Compatibility using Hydro Com see Chapter 4 Configuration The 500 Ohm resistor supplied with the cable is required to convert the analogue current output to a voltage signal This should be fitted as shown in Figure 19 at the Hydro Control IV or Hydro View s E 4 x Aa z E 4 n i s 2 s v 0090A twisted pair m m o M m m gt m Sensor Cable a x gt u a o m lt Junction i box 500 Ohm resistor for0 10V Hydro Control IV HC04 or Hydro View HVO2 Connector 2000200000000 Figure 17 Connecting to Hydro Control IV or Hydro View HYDRO MIX VI USER GUIDE HD0304 REV 1 2 0 23 CHAPTER 3 ELECTRICAL INSTALLATION COMMUNICATION Connecting to a PC A converter is required to connect one or more sensors to a PC when checking diagnostics and configuring the sensor There are three types of converter supplied by Hydronix RS232 485 converter D type Part no 0049B Manufactured by KK systems this RS232 485 converter is suitable for connecting typically up to six sens
8. concrete performance If the aggregates are very wet as may be the case at the beginning of the day due to water draining in the storage bin then there may be more water in the aggregates than the mix requires The moisture content of the aggregates should be above the saturated surface dry SSD Hot cement can affect consistency workability and thus water demand Changes in ambient temperature can affect water demand Where possible the cement addition should follow within a few seconds after the commencement of the addition of sand and aggregates Combining the materials together in this way will greatly assist the mixing process Consistency The Hydro Mix VI measures moisture not consistency Many factors affect consistency but may not affect moisture content These might include Aggregate grading coarse fine ratio Aggregate cement ratio Admixture dosage dispersion Ambient temperature Water cement ratio Ingredient temperature Colours HYDRO MIX VI USER GUIDE HD0304 REV 1 2 0 33 CHAPTER 5 OPTIMISING SENSOR PERFORMANCE Calibration based water addition e When calibrating omit the admixtures e When performing a calibration it is advised that both the dry and wet mix times are extended to ensure that both are homogeneous e different calibration may be required for large variations in batch volume e g half batches e Calibrate when conditions and ingredients are typical e g not first thing in the mo
9. inner edge approximately 10 cm to 15cm 4 6 inches from the side wall of the mixer The minimum distance should never be less than 5cm 2 inches See the advice for flat surface mounting on page 12 Approximately 10cm 4ins Minimum 5cm 2ins Figure 7 Position of sensor in a planetary mixer Single shaft horizontal and ribbon mixers The sensor is generally best positioned near the base of horizontal mixers 30 degrees above the base to prevent water pooling in the base covering the sensor face It should be placed approximately half way along the length of the mixer See guidance for mounting in curved surfaces on page 12 NOTE The sensor must be on the up stroke of the mixer Figure 8 Position of sensor in a horizontal shaft or ribbon mixer HYDRO MIX VI USER GUIDE 14 HD0304 REV 1 2 0 MECHANICAL INSTALLATION CHAPTER 2 Twin shaft horizontal mixers The best position on horizontal twin shaft mixers is half way along the length of the mixer near the base at approximately 30 degrees above the base to prevent water pooling in the base covering the sensor face The sensor should be mounted on the up stroke of the mixer If this is not possible for example when the mixer unloading doors obstruct this area then it should be positioned on the opposite side on the down stroke See guidance for installation in curved surfaces on page 12 Recommended up stroke position Alternative down stroke
10. je Light Light Unused Averaging configuration Average hold dela 0 0 0 5 1 0 1 5 2 0 5 0 0 0 sec 0 0 sec High limit m96 Low limit m High limit us Low limit us Input Output configuration Unused Input Use 1 Average hold Moisture temp Moisture temp Unused Moisture temp Input output Use 2 Bin empty Data invalid Probe OK Temperature compensation Electronics temp coeff 0 016 0 016 HYDRO MIX VI USER GUIDE HD0304 REV 1 2 0 43 APPENDIX A Firmware HS0047 pre version 1 25 and firmware version HS0045 Default Parameters Parameter Range options Standard Compatibility Mode Mode Analogue output configuration 0 20mA Output type 4 20mA 0 20 mA Compatibility Compatibility Filtered moisture Average moisture Filtered Filtered unscaled unscaled Average unscaled Output variable 1 High Low Moisture calibration SSD Signal processing configuration Smoothing time 1 0 2 5 5 0 7 5 10 Light Medium Heavy Unused Light Medium Heavy Unused Slew rate Slew rate Averaging configuration Average hold delay 0 0 0 5 1 0 1 5 2 0 5 0 0 0 sec 0 0 sec High limit m 0 100 30 00 30 00 Low limit m 0 100 0 00 0 00 High limit us 0 100 100 00 100 00 Low limit us 0 100 0 00 0 00 Input Output configuration Unused Input Use 1 Average hold Moisture temp U
11. position Figure 9 Position of sensor in a twin shaft horizontal mixer HYDRO MIX VI USER GUIDE HD0304 REV 1 2 0 15 CHAPTER 2 MECHANICAL INSTALLATION Installing the sensor The Hydro Mix is fitted to the mixer using a fixing plate part no 0021 welded to the permanent floor or side wall of the mixer and the adjustable clamp ring assembly part no 0033 which is supplied with the sensor The adjustable clamp ring assembly facilitates the correct positioning and subsequent height adjustment of the sensor 127mm 5 inch hole for fixing plate Fill gap with sand or silicon sealant Fixing plate part no 0021 Mixer floor or wall Clamp ring assembly Part no 0033 Figure 10 Sensor installation Cutting hole in mixer and fitting fixing plate A hole should be cut into the mixer before welding the fixing plate The recommended minimum cut out hole size is 127mm 5 inches The actual size of the sensor is 108mm 4 25 inches Having cut the hole in the mixer and checked the clearance for the sensor the fixing plate should be welded to the mixer HYDRO MIX VI USER GUIDE 16 HD0304 REV 1 2 0 MECHANICAL INSTALLATION CHAPTER 2 Fitting the clamp ring to the sensor The clamp ring comprises the following components 3 x M8 screws 6 x M8 lock nuts Three shown 3 x M8 Nyloc nuts 3 x washers 2 x M6 screws 3 x M8 threaded stud Clamp ring at oS 2 28 A oQmm
