Hydro-Probe Orbiter User Guide (Static Mounted)
Contents
1. 14 3 Cabling to the Sensor et teeth cese aaa 17 4 Conveyor belt or free fall applications sse 19 4 1 Hydro Probe Orbiter for conveyor belt applications 19 4 2 Hydro Probe Orbiter for free fall 20 5 AWIFING COMMS CU INS ii r 21 5 1 Analogue OUNDUE 21 5 2 RS485 multi drop connection sssssssssssse e 22 5 3 CompaubllllYy MMOS acre incase ole esto M annu lad DES eM Pa ah tae 23 5 4 Connecting to B PO costos esque Papi e Dd 23 Configuring SONAS EE 25 6 1 Calibration paramete Sir inansa a E 26 6 2 Average Hold Delay dtr tr p e eet te see n e aadel 26 6 3 SIMON UMS eer DH 26 6 4 Slew rate slew Tale cuite ss step et diua wal ee hie setate 26 6 5 Temperature coefficient tese te ee e 26 6 6 Digital input OUtpUt ica eter tet ee rero ride e a 27 T Sensor CO iii 29 7 1 Keeping the sensing head clean ecce rene rre ea 29 8 Replaceable parts nono tnn enhn nent n enne 31 8 1 Changing Me SENSING ANN odis tete uate 312. 8 1 1 Removing the sensing head and 31 8 1 2 Fitting the Hydro Probe Orbiter back into the mixer 31 8 2 Calibrating a new arm to the sensor electronics eese 31 8 2 1 Autocal Hydro Probe Orbiter used in mixer 31 8 2 2 Air and water calibration 33 9 Troubleshooting tips Sima O es 35 9 1 InstallatiON EE 35 9 2 EGE do at cael Salt ee 35 9 3 A et 35 9 4 o A aa Ea e ect 36 9 5 MOT KAD INDY A ft Rate 36 9 6 pe ccn 36 9 7 MIXING 37 10 Sensor performance eese ae dadas 39 10 1 Adjustment of the blades eet ete sh ccd ERR RM Ru Me 39 19 27 GI i em a iet eetis 39 IE ACCOM rr 39 11 echnical specificatiOn ee es Coon dee ideae LED TED PER ER UL C LESER ERE 41 HYDRO PROBE ORBITER USER GUIDE HD0215 REV 1 1 0 3 TABLE OF FIGURES Figure 1 The Hydro Probe Orbiter asista lado leal cin Mi kala 6 Figure 2 Installation of sensing arm into sensor body sessee 9 Figure Sensor mounted above the mixer on 11 Figure 4 Sensor mount
3. High limit m96 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 96 Raw moisture Raw unscaled filtered unscaled Average unscaled Material temperature Output variable 2 Material temperature Filtered moisture Average moisture 96 Raw moisture 9o Raw unscaled filtered unscaled Average unscaled Material temperature High 96 20 00 0 100 Low 96 0 00 0 100 Input Use 1 Average hold Average hold Averageffiltered Moisture temp Unused Unused Unused Moisture temp Bin empty Input output Use 2 Data invalid Probe OK Temperature compensation Electronics temp coeff 0 002 Resonator temp coeff 0 0075 Table 2 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 HD0215 REV 1 1 0 25 6 1 Calibration parameters The default calibration parameters in Table 2 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 96 A x unscaled reading B x unscaled reading C The A B and C coefficients are only active when either e
4. the signal is stable 00000000 0 REMEMBER DO NOT HIT THE CERAMIC IT IS EXTREMELY WEAR RESISTANT BUT BRITTLE HYDRO PROBE ORBITER USER GUIDE HD0215 REV 1 1 0 37 Notes HYDRO PROBE ORBITER USER GUIDE 38 HD0215 REV 1 1 0 Chapter 10 10 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 10 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 All the residual mix is 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 10 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 10 3 Water addition e To facilitate the mixing action the water should b
5. 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 NE A aAa 7 1 1 ADPIC ON SA AE ALA A a Ra Rede Beco Ys 7 1 2 Typical ccm TESE a etaan 7 1 3 A A Va E E E EDI 7 1 4 Measuring LeGANIGUBS rc exe nasi AB 8 1 5 SONS COAUTOR enh A 8 1 6 SENSING 8 2 Installation process for mixers ssssssssssssssssssssseee memes 9 2 1 Assembly of sensing arm and body rt tete 9 2 2 Selecting the best position for mounting SENSO oooocccccnncccccononcnnnnnnnnnononnnnannnnnnnnnnnnnnnnnnnns 11 2 3 Fitting the square mounting DOE seed cose tied A Cau See de deo eg 12 24 Mounting sensor and final adjustments when running 13 24 1 Teightadiuslment ono tdeo Rte fte ier ta co io Dateien 13 2 4 2 Sensing head angle adjustment for optimum
