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Hydro-View User Guide

1. Analogue output to batch computer e Figure 1 Batch weighing example Connect the analogue output to the batch computer and set the output variable to AVERAGE The output range should be set according to the working moisture range of the material for most concrete batch applications the default values of 0 and 20 are appropriate Refer to nstallation later in this document for wiring details You may be tempted to short cut this approach in some of the ways described below if you do this you are unlikely to achieve satisfactory results and Hydronix cannot provide technical support under these circumstances Recommendations for best performance ALWAYS make use of the average hold facility Even if your batch computer is computing the average moisture value in the batch you will still need to display the average unscaled HYDRO VIEW USER GUIDE 00022 REV 1 06 11 APPLICATIONS OF HYDRO VIEW WITH HYDRONIX MOISTURE SENSORS input reading for calibration purposes which can only be done by providing the average hold input as described ALWAYS position the sensor so that the moisture value used is representative of the batch being weighed Generally this means positioning the sensor as close to the point of weighing as possible within the constraints of ensuring sufficient material covers the sensor ALWAYS perform the weight correction on the fly towards the end of the same weighing cycle S
2. i 15 d Input2 16 17 To terminal 7 e Figure 25 Digital inputs Terminals 13 and 17 are connected to an internal dc power supply which may be used as an excitation supply for voltage free contacts if required as shown in Figure 26 13 Input 1 Input 1 1 14 14 Input 2 Input 2 15 REN 19 16 16 17 Internal excitation External excitation Figure 26 Internal external excitation 60 HYDRO VIEW USER GUIDE 00022 REV 1 06 INSTALLATION Terminals 7 and 17 are connected internally if the internal supply is used for input excitation then galvanic isolation between analogue output and the digital inputs cannot be achieved A 500mA fuse FS2 protects the internal 24V supply from external wiring errors The fuse is a plug in type and is easily replaced should it fail Warning Do not attempt to use the internal 24V supply for purposes other than providing digital input excitation for the Hydro View Relay output connections The alarm and set point output relays are implemented using reed relays as shown in Figure 27 FS3 18 19 Common 500mA RLYT gt lt N 19 Alarm RLY2 gt Set point 1 RLY3 N 2 Set point 2 e Figure 27 Relay output schematic Care must be taken to avoid contact welding by fitting external contact snubber typically 100R in series with 0 1uF across the contacts when driving ind
3. 23 Power supply 2 2 vot 55 hoc me 61 R9232 i iode bert 35 71 39405 seit 35 72 station 35 ie TP 35 Ij rge D M 43 Select 21 Sensor 58 34 DOSIliOn uei reo tete 12 17 18 SOUP MENU ner pleines 32 Set Poit daredes raisini eases 25 28 Slo AER 22 SM 32 Storage bins 12 Trend display 12 25 Troubleshooting 64 Unscaled input sees 32 Water valve control 28 Weight 22 2 12 HYDRO VIEW USER GUIDE 00022 REV 1 06 81 Notes 82 HYDRO VIEW USER GUIDE 00022 REV 1 06
4. REA 37 Factory default settings tie a dedita ROT lette n 37 DENSOMSEILUP E 38 Output Setsup i tet Gat at tait tete e tme 38 5 oes 38 set up tte ei e ee aon d ade Gee i dette ems 38 Other paramleters tete em eet eet e at omes eee rec peii da ues 39 Suggested working values itt d Fede aiid Fede n 40 Sensor set up Letti rre a eL teet seated be 40 Output set up tem bedient cette t tte 40 sensor calibration est pre Er tp Meta api 40 oetspolnt set ulp c cm emt ctt t e tarte ete dae hy hae 41 Other paramieters uite te t e eget testas n Hat RS base t est A cote 41 Calibration and sampling 43 Recommendations for best 43 Equipment required x nitet e Real elt E os 44 Takitig the Samples e gated ilie pice 44 Batch mixer system sampling 44 4 HYDRO VIEW USER GUIDE D0022 REV 1 06 TABLE OF CONTENTS Continuous system sampling 45
5. Note that only the Low and High cut off values can be adjusted unless an access code is entered When this option is selected from the main menu you will first be prompted for the set point number which you wish to adjust 28 HYDRO VIEW USER GUIDE 00022 REV 1 06 HYDRO VIEW QUICK START Material in use The Hydro View stores calibration settings for up to ten different materials numbered 1 to 10 You must ensure that the material number in use by the Hydro View matches the material being presented to the sensor otherwise you will get erroneous moisture values Quite often the selection of material number may be controlled by an external system in which case you will not be able to adjust the material number from the Hydro View keypad although the current setting will be displayed To select the material number from the moisture display page Press display the Main menu The moisture display item is highlighted Press to highlight the Material in use item Press El again A pop up will appear Adjust to the required value as described in Changing operating values p27 press Elto accept the new value Return to the current display page by pressing HYDRO VIEW USER GUIDE D0022 REV 1 06 29 MATERIAL IN USE Notes 30 HYDRO VIEW USER GUIDE D0022 REV 1 06 Advanced user options and configuration The menu options described in this section are only available if the relevant access code
6. HYDRO VIEW USER GUIDE D0022 REV 1 06 41 SUGGESTED WORKING VALUES Notes 42 HYDRO VIEW USER GUIDE 00022 REV 1 06 Calibration sampling techniques When using Hydronix moisture measurement equipment it is customary to calibrate the equipment to read real moisture percentage since the sensor reading will be affected by basic physical dielectric properties of the material being measured Therefore it is necessary to make independent tests to determine the real moisture content A common method of determining moisture content is based on the desiccation drying of a sample and a suitable technique for use on site is described here With materials such as sand large variations of moisture content can be encountered in a single batch For instance with stockpiles of sand it is quite possible to measure 4 moisture level at the top of the pile and 16 towards the bottom When this material is loaded into the storage bins inevitably material is scooped from both the bottom and the top of the pile thus creating localised stratification of moisture in the bin As a bin is being emptied the stagnant material from the sides which almost certainly will be at a different moisture level periodically falls in with the fresh material Another feature is the dynamic state of the moisture content in a bin due to the free properties of the material This is even noticeable in small laboratory samples in plastic containers which if left to
7. MR 27 Figure 11 Changing en ete aden dee aee dede ed 28 Figure 12 Sensor diagnostic 34 Figure 13 Communications diagnostic 36 Figure 14 Sensor calibration emm nennen rernm 47 Figure 15 Group moisture 50 Figure 16 Twin bin grouped 51 Figure 17 Four bin grouped 53 Figure 18 Panel mounting the 55 Figure 19 Hydro View mains 56 Figure 20 Connecting the Hydro View to Hydro Probe 57 Figure 21 Sensor extension cable 58 Figure 22 Hydro View rear 58 Figure 23 Hydro View main circuit 59 Figure 24 Analogue output 60 Figure 25 Digital inputs 3 21 ln cete tan e dH de e Odd 60 Figure 26 Internal external 60 Figure 27 Relay output 61 Figure 28 Material selection using digital 62 Figure 29 Factory loop back test
8. emm 65 Figure 30 Using test blocks abe bebo EM 68 Figure 31 s 5232 56 POM iih E eee Dee deca rr ten dese RR DR UR n 71 32 5485 wn 72 Figure 33 RS485 module circuit 73 HYDRO VIEW USER GUIDE 00022 REV 1 06 7 Note This manual references older versions of Hydro Probe Sensors which have now been superseded by the Hydro Probe Il Hydronix recommends that all new installations should use the latest available sensor cable which should be connected to the Hydro View according to the instructions the Hydro Probe Il User Guide 8 HYDRO VIEW USER GUIDE 00022 REV 1 06 Introduction System overview The Hydro View provides display and control system interface facilities in an easy to apply form for a single channel of moisture measurement using any of the moisture sensors from the Hydronix range Key features include sensor input including power supply source for sensor m 0 10 4 20mA analogue output link selected option with working range scaled from front panel m Graphic display provides large characters for legibility and chart recorder displays of sensor measurements m RS232 serial port built in for communication to external systems or printer m Plug in RS485 multi drop serial port module extra cost option
9. m Two digital inputs that may be configured for batch averaging input filtering and material level functions m Sensor fault or out of range alarm relay output m Two programmable set point relay outputs m Panel mounting model 02 has 146x98mm facia dimensions with 140x92mm panel cut out Overall depth including IEC connector is 205mm Scope of this document This guide describes Hydro View model 02 and associated options as indicated on the rear panel label Earlier versions of the Hydro View do not contain all the features of the 02 and you should refer instead to the appropriate guide Organisation of this document This guide is organised into the following sections Section Readership _Description start select displays change working values etc Advance user Engineer How to configure the Hydro View for a particular options and application configuration Calibration and Supervisor amp How to take samples of the material in use and techniques channels average values How to install the Hydro View in a control panel and connect it to your control system Using Hydro View Engineer How to configure and operate the Hydro View for serial ports use with RS232 and RS485 communications HYDRO VIEW USER GUIDE D0022 REV 1 06 9 APPLICATIONS OF HYDRO VIEW WITH HYDRONIX MOISTURE SENSORS Applications of Hydro View with Hydronix moisture sensors The Hydro View is used in conjunction with any of the moisture s