12. 20mA This is the factory default The addition of an external 500 Ohm precision resistor converts to 0 10 Vdc e 4 20mA e Compatibility This configuration must only be used if the sensor is to be connected to a Hydro Control IV or Hydro View A 500 Ohm precision resistor is required to convert to voltage Output variable 1 and 2 available in some sensors according to version NOTE This parameter is not used if the output type is set to Compatibility These define which sensor readings the analogue output will represent The Filtered Unscaled output is a reading which is proportional to moisture and ranges from 0 100 This is the recommended setting The Filtered Moisture output is the alternative setting This is derived from the unscaled reading by scaling it with a set of material calibration coefficients These are the A B C and SSD saturated surface dry values in the configuration which in nearly all cases are not set for the specific material being measured If A B and C values are not specifically set for the material then the Filtered Moisture output will not represent actual moisture HYDRO MIX VI USER GUIDE HD0304 REV 1 2 0 27 CHAPTER 4 CONFIGURATION Low and High NOTE These parameters are not used if the output type is set to Compatibility These two values set the moisture range when the output variable is set to Filtered Moisture The default values are 0 and 20 where e 0 20mA O
13. Hydro Mix VI User Guide To re order quote part number HD0304 Revision 1 2 0 Revision date September 2007 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 O 2006 Hydronix Limited 7 Riverside Business Centre Walnut Tree Close Guildford Surrey GU1 4UG United Kingdom All rights reserved CUSTOMER RESPONSIBILITY The customer in applying the product described in this documentation accepts that the product is a programmable electronic system which is inherently complex and which may not be completely free of errors In doing so the customer therefore undertakes responsibility to ensure that the product is properly installed commissioned operated and maintained by competent and suitably trained persons and in accordance with any instructions or safety precautions made available or good engineering practice and to thoroughly verify the use of the product in the particular application ERRORS IN DOCUMENTATION The product described in this documentation is subject to continuous development and improvement All information of a technical nature and particulars of the product and its use including the information and particulars contained in this documentation are given by Hydronix in good faith Hydronix welcomes c
14. ICAL INSTALLATION COMMUNICATION Notes HYDRO MIX VI USER GUIDE 26 HD0304 REV 1 2 0 Chapter 4 Configuration The Hydro Mix VI may be configured using the Hydro Com software which can be downloaded free of charge from www hydronix com as can the Hydro Com User Guide HD0273 Configuring the sensor The Hydro Mix VI has a number of internal parameters which can be used to optimise the sensor for a given application These settings are available to view and change using the Hydro Com software Information for all settings can be found in the Hydro Com User Guide HD0273 All Hydronix sensors operate in the same way and use the same configuration parameters However not all the functions are used in mixer sensor applications Averaging parameters for example are typically used for applications with the Hydro Probe 11 Only the parameters used in mixer applications are covered in this section The relevant parameters for mixer applications are those which set up the analogue output filtering and in some instances the digital input Analogue output setup The working range of the current loop output can be configured to suit the equipment to which it is connected for example a PLC may require 4 20 mA or 0 10Vdc etc The output can also be configured to represent different readings generated by the sensor e g moisture or temperature Output type This defines the type of analogue output and has three options e 0
15. LECTRICAL INSTALLATION COMMUNICATION CHAPTER 3 Hydronix Part No 0049B RS485 RS232 RS485A Connect to PC RS485B serial port 6 dipswitches control the configuration of the converter For both the 0049 and 0049B these should be set to Switch 1 ON Switch 3 OFF Switch 5 OFF Switch 2 OFF Switch 4 ON Switch 6 OFF Figure 18 RS232 485 converter connections 1 Hydronix Part No 0049A KD485 STD Hydronix Hydronix Sensor Sensor P1 P2 PC DOS BO S 1 1 Q F RS485 A F RS485 A or 9 way D Type Control System connector S 21S RS485 B 485 8 TX Q 3 3 Q g RS232 full duplex RX la alS Host System RIS 7 S E y 8 5 GND Dip Switch Power supply S 7 Settings m RJ11 7 35V DC S s 27 port 1234 Figure 19 RS232 485 converter connections 2 Hydronix Part No SIMO1 Connect to PC USB port 0 B B RS485 sensor connections Sensor A Interface ov n Sensor power optional v Module gt gt Connect to 24Vdc power supply optional The Sensor Interface Module is powered from the USB port The external 24V power supply can be used if sensor power is required See user guide HD0303 for further information Figure 20 RS232 485 converter connections 3 HYDRO MIX VI USER GUIDE HD0304 REV 1 2 0 25 CHAPTER 3 ELECTR
16. de of the output which may benefit from a separate recipe and calibration The sensor cannot discriminate when it is exposed to material or not Therefore in all cases when reduced batches are made and moisture control is required it is very important to check if the sensor surface is continually covered by material by looking into the mixer during mixing As a rule the accuracy of the signal is not guaranteed if the batch is at or less than half the capacity of the mixer Q If change the ceramic on my sensor do I have to recalibrate the sensor A No the sensor will not need to be re calibrated but the recipe calibrations should be checked If there is any difference in consistence of the final mixes then the recipes will need to be recalibrated Q If have to exchange the sensor in my mixer do I have to recalibrate my recipes A It is prudent to check the recipe calibrations if your sensor has been moved or exchanged Q The sensor readings are changing erratically not consistent with the changes in moisture in the material Is there a reason for this A In this case the installation should be completely checked Is the ceramic cracked Is the sensor mounted flush and are the mixer blades adjusted as recommended in the routine maintenance section If the problem persists then check the output when reading only air and check also by placing sand over the sensor If the output is still erratic then the sensor could be faulty and y