6. 18 Din rail mounting RS232 RS485 24 Figure 19 The Hydronix A tocal Dongle ene dee n teatada ia 32 Figure 20 Connecting the Hydronix Autocal Dongle for calibration 32 Figure 21 Air water calibration certet eher ent rete tahkete nad Vuka 33 HYDRO PROBE ORBITER USER GUIDE 4 HD0215 REV 1 1 0 HYDRO PROBE ORBITER USER GUIDE HD0215 REV 1 1 0 5 Hose clamp tube Cable Protective hose for cable gt Sensor body _ gt 25 35mm square mounting bar provided by customer Clamp block Arm clamp ki Replaceable sensing arm Ceramic face plate Sensing head ee EN Rapid response temperature sensor Two lengths of arm are available Overall length 560mm or 700mm Figure 1 The Hydro Probe Orbiter HYDRO PROBE ORBITER USER GUIDE 6 HD0215 REV 1 1 0 1 Introduction 1 1 Applications The Hydro Probe Orbiter may be used for three different types of application Type 1 For static mounting of the Hydro Probe Orbiter sensor ORB1 in rotating mixers or for conveyor belts or material in free fall applications Type 2 For a rotating mounting in static pan mixers using a rotating connector for connecting the cable to the Hydro Probe Orbiter Type 3 Also for a rotating moun
7. Hydro Probe Orbiter User Guide For model ORB1 static mounting This guide is for model ORB1 with standard sensor cable FOR STATIC MOUNTING IN ROTATING PAN MIXERS OR ON CONVEYOR BELT APPLICATIONS Typical applications D type Eirich Croker or Turmac mixers Conveyor belts and material in free flow To re order quote part number HD0215 Revision 1 1 0 Revision date March 2004 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 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 described in
8. 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 6 2 Average Hold Delay This parameter would only be used for applications where the Hydro Probe Orbiter is replacing the Hydro Probe II for example in high wear environments In mixer applications this should be set to zero 0 for the Hydro Probe Orbiter 6 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 6 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 these correspond to 5 2 5 and 1 25 unscaled units per second 6 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 no
9. Wiring connections The Hydro Probe Orbiter is connected using a 4 metre cable part no 0090A An extension cable twisted pairs from the plant control room should be provided by the customer or agent installing the sensor Up to 6 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 35mmY conductors Recommended cable types are Belden 8306 or Alpha 6377 The cable screen must be connected at the sensor end only and therefore it is essential that the sensor body has a good connection to an electrical earth The extension cable run from the sensor to the control unit must be separate from any heavy equipment power cables particularly the power cable for the mixer Failure to separate the cable runs can lead to signal interference 5 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 6 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 14 NOTE If a 0 10V signal is required connect the res
10. able 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 HD0215 REV 1 1 0 31 e Using the Hydronix Autocal Dongle The Autocal Dongle as shown in Figure 19 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 20 Figure 19 The Hydronix Autocal Dongle Sensor body Figure 20 Connecting the Hydronix Autocal Dongle for calibration The simple procedure outlined below should take less than one minute to complete k 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 20 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 wa
11. ackage 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 17 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 18 which is designed for industrial applications and is DIN rail mounted Note that this unit has an additional RJ 11 type RS232 port if the customer wishes to connect to a PC using a suitable cable 5485 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 HD0215 REV 1 1 0 23 RS485 RS232 RS485 A Connect to PC serial port ED RS485 B Hydronix Part No 0049 RS485 RS232 RS485 A SN Connect to RS485 PC serial port 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 Sw
12. avy duty rubber hose that is firmly secured at either end using hose clamps Securing along the underside of the mixer arm as shown in Figure 11 will also protect the cable from the incoming load Hose clamp Y A 32mm ID Protective Rubber Hose clamp Hose Figure 11 Cabling to the sensor HYDRO PROBE ORBITER USER GUIDE HD0215 REV 1 1 0 17 Notes HYDRO PROBE ORBITER USER GUIDE 18 HD0215 REV 1 1 0 Chapter 4 4 Conveyor belt or free fall applications THE HYDRO PROBE II IS VERY POPULAR IN FREE FALL AND CONVEYOR BELT APPLICATIONS IF THE MATERIAL IS VERY ABRASIVE THEN THE HYDRO PROBE ORBITER PROVIDES A GOOD ALTERNATIVE 4 1 Hydro Probe Orbiter for conveyor belt applications In concept the sensor may be fitted in a similar manner with the sensing face angled at approximately 35 to the flow of material or 55 to line perpendicular to the direction of the flow Flow of material p gt p Figure 12 Mounting the Hydro Probe Orbiter for conveyor belt applications HYDRO PROBE ORBITER USER GUIDE HD0215 REV 1 1 0 19 4 2 Hydro Probe Orbiter for free fall applications Fitting should be as indicated in the drawings below Sensing arm end on view Hydro Probe Orbiter body Hydro Probe Orbiter body Sensing arm in flow of material Figure 13 Mounting the Hydro Probe Orbiter for free fall applications conveyor and silo HYDRO PROBE ORBITER USER GUIDE 20 HD0215 REV 1 1 0 5