10. The mains input voltage for the Hydro View is selected internally as follows 1 Remove the 7 screws securing the lid to the case 2 Remove the lid to reveal the mains transformer and 230 power supply assembly which is mounted on the 110 inside of the lid 100 Neutral 3 Move the BROWN wire to select the appropriate Earth mains voltage as indicated in Figure 19 opposite 4 Refit the lid and screws e Figure 19 Hydro View mains 5 Indicate the new operating voltage on the rear panel transformer using the labels supplied Field connections All field connections except mains and RS232 serial port are made via plug in screw terminal blocks located on the rear panel of the instrument You should refer also to the wiring labels fitted to the lid of the Hydro View The terminals numbered 1 through 21 are allocated as follows Terminal Group function Terminal Description group 1 Moisture sensor 15V sensor power e 14 10 sensorinput 1 5 OO 67 Analogue output 6 0 10 or 4 20mA analogue output 1 7 Analogue 8 12 RS485 serial port 8 i y O 8 DaB 01 SE __ 12 4 5485 0 for test purposes only 14 Jjpiialinptt 1715 1716 Digitalinputcommon 21 17 I
11. The station number has the top bit set as described in Basic Frame Format above The request field is returned unaltered The data field is a series of single bytes two hex digits code according to the request frame being processed Request frame types Command set The different types of request which a slave will respond to are given below in terms of the request code hexadecimal request data field and reply frame description Read Moisture request code 01 This will return the current moisture values from the slave together with some status flags Request data Format Description Material HH Two hex digits one byte representing the material number number to use in the range allowed by the Hydro View currently decimal 1 10 If this field is set to 00 then the material number in the slave will not be changed The slave will not allow its material number to be changed unless it is configured appropriately Reply data Format Description Now value Four hex digits two bytes LSB first representing the instantaneous NOW moisture in the slave The data transmitted is in 0 01 units Average value HHHH Four hex digits two bytes LSB first representing the batch AVERAGE moisture in the slave The data transmitted is in 0 01 units Control flags HH Two hex digits one byte representing some status flags as follows Bit Represent the state of the batch average hold function This is code
12. Digital input connections io ota eto 60 Relay output connections s it pe eta p eta p edes 61 Material selection using Digital sse emm emm nenne 61 Protection from lightning 5 8 63 Troubleshootiiig 2 ios iecit ands En oo has ipee bici te asocia d 64 Factory test display apa ee pep edi 64 Installation problems e E 65 Sensor installation faults cei e ER i yo eiae tet 66 Sensor e 67 HYDRO VIEW USER GUIDE D0022 REV 1 06 5 Using Hydro View serial ents nie ed ede e o Rn i dd ede 71 RS232 serial T 71 RS465 sefial died tt a utat tle t ett de 72 Installation of RS485 module bett Rt IO 72 RS485 connectons memo dee d oe ein dde rt eee E ecd ree ERG 72 RSA4S85 teriminatlon c eet He oca HE cog Ur eem ums ine ie 72 Data log mode iin Rmi mau nin 73 printmode i oue etiaai tite edicti tub dat 74 ASCGIIFleximmodes Rut o e oH neta te ES 75 ie M 75 ertet ee pi a e att p s 75 Line signalling i
13. REV 1 06 35 COMMUNICATIONS DIAGNOSTIC PAGE Communications diagnostic page This provides a page of information relating to the performance of the RS232 and RS485 communications ports and will be used to assist the installation and commissioning of a system The format is shown below RS232 RS485 Good 0 0 Bad reply xX Overrun lt Timeout Checksum Char err e Figure 13 Communications diagnostic The two columns of figures will increment as a communications event of the relevant type occurs The events are relevant only to ASCII Hex and Master port settings and are interpreted as follows Good No reply Bad reply Overrun Timeout Checksum Char err Input 1 Input 2 use The communications transaction was completed successfully The Hydro View issued a request but did not get a reply within a predetermined period The reply to a request contained invalid data or was of incorrect length Too many characters were received to process A frame start character was received but the rest of the frame did not complete within the allowed time The received frame of data contained an invalid checksum A character framing error occurred Two general purpose digital inputs are provided on the Hydro View However different applications may demand that these be used in different ways and therefore it is possible to configure each input for a specific use The options avail
14. To weigh 1 Kg Accurate to 0 1g Heat source For drying samples either hot plate or microwave oven Container For storing samples either bucket with sealable lid or polythene bags Scoop For collecting samples Preparation It is necessary to set the Hydro View to work in the Average mode when calibrating the system If the system is configured to work in the Average mode already then go to the Calibration section below To configure the system to work in the Average mode carry out the following Enter the main menu and log into the system using access code 336 Move down until Input 1 Use is highlighted and Press the enter key Record this setting to enable the system to be reset to the original configuration after calibration Press either the up or down arrow soft key until Average Hold is displayed Then press the Enter key A question will appear asking you to confirm any changes Return to the main moisture display Press Connect the following wiring and switch if not already connected Remove power from the Hydro View by pulling the power cord from the back of the unit Connect the following HYDRO VIEW USER GUIDE D0022 REV 1 06 13 CALIBRATION mhs Connect a single pole rocker switch across terminals 13 and 14 L p 16 16 Connect a wire link across terminals 16 and 17 Hydro View Rear connector gt Reconnect power to the Hydro View Calibration Read
15. View to be chosen from a list of supported languages Allows factory default parameters to be restored Executes a set of diagnostic programs on the Hydro View to verify operation of the unit The electrical properties of different materials can be quite diverse and it is often necessary to calibrate the moisture sensors to suit different materials Hydro View allows the calibration values for up to ten different materials to be stored internally in a material table which can then be recalled instantly by using a Material in use number This number can be selected either locally at the keypad or remotely using the serial ports The Hydro View uses a two point calibration method which requires you to enter values from two samples of material at different moisture contents A minimum difference of 196 in moisture content between the two samples is required to reduce possible calibration errors although a larger difference is preferable Parameter name Default Value Description Unscaled 1 Unscaled input value for calibration sample 1 Actual moisture value for calibration sample 1 000 Unscaled i 2 28 40 Unscaled input value for calibration sample 2 Moisture 2 11 00 Actual moisture value for calibration sample 2 SSD 000 SSD offset for this material HYDRO VIEW USER GUIDE D0022 REV 1 06 31 SENSOR SET UP MENU The basic calibration procedure is as follows Monitor the Unscaled Input display on Hydr
16. be avoided Language selection The Hydro View now supports operation in many common languages with additional support being added as required To select the operating language choose Language from the main menu and simply select from the list of available languages shown Factory default settings Prior to shipment by Hydronix the Hydro View operating parameters will have been set to default values Since these are quite numerous it is useful to be able to reset them all to a known state particularly when first commissioning a system Selecting Factory defaults from the main menu produces a display referring the reader to this manual This is to avoid unintentional resetting of the values To restore the factory defaults press the centre and right hand function keys simultaneously A confirmation pop up box will appear which you must accept before the default values are restored The current default values are tabulated in the following pages Use the right hand column in each section to record the values you have used in your system A copy of these tables will also be helpful should you need to call Hydronix for technical support HYDRO VIEW USER GUIDE D0022 REV 1 06 37 FACTORY DEFAULT SETTINGS Sensor set up Parameter name Default Value Your value Notes Samples delay poe Maximum volts 12 0V Trend upper 96 20 00 Type 1 Trend step s Output set u