17. e input active the analogue output will indicate the appropriate moisture variable unscaled or moisture When the input is activated the analogue output will indicate the material temperature in degrees centigrade Temperature scaling on the analogue output is fixed zero scale 0 or 4mA corresponds to 0 C and full scale 20mA to 100 C HYDRO MIX VI USER GUIDE 28 HD0304 REV 1 2 0 CONFIGURATION CHAPTER 4 An input is activated using 15 30 Vdc into the digital input connection The sensor power supply may be used as an excitation supply for this or alternatively an external source may be used as shown below 8 o o m S ka 0090A 0090A 15 30Vdc twisted pair twisted pair Sensor Sensor Cable Cable Internal excitation 1 1 External excitation IP1 Figure 21 Internal external excitation of the digital input Filtering The default filtering parameters can be found in Engineering Note EN0027 In practice the raw output which is measured 25 times per second contains a high level of noise due to irregularities in the signal from the mixer blades and pockets of air As a result this signal requires a certain amount of filtering to make it usable for moisture control The default filtering settings are suitable for most applications however they can be customised if required to suit the application It is not possible to have default filtering settings
18. e mixer wall Figure 4 Mounting in curved surface In all installations it is recommended that the sensor is fitted in an area where it is away from any possible collection of sitting water HYDRO MIX VI USER GUIDE 12 HD0304 REV 1 2 0 MECHANICAL INSTALLATION CHAPTER 2 Turbo mixers The sensor may be positioned in the floor or side wall of static pan mixers Generally floor mounting is recommended as the mixer can be used with small batch sizes If the side wall installation is used it must be ensured that there is sufficient material to cover the sensor When the sensor is mounted in the floor it should be approximately 2 3 distance from the mixer centre to the side wall 7 radius Sidewall Mounted Floor Mounted Figure 5 Position of sensor in a turbo mixer If the sensor is mounted in the side wall it should be positioned approximately 60mm above the floor of the mixer Approximately 60mm 2 ve inches Figure 6 Position of sensor in side wall of mixer HYDRO MIX VI USER GUIDE HD0304 REV 1 2 0 13 CHAPTER 2 MECHANICAL INSTALLATION Planetary mixer The sensor should be fitted in the base of the planetary mixer ideally in a position where the flow of material is smoothest away from the area of severe turbulence caused by the mixing action of the blades This is normally close to the side wall of the mixer Therefore it is generally recommended that the sensor be positioned with the
19. ealant from around the sensor e Remove nuts C and carefully ease the sensor and clamp ring assembly from the mixer Replacing the ceramic Should the ceramic face plate of the sensor become damaged it can easily be replaced by end users or their dealer It is advised that a replacement kit part no 0830 is held in reserve in case of this event Full instructions on replacing the ceramic can be found in Appendix B or in the installation instructions accompanying the replacement kit HYDRO MIX VI USER GUIDE HD0304 REV 1 2 0 19 CHAPTER 2 MECHANICAL INSTALLATION Notes HYDRO MIX VI USER GUIDE 20 HD0304 REV 1 2 0 Chapter 3 Electrical Installation and Communication The Hydro Mix VI must be connected using the Hydronix sensor cable part no 0090A available in different lengths to suit the installation Any extension cable required should be connected to the Hydronix sensor cable using a suitable screened junction box See Technical Specification Chapter 8 for cable details Installation guidelines Ensure that the cable is of a suitable quality see Chapter 8 Technical Specification Ensure that the RS485 cable is taken back into the control panel This can be used for diagnostic purposes and takes the minimum of effort and cost to connect at the time of installation Route the signal cable away from any power cables in particular the mixer power supply Check that the mixer is properly grounded Note that there is an M4 t
20. for example a side wall or horizontal shaft mixer ensure that the sensor does not protrude to hit the blades and that it is flush to the inside radius of the mixer e Avoid areas of severe turbulence The optimal signal will be obtained where there is a smooth flow of material over the sensor The sensor should be positioned where it will see a continuous sample of the flowing material and where the sweeping action of the blades ensures no build up of material on the face of the sensor e Position the sensor away from any electrical interference See Chapter 3 e Position the sensor so that it may be easily accessible for routine maintenance adjustment and cleaning HYDRO MIX VI USER GUIDE HD0304 REV 1 2 0 11 CHAPTER 2 MECHANICAL INSTALLATION Positioning the sensor The sensor may be installed into many types of mixer or application In most cases the sensor will work exceptionally well with the standard filtering parameters Some mixer types and certain applications may require further adjustments to the internal filtering parameters of the sensor For further information please contact your dealer or e mail Hydronix at support hydronix com General mounting advice For installations in flat surfaces the top of the sensor must be flush with the floor of the mixer Figure 3 Mounting in flat surface When installing the sensor in curved surfaces ensure that the centre of the ceramic is flush with the radius of th