13. 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 e p gt Sensor in the water bath Sensor Minimum water depth 200mm Figure 21 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 Itis therefore advisable to recalibrate the recipes before continuing batching HYDRO PROBE ORBITER USER GUIDE HD0215 REV 1 1 0 33 Notes HYDRO PROBE ORBITER USER GUIDE 34 HD0215 REV 1 1 0 Chapter 9 9 Troubleshooting tips These tips are intended as suggestions for troubleshooting when problems occur with the water control system 9 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 f 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 Prob
14. ceramic faceplate facing upwards aligned with the hole in the head unit e For ease of fitting apply a small amount of silicone 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 Ifthe arm is a replacement then a recalibration procedure will need to be carried out See section 8 2 Calibrating the new arm to the sensor electronics HYDRO PROBE ORBITER USER GUIDE 10 HD0215 REV 1 1 0 2 2 Selecting the best position for mounting sensor Depending on the mixer type the sensor may need to be fitted either inside Figure 4 or above the mixer Figure 3 A square support bar needs to be fitted securely and rigidly to a cross member or the static side wall of the mixer to provide solid support for the Hydro Probe Orbiter 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 The sensing head is to be positioned in an area where the flow of materia
15. d down the square support bar The recommended height for typical applications is 50mm above the floor of the mixer Figure 7 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 Ex 50mm Mixer floor Figure 7 Height setting of the sensing arm HYDRO PROBE ORBITER USER GUIDE HD0215 REV 1 1 0 13 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 8 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 8 Adjusting the sensing head angle The angle of the sensing head face should be adjusted to provide consistent compact
16. dened wear head with easy calibration procedure for matching new microwave sensing head and arm to main electronics HYDRO PROBE ORBITER USER GUIDE HD0215 REV 1 1 0 7 1 4 Measuring techniques The Hydro Probe Orbiter uses the very 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 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 6 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 reinforcing collar that fits over the top of the arm see Figure 2 This is included to increase the strength of the arm CAUTION NEVER HIT THE SENSING ARM HYDRO PROBE ORBITER USER GUIDE 8 HD0215 REV 1 1 0 2 Installation process for mixers The Hydro Probe Orbiter may be clamp
17. e Orbiter or the control system 9 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 8306 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 boxes e Keep the number of joints in the cable to a minimum e Note that there is a M4 threaded hole provided on the back plate of the Hydro Probe Orbiter body for a ground connection 9 3 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 HD0215 REV 1 1 0 35 9 4 Ingredie
18. e 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 HD0215 REV 1 1 0 39 Notes HYDRO PROBE ORBITER USER GUIDE 40 HD0215 REV 1 1 0 11 Technical specification 11 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 11 2 Construction e Body stainless steel AISI 304 e Sensing head Hardened stainless steel wear resistant surface coating also available e Faceplate Alumina ceramic 11 3 Penetration of field e Approximately 75 100 mm dependent on the material 11 4 Operating temperature range e 0 60 C The sensor will not measure in frozen materials 11 5 Supply Voltage lt lt 15V to 30 V DC 4 watt max 11 6 Connections 11 6 1 Sensor cable e 6 pairs twisted 12 cores total screened shielded cable with 22 AWG 0 35mm conductors e Screen shield Braid with 65 minimum coverage plus aluminium po