17. has been applied The controls are modelled on those of a tape recorder HYDRO VIEW USER GUIDE 00022 REV 1 06 25 TREND DISPLAY PAGE HYDRO VIEW Display next trace Record H Pause e Figure 8 Trend display The current value of the variable whose trace is being displayed is shown at the top left hand corner of the display For clarity on the small display the vertical axis is not labelled However the traces are scaled according to the values programmed in the Sensor set up menu You can select the trend display from any non menu display page using the following keys Press display the Main menu The moisture display item is highlighted gt Press to highlight the trend display item Press again to select the trend display page Once the record option has been chosen the most recent 100 values will be recorded continuously until the pause option is chosen even if another display page is selected in the meantime You can adjust how often a reading is taken by the trend display from the Sensor set up menu 26 HYDRO VIEW USER GUIDE D0022 REV 1 06 HYDRO VIEW QUICK START Changing operating values Hydro View operating values or parameters are organised in lists of related items The method for changing these values is described below Choose the list you wish to examine from the Main menu and then select the item you wish to change by highlighting it using the soft keys
18. is configured as a Master on the other serial port The data stream is again in ASCII format and contains the GROUP moisture values updated according to the programmed data log rate The data format used is as follows lt STX gt MMM MM NNN NN AAA AA lt CRLF gt where lt STX gt is the ASCII start of text character hex 02 MMM MM is the group M1 value in the ranger 99 99 to 99 99 NNN NN is the group M2 value in the range 99 99 to 99 99 HYDRO VIEW USER GUIDE D0022 REV 1 06 73 BATCH PRINT MODE AAA AA is the group average moisture value in the range 99 99 to 99 99 lt CRLF gt is the ASCII carriage return line feed combination hex OD hex 0A Batch print mode The Hydro View provides a report at the end of a batch as determined by the state of the average hold input on the relevant port which may be printed or captured by an external device This data stream is in ASCII format and contains the NOW and AVERAGE moisture values updated once per second The data format used is as follows Now NNN NN Avg AAA AA lt CRLF gt where NNN NN is the NOW moisture value in the range 99 99 to 99 99 is the AVERAGE moisture value the range 99 99 to 99 99 lt CRLF gt is the ASCII carriage return line feed combination hex OD hex 0A The data rate format used is 9600 baud 8 data bits no parity 1 stop bit This cannot be altered The batch print format changes when the unit
19. materials Recommendations for best performance ALWAYS site the Hydro Mix sensor in the most appropriate place for the mixer design The position chosen should ensure that the sensor is covered by sufficient material at all parts of the mixer cycle and is not in an area prone to build up of waste material which would lead to erroneous readings General advice on this can be found in the Hydro Mix sensor data sheet and by contacting your Hydronix supplier HYDRO VIEW USER GUIDE D0022 REV 1 06 17 ALWAYS pay attention to the sensor filter requirement Static pan mixers in particular create large air pockets in the mix which cause large spikes in the sensor reading The digital filter built into the Hydro View is quite effective at removing these and the constants given in Suggested working values p40 should be adequate for most pan mixer applications ALWAYS ensure that the sensor reading has stabilised within the required tolerance band before taking a reading This indicates that the mix is homogeneous This may mean extending the mixing time accordingly although excessive mixing times should be avoided to prevent damage to the mix ALWAYS position the sensor so that it is easily inspected without removal i e so that it can be clearly seen from an inspection door NEVER reduce the digital filter constants so low e g 0 01V as to make the signal response very slow although this will produce a stable reading it will probably be
20. this is the moisture content of the sample Repeat the drying sequence for another 1kg removed from the sample above If the moisture is different by more than 0 1 then one of the samples was not dried out completely and the test has to be restarted Record the average of the two readings 14 HYDRO VIEW USER GUIDE D0022 REV 1 06 BATCH WEIGHING CALIBRATION PROCEDURE Inputting the calibration into the Hydro View Unscaled I P 2 and moisture 2 must always be of a higher moisture content than Unscaled I P 1 Moisture 1 If the factory default figures for Unscaled Input 1 and Moisture 1 are displayed and the new moisture calibration figures are higher than the displayed Unscaled input 2 and moisture 2 then the displayed Unscaled Input 2 and moisture 2 should be transferred into Unscaled Input 1 and Moisture 1 and the new figure entered as Unscaled Input 2 and Moisture 2 Select Sensor Calibration from the Hydro View main menu gt Input the material table number for the material code to be calibrated Enter the new calibration figures Before exiting the calibration check that the calibration makes sense The M value displayed at the bottom of the display should be in the range 0 3 0 6 If it is outside this range the figures input should be checked and the method of collecting and drying the sample checked If all is correct with the data then contact Hydronix for further assistance Exit the calibration page by p
21. 06 INSTALLATION Notes HYDRO VIEW USER GUIDE 00022 REV 1 06 69 Using Hydro View serial ports RS232 serial port The RS232 connection is via a 6 way RJ11 style plug Hydronix can supply a standard 2m lead terminated in a 9 pin female D type for connection to a IBM PC compatible communication COM port please ask for details Model HVO2IAIB CIDIETFIGIHLTTJ 4 10 e 230V foo Fuse 250mA Manufactured in England by Hydronix Cranleigh GU68JJ 89 336 WARNING THIS UNIT MUST BE EARTHED 1121314151617 819 10 11 13 114 15 16 17118119 20 21 BEBEEEBEBEEEEN ERR Serial no 123456 AA d 1 6 RS232 serial port e Figure 31 RS232 serial port RJ11 Pin Signal relative to Hydro View PC compatible 9 way 1 Request to send biassed internally to active state Note to ensure that the system meets the requirements of EMC directive 89 336 EEC the cable should be fitted with a ferrite rf attenuator close to the RS232 socket of the Hydro View when the serial port is in use HYDRO VIEW USER GUIDE 00022 REV 1 06 71 RS485 SERIAL PORT RS485 serial port The RS485 serial port provides an optically isolated twisted p
22. 2672 2 259 Bxa e ane ee ee e e ee e e ee e ee ee ee e e ee e e ee eo e e eo e e eo e ee e e e 1 1 e 1c e oich e c19 eC S 9 8 ojojo e e ee ee ee e e e ee e ee ee Y ee le o 6 e e Position 1 2 4 20mA source e 2 Position 2 3 0 10Vdc Semis 7 Figure 23 Hydro View main circuit board Wiring details are shown in Figure 24 Note that the analogue output shares a common supply rail with the internal 24V supply connected to terminal 17 see Digital input connections on page 60 for further details The working range of the analogue output is set in the Output set up menu see p33 HYDRO VIEW USER GUIDE D0022 REV 1 06 59 SENSOR CONNECTIONS HYDRO PROBE Jumper 6 C fiov 17 e Figure 24 Analogue output wiring Digital input connections The two digital inputs terminals 14 amp 15 share a single common terminal 16 and are arranged internally as shown in Figure 25 13 FS2 e gt lt 14 500 Input 1
23. 85 usage RS232 port is unused The current moisture values are transmitted periodically as determined by the Data Log Rate parameter Provides two way communication between the Hydro View and another system using a simple ASCII Hex protocol The port acts as a master device to another Hydro View unit configured for ASCII Hex on its RS232 port See Grouping channels p49 for further details The port will print a report of the moisture variables each time the Average hold input is turned off thus providing an end of batch report All information received by the RS485 port will be retransmitted on the RS232 port By connecting the RS232 port to a personal computer running a terminal emulation program it is possible to monitor what is happening on the RS485 port for testing purposes This will output the sensor voltage reading at a rate of 100 samples per second It is normally used to capture the signal wave form from the sensor for testing purposes The value is output as a four digit hexadecimal number where 0000 corresponds to 0 00V and 7FFF corresponds to 12 00V The optional RS485 serial port may be configured to operate in a similar way to the RS232 port However the RS485 port allows multi drop communication on a simple twisted pair cable permitting several moisture measurement channels to be interfaced with a single communications port Permitted options are Disable Data Log ASCII Hex Master Batch Print RS485 por
24. Description STX Station number 83 slave reply sets the top bit Request code 01 read moisture STX _ NOW value hexadecimal is 02A3 Converting this to decimal gives 675 or 6 75 AVERAGE value in hexadecimal is 0271 Converting this to decimal gives 625 or 6 25 Status flags indicating Unit is in average hold delay period Set point 1 is ON Set point 2 is OFF Material level is OK Alarm output is OFF Checksum 7E 33 a 30 32 37 31 30 32 31 31 15 22203 78 HYDRO VIEW USER GUIDE 00022 REV 1 06 Appendix Access codes The Hydro View supports several levels of operator access each protected by an appropriate code which is entered at the Access code option in the Main menu Facilities enabled by entering an access code will remain active until a new code is entered The access codes are fixed in current models of Hydro View For security reasons you are advised to remove this page from the manual if necessary to prevent unauthorised access to the Hydro View parameters Access code Facilities 0 default View main displays and adjust set point ranges 190 View diagnostic displays and calibrate sensor 213 Engineering level other than communications related parameters 336 Full engineering access 1459 Reset factory defaults and display factory test page Electromagnetic Compatibility Directive 89 336 When installed and operated according to the instruc