21. he Sensor up ep tette ROB e RU eee Eb deduce bee br eden 27 Chapter 5 Optimising sensor performance 1 mener nnn 33 Chapter 6 Frequently asked questions us 35 Ghapter7 Sensor inet eH hp bie u et a io Paus 39 Chapter 8 Technical specification is 41 Appendix A Default parameters ss 43 Appendix B Ceramic Disc Replacement ss 45 HYDRO MIX VI USER GUIDE HD0304 REV 1 2 0 5 Table of Figures Figure 1 The Hydro Mix VI and clamp ring ser 7 Figure 2 Connecting the sensor overview 10 Figure 3 Mounting in flat surface iii 12 Figure 4 Mounting in curved surface iii 12 Figure 5 Position of sensor in a turbo mixer sine 13 Figure 6 Position of sensor in side wall of mixer 13 Figure 7 Position of sensor in a planetary mixer 14 Figure 8 Position of sensor in a horizontal shaft or ribbon mixer 14 Figure 9 Position of sensor in a twin shaft horizontal mixer 15 Figure 10 Sensor installation siennes 16 Figure 11 Clamp ring components sise 17 Figure 12 Fixing plate prepared for attaching clamp ring 17 Figure 13 Clamp ring assembled and fitted to fixing 18 Figure 14 Clamp ring 0033 fitted to fixing plate 0021 and Hydro Mix VI
22. hen using a Hydro Control check also to see if there are timers being used after the mixer is charged prior to the start signal and after the mix complete prior to the mixer discharge These timers are not needed HYDRO MIX VI USER GUIDE HD0304 REV 1 2 0 37 CHAPTER 6 FREQUENTLY ASKED QUESTIONS Q Is the mounting position of the sensor important A The mounting position of the sensor within the mixer is very important Refer to Chapter 3 Mechanical installation Q What is the maximum length of cable can use A See Chapter 8 Technical specification HYDRO MIX VI USER GUIDE 38 HD0304 REV 1 2 0 Chapter 7 Sensor diagnostics The following tables list the most common faults found when using the sensor If you are unable to diagnose the problem from this information please contact Hydronix technical support Symptom No output from sensor Possible explanation Check Required result Action required on failure Output is working but not Perform simple test with Output similar to as Power down and re correctly hand on sensor shown in table 2 power sensor No power to sensor DC power at junction 15Vdc to 30Vdc Locate fault in power box supply wiring Sensor has temporarily Power down and re Sensor functions Check power locked up power sensor correctly No sensor output at Measure sensor output Milliamp reading within Check cabling back to control system cur
23. hreaded hole provided on the bottom of the Hydro Mix VI for a ground connection if required The sensor cable should only be grounded at the mixer Ensure that the cable screen is not connected at the control panel Ensure that there is continuity of the screen through any junction boxes Keep the number of cable joins to a minimum Analogue output A DC current source generates an analogue signal proportional to one of a number of selectable parameters e g filtered unscaled filtered moisture average moisture etc See Chapter 4 Configuration or the Hydro Com User Guide HD0273 for further details Using the Hydro Com or direct computer control the output may be selected to be e 420mA e 0 20 mA 0 10 V output can be achieved using the 500 Ohm resistor supplied with the sensor cable HYDRO MIX VI USER GUIDE HD0304 REV 1 2 0 21 CHAPTER 3 ELECTRICAL INSTALLATION COMMUNICATION 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 2 Analogue Positive Brown where available 6 K 2 Analogue Return Black where available H Screen Screen Table 1 Sensor cable Part no 0090A connections
24. in Connect sensor to a PC is faulty analogue output from the normal range 0 and run Hydro Com the PLC and measure with an ammeter 20mA 4 20mA Check analogue output on the diagnostics page Force the mA output to known value and check this with an ammeter PLC analogue input card is faulty Disconnect the analogue output from the PLC and measure the analogue output from the sensor using an ammeter Milliamp reading within the normal range 0 20mA 4 20mA Replace analogue input card Symptom Computer does not communicate with the sensor Possible explanation Check Required result Action required on failure No power to sensor DC power at junction 15Vdc to 30Vdc Locate fault in power box supply wiring RS485 incorrectly wired Converters wiring RS485 converter Check PC Com port into converter instructions and A and B correctly wired settings signals are the correct orientation Incorrect serialCom Port Com Port menu on Switch to the correct Possible Com port selected on Hydro Com Hydro Com All Com Port number used is higher available Com Ports are than 10 and therefore highlighted on the pull not selectable in the down menu menu on Hydro Com Determine the Com Port number assigned to the actual port by looking at the PC device manager Com port number is The Com Port Renumber the Com Port Check sensor higher than 10 andis not assignments inthe PC s used for c
25. ixing plate 0021 and Hydro Mix VI HYDRO MIX VI USER GUIDE 18 HD0304 REV 1 2 0 MECHANICAL INSTALLATION CHAPTER 2 Adjusting the sensor NEVER HIT THE CERAMIC THE CERAMIC IS VERY HARDWEARING BUT IS BRITTLE AND WILL CRACK IF STRUCK The ceramic face plate of the sensor is extremely resistant to abrasion The mixer wear plates will wear more rapidly than the ceramic Consequently from time to time it will be necessary to adjust the sensor so that it maintains the same relative position to the wear plates following this procedure a recalibration of the recipes may be required To move the sensor IN to the mixer e Clean out compacted sand or silicone sealant from around the sensor e Loosen the lock nuts B and screws e Tighten nuts C evenly max 50Nm or 37ft Ib until the sensor is in the desired position e Tighten screws A 20Nm or 15ft Ib e Tighten lock nuts B 40Nm or 30 ft lb e Fill the gap around the mixer with silicone sealant preferred or compacted sand To move the sensor OUT of the mixer e Clean out compacted sand or silicone sealant from around the sensor e Loosen lock nuts B and nuts C e Tighten screws A evenly max 60Nm or 45ft Ib until the sensor is in the desired position e Tighten nuts C 20Nm or 15ft Ib e Tighten lock nuts B 40Nm or 30ft Ib e Fill the gap around the mixer with silicone sealant preferred or compacted sand Removal of the sensor e Clean out compacted sand or silicone s