19. ed inside the mixer wnrrrnnnrearaenres 11 Figure 5 Protective roof placed over the sensor 12 Figure 6 Removing the mounting bar clamp blocks ready for fitting to the 13 Figure 7 Height setting of the sensing 13 Figure 8 Adjusting the sensing head 14 Figure 9 Setting the sensor angle for optimum 14 Figure 10 The Hydronix angle aligner for sensing face 15 Figure 11 Cabling to the Sensor ooo afe Pate ste ola spese iet aaa a 17 Figure 12 Mounting the Hydro Probe Orbiter for conveyor belt applications 19 Figure 13 Mounting the Hydro Probe Orbiter for free fall applications conveyor and silo 20 Figure 14 Sensor cable 0090A connection 22 Figure 15 kde ee teh n Eo ERR RE UE ER Roa ex eres deua ed 22 Figure 16 Compatibility mode oae dte dete ee tas ttes taotakse sce c cR pup ta Ma 23 Figure 17 RS232 485 converter connections 24 Figure
20. ed to a vertically or horizontally mounted 25 35mm square 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 Cabling to the sensor 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 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 Two O rings have to be installed to the end of the barrel Strengthening Locking bolt A to collar be removed Figure 2 Installation of sensing arm into sensor body HYDRO PROBE ORBITER USER GUIDE HD0215 REV 1 1 0 9 e Lay the sensing arm on the same clean flat surface with the
21. ion of material against the ceramic measuring face and at an angle that avoids build up of material on the sensing head Hydro Probe Orbiter Centre of mixer Direction of material flow 1 4 to 1 3 R Figure 9 Setting the sensor angle for optimum performance HYDRO PROBE ORBITER USER GUIDE 14 HD0215 REV 1 1 0 e Anangle of 55 generally provides good results Use the angle aligner provided to set the angle Figure 10 e t has been found in some rotating pan mixers an angle of approximately 65 to the mixer centre is more appropriate to prevent too much build up of material e Ensure all clamp bolts are tightened to a torque of 28Nm 21lb ft after adjustment Aligner positioned against face plate pointed towards the mixer centre Figure 10 The Hydronix angle aligner for sensing 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 HD0215 REV 1 1 0 15 Notes HYDRO PROBE ORBITER USER GUIDE 16 HD0215 REV 1 1 0 3 Cabling to the sensor The cable to the sensor must be protected from the actions of the mixer and from damage that may be caused by the loading of aggregates into the mixer It is recommended that the cable be sheathed in a he
22. istor 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 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 6 K 2 Analogue Return Black H Screen Screen Table 1 Sensor cable 0090A connection Applies to analogue and multi drop connections HYDRO PROBE ORBITER USER GUIDE HD0215 REV 1 1 0 21 DK D E B A brown green blk white blue yellow red i i p Junction box e AE O Ea si n SUM m Ms m mm al m amp control cabinet AS kr 1 __ i O PNE E QUEE Ro EE SR Ko e 500R resistor for a 0 10V _ Positive Reum D B A Pose Reim Di Ww E a ll m 25 4 2 Analogue Output 2 Digital RS485 1 Analogue Output f Digital Supply 15 30V DC Input Input i Control Room Wiring Figure 14 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 sens
23. itch 3 ON Switch 5 OFF Switch 2 OFF Switch 4 OFF Switch 6 OFF Figure 17 RS232 485 converter connections KD485 STD Hydronix Part No Hydro Probe Hydro Probe 0049A Orbiter Orbiter P1 P2 PC S 1 1 S F RS485 A RS485 A gt or 9 way D Type PC i Control System mae S 2 2 S G RS485 B G RS485 B gt TX S 3 O RS232 A K full duplex RX 4169 7 Host System MO S E 5 Q 5 GND S 6 6 S Dip Switch Settings Power Supply S 9 7 35 DC m RJ11 S 8 4 RS232 vM port 1234 Figure 18 Din rail mounting RS232 RS485 converter HYDRO PROBE ORBITER USER GUIDE 24 HD0215 REV 1 1 0 Chapter 6 6 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 Hydro Probe Orbiter Parameter Range options Standard Default Moisture calibration A 0 0000 B 0 2857 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