25. Drying the samples rar EHE Heus HE dote d 45 Recommendations for best 45 Calculating the moisture 45 Entering results into the Hydro View 46 What happens with your results reet nets E E aee or ARI ERR Te CUR EDI Ee LUN 46 Grouping Channels seit rate atem mtt EL 49 Group moisture varlables rt cte last seat dt e E Mh Fett ubi ter iced quid 49 Group moisture display mete mete etm rt tem e etn b e i 49 Effect of communications errors on grouped systems 50 Example a twin bin grouped system using 5232 51 Example a four bin grouped system using RS485 52 55 Power SUPPIY CONNECTIONS de pls 55 Adjusting the Hydro View mains operating voltage em 56 Field corinectlons Eee beoe tet citet bud ias 56 Sensor Connections Hydro Probe 57 Installation guidelines t edocti ota oe dota eden aded 57 Connecting the Hydro Probe II to the Hydro View 57 Sensor Connections Hydro Probe 58 Analogue output connections gt itte o iced ice ea ede 59
26. Hydro View User Guide Refer to Page 13 for Calibration Procedure when used in Batch Weigher system Applications Hydronix part number 00022 Revision 1 06 Revision date 12 June 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 1996 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 docum
27. RO VIEW Group M2 reading Alarm pop up indicates that alarm condition exists e Figure 15 Group moisture display Effect of communications errors on grouped systems The communications links between the master unit and the slave units should be trouble and maintenance free if correctly installed However in the event that a communications error occurs between the master and a slave the slave station will be taken out of the system for a few seconds to allow it to recover and automatic retries will be performed periodically These errors are most likely to occur during power up power down of slave systems A slave unit which has been powered down will be brought back on line automatically within a few seconds of power being applied Performance of the communications link can be viewed on the communications diagnostic page on the master Hydro View 50 HYDRO VIEW USER GUIDE 00022 REV 1 06 GROUPING CHANNELS Example a twin bin grouped system using RS232 Figure 16 shows probably the most common requirement for grouping moisture channels together The majority of batch computers only provide a single channel of moisture input and when feeding simultaneously either from two bins or from another gate on the same bin there is no provision for combining the results of two moisture measurements In this case the Hydro View on the left would be configured as a MASTER on its RS232 port whilst that on the right
28. Sensor setup menu Type Samples A H Delay s dV Coarse HYDRONIX HYDRO VIEW _ Select the parameter using this key Highlight the required parameter using these keys e Figure 9 Selecting parameters Press again the soft key legends will change to allow the value to be edited in a pop up window Restore previous value Accept new value 1 Exit Increase Decrease e Figure 10 Changing a value gt Holding down Iii or will allow the value to be changed rapidly the rate accelerates as you hold the key down The value is bounded at lower and upper limits beyond which it cannot be changed and sometimes these limits will be based on the current values of other items Press keys to accept the new value or press to restore the previous value If nothing happens when you press over a highlighted value you do not have permission to change this value and will need to enter the appropriate access code HYDRO VIEW USER GUIDE D0022 REV 1 06 27 ADJUSTING SET POINTS Sometimes the parameter is not numeric but is instead one of a list of options In this case ill or will step through the list Restore previous value Accept new value New n menu Language Spanish e E a Exit Increase Decrease e Figure 11 Changing options Usually the new value will not take effect
29. TALLATION Contact your distributor for further details if any of the above fail to operate correctly CO CO I mm Nr Re c 5232 Port 11 conector 9 pin D type Installation problems connector e Figure 29 Factory loop back test wiring The table below lists some symptoms that may be encountered during installation of the Hydro View If you are unable to solve the problem please contact your Hydronix distributor Symptom Probable cause Remedy Blank display Display contrast set Adjust contrast See Display contrast incorrectly adjustment p21 No mains power Check mains supply and IEC inlet fuse If fuse blows repeatedly contact your supplier Sensor readings No sensor power Check internal fuse FS1 and replace if do not change supply required see Figure 23 p59 See also Sensor installation faults overleaf Incorrectly wired cable Bad sensor location HYDRO VIEW USER GUIDE 00022 REV 1 06 65 SENSOR INSTALLATION FAULTS Symptom Probable cause Cannot see Access code not required menu entered item Unable to enter Incorrect order of calibration moisture value values No analogue Fuse blown output Analogue output does not change Output set up is set for Calibrate variable Digital inputs do No inp
30. able are Ave Hold Coarse Fine Level Material Sync Input is used to control batch averaging of the moisture value Relevant only to batch applications such as ready mix plants Input is used to select between the Coarse and Fine filter control values set in the Sensor set up menu This is relevant only to mixer applications in pre cast and similar industries An input indicates that sufficient material is covering the sensor and therefore that the value from the sensor can be used in the averaging process Relevant only to batch applications such as ready mix plants In no inputs are configured as evel inputs the material level is always deemed to be acceptable by the Hydro View Input is used to control material number selection One of four materials may be selected in this way as described in Material selection using digital I O Input is used to synchronise sensor readings to some external timing signal Useful in certain batch mixer applications to help remove unwanted noise 36 HYDRO VIEW USER GUIDE 00022 REV 1 06 ADVANCED USER OPTIONS AND CONFIGURATION Since there are only two physical inputs available on the Hydro View it is not possible to use all of these facilities on a single installation However it is most unlikely to need any more than two facilities on the same system and so there is not usually a problem Setting both inputs to perform the same function will lead to unspecified results and must
31. air interface between multiple Hydro View units and a host computer or master Hydro View Installation of RS485 module The RS485 interface is supplied on a plug in module which must be inserted into the Hydro View unit unless this was installed as a factory option gt Remove the screws securing the lid of the Hydro View Lift the lid off the unit to expose the circuit board Locate the RS485 module connector on the circuit board as shown in Figure 23 on page 59 Plug the module into this connector only one orientation is possible gt Refit the lid and screws RS485 connections The Hydro View implements RS485 using a two wire interface This is shown in Figure 32 pie Tx Rx De x re 3 B Master 89 89 Hydro View Hydro View 2 Wire RS485 interface e Figure 32 RS485 interface Shielded twisted pair cable is recommended for EMC purposes The shield should be connected to ground at one end only to minimise capacitive coupling the twisted pair cable will minimise magnetic coupling RS485 termination Note that the twisted pair cable should be terminated at each end in a resistor equivalent to the characteristic impedance of the cable used typically 100R 0 5W These are indicated by Rt in Figure 32 The RS485 module shown in Figure 33 contains a termination resistor which may be placed in circuit by inserting jumper J3 on
32. application It is recommended that you leave power applied to the Hydro View wherever possible as this will also help to maintain the moisture sensor at normal working temperatures Keypad The keypad is of a sealed membrane switch construction using dedicated keys for the most commonly used operator level functions Legend Name Description Yes Confirms changes to data items Also cancels an audible alarm Cancels changes to data items x Also used to adjust display contrast Context sensitive help facility Select When pressed causes a menu to be displayed or selects the ER highlighted item on the menu HYDRO VIEW USER GUIDE D0022 REV 1 06 21 MOISTURE DISPLAY PAGE Legend Name Description Soft key Allows selection of options displayed above the key which are described in Soft key legends next Soft key legends Legend Name Description Return to the previous display or menu EON up Moves the ee eee cursor to the previous menu item Moves the eed cursor to the next menu item Increment When editing a numeric value causes the value to be value incremented Holding the key down will speed up the count Decrement When editing a numeric value causes the value to be value decremented Holding the key down will speed up the count oe O Indicates more available Lu recording data Moisture display page When power is applied a start up display is shown for a fe