26. mA represents 0 and 20mA represents 20 e 4 20mA 4mA represents 0 and 20mA represents 20 These limits are set for the working range of the moisture and must be matched to the mA to moisture conversion in the batch controller Digital inputs output The Hydro Mix VI has two digital inputs output the first of which can be configured as an input only whereas the second can be either an input or output The digital output is not applicable to mixer sensors and therefore the second digital input output is not considered here The first digital input can be set to the following Unused The status of the input is ignored Average Hold This is not applicable to a mixer application but may apply in chutes or other flush mount applications It is used to control the start and stop period for batch averaging When the input signal is activated the Filtered values unscaled and moisture start to average after a delay period set by the Average Hold delay parameter When the input is then deactivated averaging is stopped and the average value is held constant so that it can be read by the batch controller PLC When the input signal is activated once again the average value is reset and averaging commences Moisture Temperature Allows the user to switch the analogue output between the unscaled or moisture whichever is set and temperature This is used when the temperature is required whilst still using only one analogue output With th
27. nused Moisture temp Unused Moisture temp Input output Use 2 Bin empty Unused Unused Data invalid Probe OK Temperature compensation Electronics temp coeff 0 01 0 01 Second digital input output is not available in older firmware 50045 HYDRO MIX VI USER GUIDE 44 HD0304 REV 1 2 0 Appendix B Ceramic Disc Replacement Cover Ceramic Support a CONTENTS OF REPLACEMENT KIT C Spanner M5x10 slotted counter sunk stainless steel screws x4 Protection Ring O ring 90 I D x 2 5 section O ring 95 I D x 2 0 section O ring 3 239 I D x 0 070 section Ceramic Disc M5x25 stainless steel screws x2 Sachet of grease not shown Assembly Jig c rommoo gt REMOVAL OF CERAMIC DISC Unscrew 4 screws B and remove the Protection Ring C If there is no mark aligning the Ceramic Securing Ring K with the Ceramic Support draw one as shown as a guide for re assembly Fit 2 screws H in to opposite sides of the Ceramic Support This will enable the body to be laid flat and prevent it from rotating when unscrewing the Ring K Alternatively use Ceramic Tightening Jig J Part 0034 in a vice Use C Spanner A to unscrew ring K Remove Ring K and retain for re assembly Remove Ceramic Disc G and O rings D E and F HYDRO MIX VI USER GUIDE HD0304 REV 1 2 0 45 APPENDIX B Grease thread N RE ASSEMBLY WITH NEW CERAMIC DISC Clean and deg
28. o Mix VI can be connected to the mixer control system e Analogue output A DC output is configurable to e 4 20 mA e 0 20 mA e 0 10 V output can be achieved using the 500 Ohm resistor supplied with the sensor cable e Digital control an RS485 serial interface permits direct exchange of data and control information between the sensor and the plant control computer or Hydro Control system e Compatibility mode this allows a Hydro Mix VI to connect to a Hydro Control IV or Hydro View unit The sensor may be configured to output a linear value of between 0 100 unscaled units with the recipe calibration being performed in the control system Alternatively it is also possible to internally calibrate the sensor to output a real moisture value Power supply 15V 30 Vac 1A min Analogue output 0 20mA 4 20mA 0 10V Digital inputs RS485 serial communications Figure 2 Connecting the sensor overview HYDRO MIX VI USER GUIDE 10 HD0304 REV 1 2 0 Chapter 2 Mechanical Installation A significant benefit of the Hydronix system is that only one sensor is required in the mixer However it is important that it is positioned correctly in relation to the mixer floor aggregate and water inlets and other moving parts such as blades and paddles General to all applications Always ensure that the sensor is correctly positioned in relation to the mixer floor and other moving parts such as paddles Although paddles or scrape
29. omments and suggestions relating to the product and this documentation ACKNOWLEDGEMENTS Hydronix Hydro Probe Hydro Mix Hydro View and Hydro Control are Registered Trade Marks of Hydronix Limited HYDRO MIX VI USER GUIDE 2 HD0304 REV 1 2 0 Revision history ee Date Description of change January 1 0 0 2006 Original version 1 1 0 May 2006 Addition of Appendix A Default sensor parameters 120 September Addition of Appendix B Replacement Ceramic 2007 Instructions HYDRO MIX VI USER GUIDE HD0304 REV 1 2 0 3 HYDRO MIX VI USER GUIDE 4 HD0304 REV 1 2 0 Table of Contents Chapter 1 Introduction aaa dinde rapelle 9 augere eio cmt 9 Measuring techniques 10 Sensor connection and configuration ss 10 Chapter 2 Mechanical Installation ss 11 General to all appliCations 53 sala A ERRARE SCELERE 11 Positioning tlie Sensor 2 att i de dr een ree e cid ee itr iter 12 Installing ihe Sensors asa o eor a 16 Replacing the Ceramic viciado avan 19 Chapter3 Electrical Installation and Communication 21 Installation guidelines 4 uu nuna detente ie cet tt t e dal eile 21 Analogue Output cation ee et ein ieee ie an eee ies 21 RS485 m t drop GONNA C O ici 23 Hydro Control IV Hydro View connection ss 23 Gonfnectlngito aiBG i I hnc d a Rs eiTe a 24 Ghapter 4 Gonfiguration iei aa 27 Gonfig ring t
30. ommunication addresses available to use in Hydro Device Manager with the sensor to an Com window unused port number between 1 and 10 More than one sensor Connect to each sensor Sensor is found at an Try an alternative has the same address individually address Renumber this RS485 RS232 USB if number sensor and repeat for all available the sensors on the network HYDRO MIX VI USER GUIDE 40 HD0304 REV 1 2 0 Chapter 8 Technical specification Dimensions e Diameter 108mm e Length 125mm 200 including connector e Fixing a 127mm diameter cut hole Construction e Body Stainless steel e Faceplate Ceramic e Wear ring Hardened steel Penetration of field e Approximately 75 100mm dependent upon material Operating temperature range e 0 60 32 140 F The sensor will not work in frozen materials Power supply voltage e 15 30 VDC 1 A minimum required for start up normal operating power is 4W Connections Sensor cable e Six pairs twisted 12 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 8306 Alpha 6373 e Maximum cable run 200m separate to any heavy equipment power cables Digital serial communications e Opto isolated RS485 2 wire port for serial communications including changing operating parameters and sensor diagnostics