24. l is the smoothest Normally this is a quarter or a third of the distance in from the outer edge of the mixer wall Figure 9 Supporting cross lt member supplied by customer Figure 3 Sensor mounted above the mixer on cross beam Reinforcement may be required Figure 4 Sensor mounted inside the mixer HYDRO PROBE ORBITER USER GUIDE HD0215 REV 1 1 0 11 Protective Figure 5 Protective roof placed over the sensor body 2 3 Fitting the square mounting bar A 25 35mm square bar should be very firmly welded to the appropriate cross member or static side wall of the mixer It should be suitably reinforced to provide a rigid fixing that will withstand the thrust generated on the sensor head and body from the moving material Ensure that the bar is perpendicular to the floor in both planes 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 HYDRO PROBE ORBITER USER GUIDE 12 HD0215 REV 1 1 0 Figure 6 Removing the mounting bar clamp blocks ready for fitting to the mixer 2 4 Mounting 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 an
25. lyester foil e Recommended cable types Belden 8306 Alpha 6373 e Maximum cable run 100 m separate to any heavy equipment power cables 11 6 2 Digital serial communications e Opto isolated RS485 2 wire port for communications including changing operating parameters and sensor diagnostics 11 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 11 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 11 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 HD0215 REV 1 1 0 41
26. nts e If the 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 Ifthe 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 demand and hence moisture content e Changes in ambient temperature also affect water demand 9 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 0000000 9 6 Calibration e Leave out the admixtures when calibrating e If the wet mix time i
27. or 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 5 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 15 Multi drop connection HYDRO PROBE ORBITER USER GUIDE 22 HD0215 REV 1 1 0 5 3 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 6 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 16 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 Figure 16 Compatibility mode 5 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 p
28. rmally be altered HYDRO PROBE ORBITER USER GUIDE 26 HD0215 REV 1 1 0 6 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 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 O amp O HYDRO PROBE ORBITER USER GUIDE HD0215 REV 1 1 0 27 Notes HYDRO PROBE ORBITER USER GUIDE 28 HD0215 REV 1 1 0 Chapter 7 7 Sensor care 7 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 i
29. s 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 32 HD0215 REV 1 1 0 8 2 2 Air and water calibration Can be used for mixer applications required when the Hydro Probe Orbiter is used on conveyor belts and freefall applications 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 5 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 of 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 21 hence the measurement is
30. s 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 CAUTION NEVER HIT THE SENSING ARM HYDRO PROBE ORBITER USER GUIDE HD0215 REV 1 1 0 29 Notes HYDRO PROBE ORBITER USER GUIDE 30 HD0215 REV 1 1 0 Chapter 8 8 Replaceable parts 8 1 Changing the sensing arm The sensing arm is a replaceable item The wear life of the 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 8 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
31. s 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 mix time must be long enough to obtain signal stability o Good measurement requires time HYDRO PROBE ORBITER USER GUIDE 36 HD0215 REV 1 1 0 9 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 batches of 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
32. section 2 1 8 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 8 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 For conveyor belts or freefall applications a separate AIR and WATER calibration is needed 8 2 1 Autocal Hydro Probe Orbiter used in mixer applications During any Autocal the ceramic face must be clean dry and free from obstruction This calibration can be performed in three ways e Using Hydro Com PC utility The sensor should be connected to a computer see section 5 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 avail
33. ting 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 1 FOR THE STATIC MOUNTING OF THE HYDRO PROBE ORBITER IN ROTATING PAN MIXER OR CONVEYOR BELT APPLICATIONS USING THE STANDARD SENSOR CABLE PART NO 0090A 1 2 Typical Mixers D type Eirich Croker and Turmac 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 sensing head end plate e Easily replaceable sensing arm and har
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