33. at REQUEST Two Two ASCII Hex characters representing a request to ASCII Hex be processed Valid request codes are in the range characters 01 FF but only certain commands will be recognised by the Hydro View see below Two As required by the COMMAND field ASCII Hex Data entities larger than one byte are transmitted characters per low byte first in keeping with the order used by Intel byte of data family processors such as those in the IBM PC which allows data to be streamed directly into a C data structure for example without re ordering of data Motorola family processors will need to assemble the data bytes accordingly for both transmission and reception CHECKSUM Two Byte wise exclusive OR XOR of all characters from ASCII Hex the station number to the end of data inclusive characters ETX Frame types The master device issues request frames These frames either solicit data from the slave or send information to the slave for it to process or a combination of both The slave can respond to a request in one of four ways m It processes the request and issues an acknowledge frame back to the master m t processes the request and issues a reply frame back to the master containing some data m It does not process the request because the request was invalid although not corrupted An acknowledge frame is then sent containing an error code m does nothing In this case the slave may have detect
34. be configured as a MASTER on its RS485 port whilst the remainder would be configured for ASCII HEX on RS485 with a station address of 1 2 or 3 as appropriate The units would be coupled together with a single twisted pair RS485 cable as described in Installation The analogue output of the master unit would be connected to the batch computer and the analogue output variable set to Group Average This variable is the batch average of the four channels which is what is required when all four bins are feeding at the same time The Group Average variable automatically caters for situations where for some reason batching is performed from less than four bins or gates In addition a bin level sensor input can be provided level sensor not supplied by Hydronix to prevent moisture errors in the event that one bin runs empty during a batch 52 HYDRO VIEW USER GUIDE 00022 REV 1 06 Material storage Level sensor optional Gate open limit switch GROUPING CHANNELS 5 Hyaro Probe Station 3 Station 2 RS485 twisted pair Master Station 1 Analogue output to batch computer e Figure 17 Four bi
35. cations diagnostlc i 36 Connections iuret eerie 56 belt 2 18 Data l0 CIE 35 73 Default settings 37 Display contrast 21 tein 64 iiio ioter 17 25 Front panel orent rte tena 21 Fuse FS 58 61 FSS 61 Gate Signalons erroi 11 Grouping 12 EoD o 49 24 o 21 uem 16 11 2 4 18 Inputs 36 60 55 Keypad 21 Language 31 37 Lightning protection 63 Main MENU m 24 Material EE TE A 25 29 SCICCHON 61 selection mode 34 Moisture 23 emere 11 display 22 group values 23 ninm 23 o nme 12 T
36. cordance with the information given in Figure 21 p58 Take particular care with the cross over between pins 2 and 3 of the Bulgin connector and terminals 2 and 3 at the Hydro View Also ensure that the two ground connections at pin 3 of the Bulgin are made correctly and that stray wire strands from the cable shield are not shorting to other pins within the Bulgin connector Disconnect the sensor from the Hydro View by unplugging the terminal block Use a voltmeter to check the sensor power supply voltages at terminals 1 2 14 5 to 15 5Vdc and 3 2 14 5 to 15 5Vdc at the rear of Hydro View If this test fails the 66 HYDRO VIEW USER GUIDE 00022 REV 1 06 INSTALLATION fault is in the Hydro View and may be a blown fuse check FS1 and replace if required see Figure 23 59 Later revisions of the 02 are fitted with re settable fuses so remove power for about 30 seconds and try again Disconnect the sensor at the 6 pin Bulgin connector Replace the terminal block on the Hydro View and repeat the measurements in 2 above A change in the indicated measurements suggests there is a fault in the extension cable wiring When using Hydro Probe Il Hydro Mix sensors the 15Vdc power supply rail is unused but this voltage should still be checked if the wiring is present Now reconnect the sensor and repeat the measurements in 2 You may find that the voltages reduce slightly On older Hydro View units model 1 the voltage a
37. cross terminals 3 2 will drop significantly but should still be in the range 5 to 15 5V If this test fails there may still be a fault in the extension cable wiring but also possibly a fault either internal to the sensor or in the short length of cable connecting to the sensor Verify that the power supply voltages for the sensor are present at the sensor end To do this you will need to unscrew the Bulgin connector on the extension cable side so that you can measure voltages with the sensor connected Measure this time across pins 1 3 12V to 15 5V and 2 3 5V to 15 5 Check that the sensor output signal can be measured between pin 4 and 3 at the Bulgin connector and terminals 4 and 5 at the Hydro View The signal should change according to the moisture content see below To do this test it may be necessary to remove the sensor from its installed location Check that the signal voltage measured across terminals 4 and 5 on the rear of Hydro View is the same as the displayed voltage shown on the Sensor Diagnostics display mV Differences of more than 100mV measured on an appropriate meter range suggest a fault within the Hydro View itself Sensor characteristics The sensor output signal is a DC voltage that varies inversely and in a non linear manner with the moisture of the material being measured The approximate response of a sensor is as indicated in the table below 1 Condition Approx Sensor Volts DC Ve
38. d numerically as follows 0 Hold state 1 Timing Average hold delay 2 Averaging 3 Low material level 4 F currently undefined 4 5 7 HYDRO VIEW USER GUIDE 00022 REV 1 06 77 ASCII HEX MODE This is currently the only request frame type supported but meets most application requirements Additional facilities will be added at a later date Timing constraints The ASCII hex protocol requires a communications link of reasonable performance particular m slave station will time out if the request frame does not complete within period of 0 2 seconds following receipt of the STX character m The slave will normally respond within 0 1 seconds of the request frame being received An upper limit on slave response time is set at 1 second after which the slave will not begin a transmission This figure is important to know for multi drop systems i e either 2 or 4 wire RS485 to prevent subsequent transmissions from being jammed by a late slave reply ASCII Hex protocol examples Read Moisture request The following request frame will read the moisture data from station number 3 setting the material number to 5 in the process ASCII Character code in hex Description STX Station number 03 Request code 01 read moisture Material number 05 Checksum 07 MS 33 30 i 35 30 ET typical response to this frame might be ASCII Character code in hex
39. e Hydro Probe and Hydro Skid products Group 1 2 Additional values computed in various ways from a group of Hydro and Avg Views operating together see Grouping channels p49 values It is legitimate for the moisture value to display a negative value in some processes this is a useful measurement related to water absorption whilst in others it may indicate that the calibration of the sensor is incorrect Note that the Average value is not indicated immediately but is shown the first time that the value is computed following the application of power to the Hydro View Thus systems not using the averaging facility will only see the Now moisture value displayed in large characters at the top of the display You can select the moisture display page from any other non menu page using the following keys Press to display the Main menu The moisture display item is already highlighted gt Press E again to select the moisture display page Max Min 96 display The maximum and minimum instantaneous moisture values occurring within an averaging period are recorded by the Hydro View and may be displayed on demand by pressing the left hand soft key maximum 96 or centre soft key minimum 96 The maximum or minimum value will replace the NOW value in the lower left hand corner of the moisture display page whilst the associated key is held down Note that these values are only available when the batch averaging facility is be
40. ead average hold status Read level input status m Set current material number The Hydro View communications port acts as SLAVE device when running the ASCII Hex protocol i e it will transmit data only in response to requests from your external device Future issues of the Hydro View system firmware will support additional operations via the serial port and these will be documented in updates to engineering note 0005 and later incorporated into this manual Physical connection The ASCII Hex protocol can be used on either the RS232 port which is fitted as standard to all Hydro View units or on the optional RS485 port which may be fitted as an optional extra Line signalling information The ASCII Hex protocol operates only at 9600 baud using 8 data bits 1 stop bit and no parity Basic frame format Data frames on the communications link are constructed as indicated in the table below Field Format Description Start of frame STATION Two Represents the station number of the relevant ASCII Hex Hydro View characters Valid slave station numbers are in the range 01 7F 1 127 decimal Reply frames from slave stations have the top bit of the station number set and thus reply station number fields are in the range 81 FF The purpose of this mechanism is to allow discrimination between request and reply data frames over a two wire RS485 link HYDRO VIEW USER GUIDE D0022 REV 1 06 75 ASCII HEX MODE Field Form