31. oom Figure 11 Clamp ring components Threaded studs Lock nuts B NW Fixing plate part no 0021 Figure 122 Fixing plate prepared for attaching clamp ring 1 Screw the 3 threaded studs F to the fixing plate already welded to the mixer and tighten securely using 3 lock nuts B 3 Fit the clamp ring G onto the sensor using the 2 x M6 screws E Position the clamp ring so that adjustment is possible with the ceramic head level with the mixer floor or side wall 4 Fitthe clamp ring and sensor assembly over the threaded studs of the fixing plate and use the Nyloc nuts C and washers D to position the sensor with the ceramic level with the mixer floor or side wall HYDRO MIX VI USER GUIDE HD0304 REV 1 2 0 17 CHAPTER 2 MECHANICAL INSTALLATION M8 Nyloc nuts C Figure 13 Clamp ring assembled and fitted to fixing plate 5 Fitthe three screws A along with the 3 remaining lock nuts B to the clamp ring to push against the fixing plate 6 CHECK again to ensure that the sensor head is in the correct position using a steel rule and ensure that the mixer blades and scrapers clear the ceramic face plate by manually rotating the blades 7 Fully tighten the complete assembly including the lock nuts 8 Once the sensor has been correctly fitted and adjusted fill the gap around the sensor with silicone sealant preferred or compacted sand Figure 14 Clamp ring 0033 fitted to f
32. op PC Connections Connector mil spec Consistency Converter RS232 485 Digital inputs output Electrical interference Filtered Moisture Filtered signal Filtered Unscaled Filtering default Filtering time Filters slew rate Fixing plate Hole cutting Hydro Com Hydro View Ingredients Installation advice curved surface electrical flat surface 10 21 27 35 28 36 34 21 34 35 33 33 34 19 34 19 45 17 18 10 27 27 35 21 27 35 11 11 12 14 15 21 12 13 14 mechanical 11 side wall 13 Junction box 23 Maintenance 11 Material build up 11 Measurement technique 10 Mix times during calibration 34 Mixer 33 hole in 16 horizontal 9 14 planetary 9 14 ribbon 9 14 rotating pan 9 static pan 9 turbo 9 13 twin shaft 15 Mixing 34 Moisture temperature 28 Mounting general 12 Output 27 analogue 21 Parameters default 43 Low and High 28 output variable 1 amp 2 27 Raw moisture 29 Raw unscaled 29 RS232 485 Converter 24 Saturated surface dry See SSD Sensor adjustment 19 configuration 27 connections 10 position 11 12 Sensor cable 22 Sensor performance 33 Signal stability 32 34 Slew rate filters 29 Slump See Consistency Spray bars 33 SSD 27 Temperature 33 Turbo mixer 13 USB Sensor interface module 24 Water addition 34 Wear ring replacement 19 45 Workability See Consistency HYDRO MIX VI USER GUIDE HD0304 REV 1 2 0 47
33. ors on a network The converter has a terminal block for connecting the twisted pair RS485 A and B wires and can then be connected directly in to the PC serial communication port RS232 485 converter DIN rail mounting Part no 0049A Manufactured by KK systems this powered RS232 485 converter is suitable for connecting any number of sensors on a network The converter has a terminal block for connecting the twisted pair RS485 A and B wires and can then be connected to a PC serial communication port USB Sensor Interface Module Part no SIMO01 A Manufactured by Hydronix this USB RS485 converter is suitable for connecting any number of sensors on a network The converter has a terminal block for connecting the twisted pair RS485 A and B wires and then connects to a USB port The converter does not require external power although a power supply is supplied and can be connected providing power to the sensor See USB Sensor Interface Module User Guide HD0303 for further information RS485 line termination will not normally be required in applications with up to 100 m of cable For longer lengths connect a resistor approximately 100 Ohm in a series with a 1000pF capacitor across each end of the cable Itis highly recommended that the RS485 signals be run to the control panel even if they are unlikely to be used as it will facilitate the use of diagnostic software should the need arise HYDRO MIX VI USER GUIDE 24 HD0304 REV 1 2 0 E
34. ou should contact your dealer or Hydronix for technical support If the readings are OK but appear erratic during mixing then try and connect to a PC and run Hydro Com to check the configuration filter settings Default settings can be found in Engineering Note EN0027 HYDRO MIX VI USER GUIDE 36 HD0304 REV 1 2 0 FREQUENTLY ASKED QUESTIONS CHAPTER 6 Q My sensor takes a very long time to detect the water that goes into the mixer Can speed this up A This could indicate that the mixer has a poor vertical mixing action Look at how the water goes into the mixer Try to spray the water into the mixer in as many places as practical Check the filter settings and if they are too high reduce the filtering time This should not be done to the detriment of the signal stability as unstable signals may affect the amount of water calculated and hence the quality of the final mix In some cases it has been found that the configuration of the paddles in the mixer has been misaligned Be sure to check the specifications on your mixer to be certain of the proper mixing action Q My water controller is a dribble feed system which progressively adds water to reach a final set point What filter settings do need for this A Dribble feed systems do not need to have a stable signal at the end of a dry mixing time and so it should not be necessary to filter as much as you would if you were calculating a one off amount of water to add The sensor needs to
35. r blades can be a useful mechanism to keep the sensor free from material build up they could cause damage to an incorrectly positioned sensor It will be necessary to periodically check the position as the mixer blades paddles and floor wear The sensor will occasionally need to be adjusted out from the mixer to maintain the correct position In addition the blades will need to be lowered to maintain efficiency of the mixing action and cleanliness of the sensor faceplate For accurate and representative moisture measurement the sensor must be in contact with the moving stream of material It is equally important that no material can build up over the sensor face to obscure the sensor readings If the sensor is allowed to protrude into the mixer it will be susceptible to damage from the mixer blades paddles as well as from aggregates becoming trapped between the paddles mixer floor and exposed side wall of the sensor Damaged caused under these circumstances will not be covered by warranty Follow the advice below for good sensor positioning e Itis a good idea to provide a small inspection lid in the mixer cover so that during mixing and when the mixer is empty the sensor face may be observed without having to raise the main cover plate e If the floor is not level fit the sensor in the highest point in the floor e Ensure that the sensor is fitted away from the water cement and aggregate entry points e If the mixer surface is curved