41. ed an error usually corruption but cannot reply because to do so may result in further errors An example of this may be a faulty checksum in the request the slave cannot reply here since it would not be certain that the station number itself had not been corrupted In this case the slave will ignore the faulty frame and attempt to synchronise to the next STX character Request frame format Issued by the master station Format as per table in Basic Frame Format above Acknowledge frame format Issued by slave stations The station number has the top bit set as described in Basic Frame Format above The request field is returned unaltered The data field is a single byte two hex digits code from the following table Code Mnemonic Description NL GL The request frame was received and processed without error 01 BAD REQUEST The request field of the request frame was not understood by the slave This may mean that the version number of the firmware running in the slave is out of date 76 HYDRO VIEW USER GUIDE D0022 REV 1 06 USING HYDRO VIEW SERIAL PORTS Code Mnemonic Description 02 BAD_DATA The data field contained data which was out of range for the specific request 03 BAD_LENGTH The frame length was incorrect for the request This would normally mean that you have supplied either too little or too much data Additional acknowledge codes may be added in future versions Reply frame format Issued by slave stations
42. ed with a desiccation test on a large sample of the batch to within 0 2 NEVER attempt to use the displayed value for manual input into a batch computer for weight correction if it is possible to interface directly This relies on an operator to input the value which at best will be one batch behind and at worst will never be done 12 HYDRO VIEW USER GUIDE 00022 REV 1 06 BATCH WEIGHING CALIBRATION PROCEDURE Batch weighing calibration procedure The procedure detailed below will enable the Hydro Probe when connected to a Hydro View to be used with confidence and accuracy Ultimately the accuracy of the system will only be as accurate as the method of sampling and drying Therefore great care must be taken when gathering and drying samples The Hydro View is provided with factory default values stored in memory These default values are for initial installation set up and allow the system to be used straight from the box To accurately calibrate the system two samples of aggregate are required with at least 2 3 moisture minimum of 1 difference and the aggregate flowing in the dynamic state On initial installation it can be difficult to obtain two different moisture values in one day For this reason the Dry bucket Method may be used for the second moisture value This should not be used as the final calibration value but will enable the system to work until a different moisture content is available Equipment required Scales
43. ensors from the Hydronix range Applications of the sensors normally fall into one of the following categories m Where the average moisture content of a batch of material is required the material passing over the sensor only once during the batch An example of this is in the batch weighing of materials out of a storage bin with the moisture sensor normally a Hydro Probe but possibly also a Hydro Skid mounted in or close to the outlet of the bin This type of application is referred to as a Batch Weighing application in this manual m Where the moisture content of batch of material is measured continuously with the material being recycled over the sensor which in this case would normally a Hydro Mix An example of this is a batch mixing application where the homogeneity of the batch is important This type of application is referred to as a Batch Mixing application in this manual m Where the moisture content of a continuous stream of material is required The material passes the face of the sensor only once but the moisture value is then used as a feedback signal in a control loop An example of this would be a Hydro Skid sensor mounted on the output conveyor of a continuous mixing system This type of application is referred to as a Continuous process in this manual Each of these categories of applications would require the use of different facilities and settings within the Hydro View The selection of appropriate Hydro View facilit
44. entation are given by Hydronix in good faith Hydronix welcomes comments and suggestions relating to the product and this documentation This documentation is intended only to assist the reader in the use of the product and therefore Hydronix shall not be liable for any loss or damage howsoever arising from the use of information or particulars in or any error in or omission from this documentation AKNOWLEDGEMENTS Hydronix Hydro Probe Hydro Skid Hydro Mix Hydro View and Hydro Control are Registered Trade Marks of Hydronix Limited Author R E B Holland B Eng C Eng MIEE Table of contents Table contents EE 3 0 PR 9 RYEIulBo Uu MEE 9 Scope of this 9 Organisation of this 9 Applications of Hydro View with Hydronix moisture sensors 10 A batch weighing 11 Batch weighing calibration procedure 13 ec lorum ee 14 Dry Bucket method 15 Methodi ere Re 15 A batch mixing 2 0 17 A CONTINUOUS 19 Hydro View quick start 21 Hydro View front 1 6222 220 560 0000000000 0000000 000000 nnn nr tenent nere nenne
45. equipment NOW Selects which moisture variable will be output Options available are Now described elsewhere Average described elsewhere V Clip sensor voltage after rate limiting filter has been applied Calibrate provides a fixed value determined by the Calibrate parameter above Group M1 Group M2 Group Avg see Grouping channels pon page 49 HYDRO VIEW USER GUIDE 00022 REV 1 06 33 SENSOR DIAGNOSTIC DISPLAY Sensor diagnostic display This is provided so that Hydronix technical support can assist you in the event of any problems with the system The information contained is of an engineering nature and will not normally be used However a brief description is shown in the diagram below Sensor software task results Sensor diagnostic PA Conversions 12456 Clipped input in mV Messages 12735 1 Sensor input mV ueue errors 0 mV 6253 Clip 6152 L 1232 Lavg 1276 Unscaled average Instantaneous 1034 Mavg 1065 unscaled input 7 r1 Instantaneous Average moisture value moisture value e Figure 12 Sensor diagnostic display This information is updated continuously so a description of what is happening to this display is quite useful in the diagnosis of any problems Audible Alarm The Hydro View will turn on its alarm relay output under a number of conditions m When the sensor voltage is outside the range programmed in the Sensor Set up menu Th
46. erial Hence the following formula is used _ 100 Where HYDRO VIEW USER GUIDE 00022 REV 1 06 45 ENTERING RESULTS INTO THE HYDRO VIEW Moisture content A weight of container B weight of container and wet sample C weight of container and dry sample Entering results into the Hydro View When you have obtained the moisture content of the sample you need to enter this value together with the corresponding unscaled input value into the relevant material table Calibration results are entered in the following way Select Sensor Calibration from the main menu You will be prompted to enter a material number with which to associate the results Enter the unscaled input and associated Moisture 96 in positions 1 or 2 on the page as appropriate The Hydro View requires that the higher moisture content value is entered in position 2 As the values for the two calibration points are entered the values of m and c are updated dynamically These values describe the slope and intercept of the moisture calibration line which the Hydro View will use to calculate the moisture reading from the unscaled sensor input When you finish entering the values you will be asked to confirm whether or not the system is to be updated If you accept then the material calibration table will be updated and if this material number is currently in use the sensor calibration will be changed What happens with you
47. f the valve controller Systems such as this have been used successfully in the tempering of materials such as clay and PFA Dry material Water Analogue output to control system Continuous mixer Hydro Skid sensor e Figure 3 Continuous mixing process Recommendations for best performance ALWAYS site the moisture sensor in the most appropriate place for the application preferably as near to the control point as possible to minimise time lag without compromising the homogeneity of the material passing the sensor The position chosen should ensure that the sensor is covered by sufficient material at all times during measurement and is not in an area prone to build up of waste material which would lead to erroneous readings General advice on this can be found in the Hydronix moisture sensor data sheets and by contacting your Hydronix supplier ALWAYS ensure that the sampling and filter parameters are set appropriately for the application guidelines are given in Suggested working values p40 ALWAYS provide some means of detecting an empty belt condition when using the Hydro Skid sensor In many cases simply setting the sensor maximum voltage parameter to a suitable value will suffice The purpose of this would be to prevent the control loop adding water to apparently very dry mater