36. rease Cover Ceramic Support and Ring K Using the grease supplied I lightly grease the O rings D E and the thread in the Ceramic Securing Ring K Place O ring E over the Ceramic Support to the base of the thread Grease O ring F with the grease I and place in the groove around the Cover Place Ceramic Disc G over the Cover and locate it in the recess of the Ceramic Support Place O ring D in to the groove at the base of the thread in the Ceramic Securing Ring K Place Ring K with the O ring in place over the Ceramic and Ceramic Support Carefully tighten using the C Spanner so that the two marks line up This is the minimum tightness recommended If possible tighten the Ring further Place the Protection Ring over the Ceramic and secure with 4 screws B ensuring they are properly tightened Recalibrate the sensor to air and water to ensure the sensor output characteristics remain unchanged See Hydro Com User Guide HD0273 Early models may not have a groove in the Ceramic Support for o ring F On these models omit o ring F HYDRO MIX VI USER GUIDE 46 HD0304 REV 1 2 0 INDEX Adjustable clamp ring Adjusting the sensor Admixtures Analogue output Average hold Batch size Batches volume Cable Calibration Cement addition temperature Ceramic care replacement Clamp ring adjustable fitting Compatibility Configuration Connection multi dr
37. removed 4m sensor cable 10m sensor cable 25m sensor cable Power supply 30 Watt for up to 4 sensors RS232 485 converter DIN rail mounting RS232 485 converter 9 pin D type to terminal block USB Sensor Interface Module including cables and power supply Replacement ceramic kit ceramic and protection ring kit Replacement ceramic kit excluding protection ring Replacement wear ring including screws Hydro Com configuration and diagnostics software is available for free download from www hydronix com HYDRO MIX VI USER GUIDE HD0304 REV 1 2 0 7 HYDRO MIX VI USER GUIDE 8 HD0304 REV 1 2 0 Chapter 1 Introduction Introduction The Hydro Mix VI digital microwave moisture sensor with integral signal processing provides a linear output both analogue and digital The sensor may be easily connected to any control system and is ideally suited to measure the moisture of materials in mixer applications as well as other process control environments The sensor reads at 25 times per second this enables rapid detection of changes in moisture content in the process including determination of homogeneity The sensor may be configured remotely when connected to a PC using dedicated Hydronix software A large number of parameters are selectable such as the type of output and the filtering characteristics The sensor is constructed to operate under the most arduous conditions with a wear life of many years The Hydro Mix VI should never
38. rent at control system the normal range 0 junction box 20mA 4 20mA Varies with moisture content No sensor output at Measure sensor output Milliamp reading within Check sensor connector junction box current at terminals in the normal range 0 pins junction box 20mA 4 20mA Varies with moisture content Sensor MIL Spec Disconnect the sensor Pins are bent and can be Check sensor connector pins are cable and check if any bent to normal to make configuration by damaged pins are damaged electrical contact connecting to a PC Internal failure or Connect the sensortoa Digital RS485 Digital RS485 incorrect configuration PC using the Hydro connection is working connection is not Com software and a working Sensor should suitable RS485 be returned to Hydronix converter for repair Sensor output characteristics Sensor 0 4mA 0 mA OV gt 10V exposed to air Hand on 75 85 15 17 mA 16 18 mA 7 5 8 5 V 3 6 2 8V sensor Table 2 Sensor output characteristics HYDRO MIX VI USER GUIDE HD0304 REV 1 2 0 39 CHAPTER 7 Symptom Incorrect analogue output SENSOR DIAGNOSTICS Possible explanation Check Required result Action required on failure Wiring problem Wiring at the junction Twisted pairs used for Wire correctly using box and PLC complete length of cable specified cable in the from sensor to PLC technical specification wired in correctly Sensor s analogue output Disconnect the Milliamp reading with
39. respond as quickly as possible because the moisture reading has to keep up with the water going in otherwise too much water can be put in without being detected Recommended settings would be light for both slew rate filters with a minimum filtering time of 2 5 seconds maximum 7 5 seconds Q How can l reduce my mix cycle times A There is no single simple answer to this The following could be considered e Look at how the mixer is charged with material Can the materials be loaded in a different sequence that will save some time e Can you wet the incoming aggregates with a large percentage of the total water at the instance material goes into the mixer This would reduce the dry mixing time e Are you continuing to mix the material for a long time after the moisture signal is stable If so you need only to mix up until you reach stability for 5 10 seconds e Ifyou want to save time on the dry or the wet mixing times always maintain a long enough dry mixing time as this is the most important factor for determining the water e You can take out some of the wet mixing time as this may be less important as the correct amount of water has already gone into the mixer if you do this then be aware that the final released mix may not be homogeneous e When running mixes using lightweight aggregates be certain to keep the lightweight as close to or above the SSD This will help reduce mixing time because less pre wet water is being used e W