48. g in close proximity to the sensor These unwanted signals form noise in the system and would result in errors in the reading if they were not filtered out Fortunately these noise spikes are characterised by being of short duration and having relatively fast rise and fall times and may therefore be effectively eliminated by filtering the input signal in a manner appropriate to the application The Hydro View uses the parameter list in the Sensor set up menu to control how the raw voltage signal from the sensor is processed to derive the moisture content Parameter Default Description Defines the signal processing algorithm used for this sensor moisture reading Range 1 gt 1000 and the start of averaging Range 0 0 gt 100 0 seconds 1 Delay Time interval between a sync signal arriving at a digital input and a sensor reading being taken Used to synchronise the readings to external events The Sensor Type parameter must be set to 2 for this to be used Range 0 00 gt 10 00 seconds 32 HYDRO VIEW USER GUIDE 00022 REV 1 06 ADVANCED USER OPTIONS AND CONFIGURATION Parameter Default Description dV Coarse 1 00 Positive coarse filter input rate limit Sets the maximum positive voltage change between successive samples Used to filter out noise from the signal Range 0 01 gt 10 00V negative voltage change between successive samples Used to filter out noise from the signal 0 0 0 Negati
49. has been entered otherwise they will appear as on the Hydro View display Access codes are listed at the end of this manual Sensor calibration Unscaled input Sensor set up Output set up Sensor diagnostic Audible Alarm Material Mode RS232 Usage RS485 Usage Data Log Rate Station number Number of slaves Comms diagnostic Input 1 use Input 2 use Language Factory defaults Factory test Sensor calibration Allows calibration values to be set from the results obtained by taking laboratory samples Displays the sensor input prior to scaling for use during calibration Allows the operating parameters of the sensor to be adjusted Allows the analogue output range and variable to be adjusted Displays some engineering values about the sensor and the Hydro View Determines whether the internal bleeper is sounded when a sensor alarm is triggered Determines how the Material in use number will be selected Configures the RS232 serial port Configures the optional RS485 port Sets how frequently moisture data will be sent to the serial port s Sets the station number of this Hydro View unit in a multi drop configuration In a master slave Hydro View configuration determines how many slave units are to be used Displays performance information about the RS232 and RS485 communications ports Selects how digital input 1 will be used Selects how digital input 2 will be used Allows the operating language of the Hydro
50. he Sensor calibration page as Moisture one 16 HYDRO VIEW USER GUIDE 00022 REV 1 06 A batch mixing system A typical batch mixer system using the Hydro View is shown in Figure 2 Two interfacing schemes are illustrated One shot calculation approach The first scheme uses the analogue output to transmit the moisture content to a batch computer then calculates how much water to add to the mixer This is an approach used in the Hydronix Hydro Control IV system which performs both measurement and water addition Improved performance in this type of system can often be obtained by using the Coarse Fine digital input to select a tighter filtering algorithm a few seconds prior to taking the measurement The filter constants are set up in the Sensor Set up menu Static pan mixer li Hydro Mix sensor I Set point outputs to water addition system Analogue output to batch computer e Figure 2 Batch mixing system Dribble feed approach The second scheme which is useful only when there are few time constraints on the mix cycle uses the set point outputs to add water to the mixer The water is added fairly slowly in this case since it must be mixed evenly before the reading is valid To speed things up a little the second set point output could be used to provide a coarse water feed in the case of very dry
51. ial The alarm output relay of the Hydro View might be used to signal the controller in this event NEVER try to use the Hydro Skid on very thin layers of material as this will give erroneous readings All Hydronix sensors work best in bulk materials HYDRO VIEW USER GUIDE D0022 REV 1 06 19 Notes 20 HYDRO VIEW USER GUIDE 00022 REV 1 06 Hydro View quick start This section provides a brief introduction to using the Hydro View for new operators and includes details of how to access the most commonly used facilities Hydro View front panel Figure 4 shows the front panel layout of the Hydro View unit You can use the keypad and display to view and change operating parameters of the Hydro View Help key LCD display HYDRO VIEW Soft keys Menu key e Figure 4 Hydro View front panel Display contrast adjustment The display contrast can be adjusted for optimum viewing by pressing the E3 key see Keypad p21 when the Moisture display page see overleaf is being shown You can press the key several times to select the most appropriate of sixteen different contrast settings Note that at very low temperatures liquid crystal displays exhibit reduced contrast and this may be particularly noticeable immediately following the application of power to the unit It may be necessary to adjust the contrast control several times until the unit has established its normal operating temperature in your
52. ies and interfacing to external equipment is essential in obtaining the best performance from your Hydronix moisture measurement system inappropriate choice of the operating conditions is the biggest single cause of poor performance Examples of these three categories are described below These may be used as a guide in developing your own systems although the applications of the Hydro View are not limited to these applications The examples show the minimum configurations required and in general do not show variations in the use of interfacing techniques which are described elsewhere 10 HYDRO VIEW USER GUIDE 00022 REV 1 06 INTRODUCTION A batch weighing system A typical example of a batch weighing system involving a moisture measurement point in this case a Hydro Probe at the output of the storage bin is shown in Figure 1 The Hydro View is interfaced as follows Feed a signal to a digital input on the Hydro View indicating when the gate is open This signal can be derived either from a limit switch on the gate or from an auxiliary contact on the Open gate output in the batch control system whichever is most convenient Configure this input as an Average Hold input see Input 7 Input 2 use on page 36 Connect the Hydro Probe sensor to the Hydro View in the standard way Material storage bin Hydro Probe Gate open limit switch gt Average Hold
53. ilable from Hydronix The optional RS485 port can be used to provide an average of up to four sensors which should satisfy most application requirements Grouping is achieved by defining one of the Hydro View units it does not matter which when using the RS232 interface as a MASTER station with the other unit s as ASCII Hex devices See examples later for clarification The results of the grouping operation can be made available to external systems using either the analogue output port or the second serial port set for data log or batch print use When grouping channels in this way you must pay particular attention to calibration and in particular do not assume that the material flowing from one gate has the same moisture content as the others they can be widely different at any instant You should always aim to take a sample from the flow of a single sensor where possible Group moisture variables The channel grouping facility results in the generation of three additional moisture variables in the system These are referred to as Group M1 The average value of the NOW variables across all grouped units This might be used in a large batch or continuous mixing application where there is some advantage in measuring the moisture at several points Group M2 The average value of the NOW variables across all grouped units which are currently in an averaging state i e the average hold input is ON and the average hold delay timer has e
54. ing the Hydro Probe 11 to the Hydro View To connect to a Hydro View the Hydro Probe Il needs to be set to compatibility mode This mode allows the Hydro Probe II to directly replace an existing Hydro Probe 1 The 500 Ohm resistor supplied with the cable is required to convert the analogue current output to a voltage signal 4 x Ww B a 8 4 x o c c S 2 o S m m mc gt m c 5 m 0090A twisted pair j Sensor Cable oben a aa a RS485 B 000mm 90000009090 02 resistor e Figure 20 Connecting the Hydro View to a Hydro Probe Il HYDRO VIEW USER GUIDE 00022 REV 1 06 57 SENSOR CONNECTIONS HYDRO PROBE Sensor Connections Hydro Probe Hydronix moisture sensors are terminated in a 6 way Bulgin connector with a 1m lead attached to the sensor It is therefore necessary to wire an extension cable between the sensor connector and the Hydro View unit The connection diagram is given in Figure 21 Hydro View terminals 6 pin Bulgin socket mates with sensor EM 4 15V 4 4 1 E 500mA 2 ov 2 3 x 15V 3 47 Signal 4 j Return 1 4 5 2 H 19 T 0 e Figure 21 Sensor extension cable connections The cable should be 5 or 6 core screened multi core with 0 5mm conductors Note that it is NOT satisfactory to use a 4 core cable with termi
55. ing used HYDRO VIEW USER GUIDE D0022 REV 1 06 23 HELP FACILITY Help facility Pressing will change the display to show the options available at any point Selecting options Enters a menu from which you can select options Exits to the previous display oono HYDRO VIEW m MICROWAVE TECHNOLOGY Press to cancel help e Figure 6 Help facility If you are in any doubt what to do next with the Hydro View try Hydro View main menu To obtain a display other than the moisture display page you must choose from a list of options in the Main menu This is activated by pressing Main menu rena display Sensor calibration Unscaled input Y 4 HYDRO VIEW ee TECHNOLOGY HYDRONIX Select the option using this key Highlight the required option using these keys e Figure 7 Main menu Choose the menu option you require by using the soft keys to highlight the option followed by pressing El again 24 HYDRO VIEW USER GUIDE 00022 REV 1 06 HYDRO VIEW QUICK START The options available on the main menu by default are Moisture display The default display when power is applied Trend display A graphical display of moisture and other values plotted against time Material in use Displays the current material number and allows this to be changed Set point set up Allows low and high cut off operating parameters associated w