40. rning when the aggregates are very wet or when the cement is hot e When using a calibration based water addition method it is essential to obtain a correct dry reading e Dry mix time must be long enough to obtain stability of the signal e Good measurement takes time Mixing e Minimum mix times are a function of the mix design ingredients and mixer not just the mixer e Different mixes may need different mix times e Keep batch sizes as consistent as possible e g 2 5m 2 5m 1 0m is not as good as 3 x 2 0m e Keep the premix time as long as possible to the detriment of the wet mix time if necessary Routine maintenance e Ensure the ceramic is always flush with the mixer wear plates e Fit the adjustable clamp ring part no 0033 for ease of adjustment and extraction e Keep the mixer blades adjusted to 0 2mm above the mixer floor This will have the following 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 Wear on the mixer floor plates will be reduced e Reduced cycle times will result in savings on power and wear REMEMBER DO NOT HIT THE CERAMIC HYDRO MIX VI USER GUIDE 34 HD0304 REV 1 2 0 Chapter 6 Frequently asked questions Q Hydro Com doesn t detect any sensor when press search A If there are many sensors connected on the RS485 network ensure that each sensor is
41. tch controller or Hydro Control which manages the moisture during batching The sensor is not calibrated directly Instead a series of recipe calibrations within the batch controller are made for each different mix design each carrying their own reference to which concrete of the correct consistency can be made Each mix design should have its own recipe because each combination of materials has an effect on the microwave response Q Do Hydronix sensors have to be calibrated to an exact moisture percent A Although possible for most applications exact moisture of the mix is not necessary All that is needed is a reference target that is known to product a good mix Therefore in the majority of situations the analogue output from the sensor is set for Filtered Unscaled 0 100 a set point is recorded at the end of each batch and stored in the recipe where it is used as the final target HYDRO MIX VI USER GUIDE HD0304 REV 1 2 0 35 CHAPTER 6 FREQUENTLY ASKED QUESTIONS Q If make a mix with the same quantities of dry materials but with different colours do need to have a different recipe A Yes pigments whether they are powder or liquid additives affect the measurement and as a result every different colour will require a different recipe and calibration Q If make regular half batches of a particular mix do need to have a separate recipe for this A A variation in batch quantities can have a small effect on the amplitu
42. tely mixed together i e the mix is homogeneous HYDRO MIX VI USER GUIDE HD0304 REV 1 2 0 29 CHAPTER 4 CONFIGURATION Final mixing Water added time i Mixer i AS le Initial discharge mixing time Mixer i loaded lt with i material 2 a lt 2 iL Figure 22 Typical moisture curve The degree of stability at points A and B can have a significant effect on accuracy and repeatability For example most automatic water controllers measure the dry moisture and calculate how much water to add to the mix based on a known final reference in a particular recipe Therefore it is vital to have a stable signal in the dry mix phase of the cycle at point A This enables the water controller to take a representative reading and make an accurate calculation of the water required For the same reasons stability at the wet end of the mix Point B will give a representative final reference indicating a good mix when calibrating a recipe Figure 26 shows an ideal representation of moisture over a cycle The output of this is the Filtered Unscaled reading The graph below Figure 27 shows raw data recorded from a sensor over an actual mix cycle clearly indicating the large spikes caused by the mixing action Raw Signal 1 co o Raw Unscaled 8 S w o N o
43. that are ideally suited to all mixers because every mixer has a different mixing action The ideal filter is one that provides a smooth output with a rapid response The raw moisture and raw unscaled settings should not be used for control purposes To filter the raw unscaled reading the following parameters are used Slew rate filters These filters set rate limits for large positive and negative changes in the raw signal It is possible to set limits for positive and negative changes separately The options for both the slew rate and the slew rate filters are None Light Medium and Heavy The heavier the setting the more the signal will be dampened and the slower the signal response Filtering time This smoothes the slew rate limited signal Standard times are 0 1 2 5 5 7 5 and 10 seconds although it is possible also to set this to 100 seconds for specific applications A higher filtering time will slow the signal response Figure 26 overleaf is a typical moisture curve during a batching cycle of concrete The mixer starts empty and as soon as material is loaded the output rises to a stable value Point A Water is then added and again the signal stabilises at Point B at which point the batch is complete and the material is discharged The main points to note with this signal are the points of stability because these signify that all the materials aggregates cement colourings chemicals etc are comple
44. ut the noise with the aim of providing a smooth signal Should there be a requirement to change the filtering then the aim is to provide as fast a response as possible whilst maintaining signal integrity Signal stability is important and mixing times have to be set appropriately in accordance with the mixer due to the variation in efficiency of mixers The default filtering parameters can be found in Engineering Note EN0027 HYDRO MIX VI USER GUIDE 32 HD0304 REV 1 2 0 Chapter 5 Optimising 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 homogeneous 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 Mixer 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 disperse the water into the mixer more quickly to shorten the mixing time Spray bars are more effective than single water inlets The wider the area the water sprays the faster it will mix into the material Ingredients If the aggregate masses are not corrected for high moisture contents then the aggregate cement ratio will change considerably having an adverse effect on consistency and
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