56. is configured as a Master on the other serial port The Hydro View provides a report at the end of a batch as determined by the state of the average hold inputs across all units involved in the group The data format used is as follows M1 2 NNN NN Avg AAA AA lt CRLF gt where MMM MM is the group M1 value in the range 99 99 to 99 99 NNN NN is the group M2 value in the range 99 99 to 99 99 AAA AA is the AVERAGE moisture value in the range 99 99 to 99 99 lt CRLF gt is the ASCII carriage return line feed combination hex OD hex 0A 74 HYDRO VIEW USER GUIDE 00022 REV 1 06 USING HYDRO VIEW SERIAL PORTS ASCII Hex mode ASCII Hex mode uses a communications protocol which is designed to be simple to implement and test whilst allowing a reasonable degree of performance to be achieved It should be possible to implement a suitable driver from most high level languages such as C or BASIC running on standard PC compatibles or even BASIC modules programmable controllers whilst trials can be performed from standard communications programs such as Microsoft Windows Terminal Hayes Smartcom etc Driver code for such applications is beyond the scope of this manual Scope Using ASCII Hex protocol you can perform tasks via the Hydro View serial port such as m Read instantaneous NOW moisture value m Read average moisture value m Read set point output status flags m R
57. is is used to detect a faulty sensor and in particular a broken cable m When the moisture value is outside the range programmed in the Sensor Set up menu m When the moisture value is outside the range programmed in the Output Set up menu The internal beeper of the Hydro View will give an alarm if the Audible Alarm parameter is set to On When an alarm occurs the beeper can be turned off by pressing although the relay output will remain energised Material mode The material calibration table number to use at any instant can be determined from any of three sources although only one such source can be used at any time The source is selected using the Material mode parameter on the main menu The possible sources are Keypad The material calibration table number to be used is entered via the keypad Digital set point output relays and digital inputs are used to select material tables 1 2 3 or 4 Refer to Material selection using Digital p61 for external connection details Serial The material table is selected remotely using either the RS232 or RS485 serial ports This option will normally be set at installation time and never changed HYDRO VIEW USER GUIDE 00022 REV 1 06 RS232 usage ADVANCED USER OPTIONS AND CONFIGURATION The RS232 port can be configured to operate in a number of different ways Disable Data Log ASCII Hex Master Batch Print RS485 Watch Sensor Trace RS4
58. ith the set point outputs to be adjusted Access code Allows access to additional operations These options are considered to be useful to most operators of the unit and therefore do not require any access code Additional facilities are described in Advanced user options and configuration p31 Trend display page The trend display allows the moisture content to be monitored over a period of time It is of particular use under the following conditions Monitoring the effectiveness of mixing action when used with a Hydro Mix sensor The display quite clearly shows the point at which thorough mixing has occurred Looking at the variation in moisture content within a batch of material It is inadvisable to take a calibration sample from a batch containing wide variations since this leads to inaccuracies During installation to set up the digital filtering parameters samples clipping etc applied to the sensor input The trend display simulates a paper chart recorder the paper moves under a fixed so that the most recent 100 readings are displayed at any time Four variables are recorded for each point Instantaneous moisture Average moisture A Raw sensor input voltage V Sensor voltage after clipping Vc Although only one trace is visible at any time on the display any of the four traces may be selected for display and so it is easy to compare say the input voltage before and after clipping
59. n 21 Display contrast 21 c 21 Soft Man MM 22 Moisture display 22 22 22 Max Min 96 23 Help facility EE 24 Hydro View main menu 24 Trend display pag 25 Changing operating 27 Adjusting set points 28 Material 58 29 Advanced user options and configuration eene nenne 31 Sensor calibration 31 Sensor 32 HYDRO VIEW USER GUIDE 00022 REV 1 06 Output edi e eae at ab ie tado 33 Sensor diagnostic display i ostio cob lose d gelb aped E HIR EE 34 Audible Alarm 34 Material MOG 34 Ross USIJE 3 eid n a eed et eR vee dite E d a 35 psnim lrpp 35 Data logirate einn REIR ema Eta t tap Rt aai 35 yet H 35 N rmber of slaves dc RE t cn ten e E Re EE E UG den Re tere ta dte diete de 35 Communications diagnostic 36 Input 1 7 Input 2 USe ai tnit er RD ep tne ee a takin 36 Language Selection
60. n grouped system HYDRO VIEW USER GUIDE D0022 REV 1 06 53 EXAMPLE A FOUR BIN GROUPED SYSTEM USING RS485 Notes 54 HYDRO VIEW USER GUIDE 00022 REV 1 06 Installation The Hydro View unit must be mounted in a control panel or suitable alternative for normal operation with only the front panel exposed to the operator For optimum display contrast the unit should be mounted approximately at eye level The control panel should be cut out to receive the unit as shown in Figure 18 140mm x 92mm cut out Control panel IEC connector Front panel Retaining d screw Retaining bar Depth 205mm e Figure 18 Panel mounting the Hydro View The retaining bar and retaining screw are used to clamp the Hydro View unit against the front panel Do not over tighten the retaining screw just sufficient torque should be applied to hold the unit in place against the control panel Power supply connections Mains power is connected to the Hydro View using a standard IEC mains connector The operating voltage of the unit can be selected by moving an internal link Warning For safety reasons and to meet the requirements of EMC Directive 89 336 EEC the earth connection in the IEC plug must be directly connected to the protective earth conductor in the external system HYDRO VIEW USER GUIDE D0022 REV 1 06 55 FIELD CONNECTIONS Adjusting the Hydro View mains operating voltage
61. nals 2 and 5 connected at the Hydro View end this will lead to common impedance type interference problems The 15V power rail is protected internally against short circuits by a 500mA plug in fuse FS1 which may be replaced easily if required Warning Never connect other equipment to the 15V supply intended for the moisture sensor Mains connector Retaining screw Model identification Fuseholder Model CIDIE F IGIH 1 J 9220 9 jd 112W max Fuse 250mA Manufactured in England by Hydronix Ltd Cranleigh GU68JJ 89 335 WARNING THIS UNIT MUST BE EARTHED AAA AAAAAIA AANA AAAAAAAAA 112 415 91101112 13 14115 16 17 18 19 20 21 LILI IL LL AN AN f Serial no 123456 iuis d EAM Retaining bar Field terminals RS232 serial port 58 HYDRO VIEW USER GUIDE 00022 REV 1 06 INSTALLATION Analogue output connections The analogue output may be configured for use either as 0 10 default or 4 20mA The selection is made via an internal jumper as shown in Figure 23 which shows the main circuit board inside the Hydro View The jumper is located close to the analogue output terminals 6 and 7 DL 9000 258 98 889009 8222222 8609
62. ne would then be used for entry into the calibration table of the Hydro View Drying the samples An electric hot plate small portable models are available camping gas burner electric oven or microwave oven are suitable Proceed as follows Weigh the empty container to obtain its tare weight Record this as value A Add the sample of material to the container and weigh again Record this as value B Dry the material using the heat source checking periodically by weighing until two measurements taken three minutes apart show no significant change If an open tray is used the material may be stirred carefully to assist evaporation Weigh the container again Record this as value Normally the drying process for one sample takes approximately 15 minutes Recommendations for best performance ALWAYS try to dry materials as quickly as possible to prevent reactions which may affect the results This is particularly true of wet mix concrete which will produce quite different results when dried overnight in an electric oven compared with drying quickly over a hot plate ALWAYS wear safety glasses during the drying process NEVER use excessive heat during the drying process This can result in violent expulsion of small pieces of material from the drying tray which are potentially dangerous Calculating the moisture percentage It is customary to express moisture present by weight as a percentage of the dry weight of mat
63. nformatlon enit hehe reete 75 Basic frame foririat imm tend cep ete d ei deno eet E iR 75 Bil 76 Request frame types command 77 Timihg constralts orn e eet el eter d o 78 ASCIIFlexprotocol examples eter edt 78 ADDOFIODC ci itti rie c b Peer et ia am cd 79 ACCOSS COd6S cciam p dae nete aee ees 79 Electromagnetic Compatibility Directive 89 336 79 Index addet me Utente 81 6 HYDRO VIEW USER GUIDE D0022 REV 1 06 TABLE OF CONTENTS List of figures Figure 1 Batch weighing 11 Figure 2 Batclhimbxng system tette hebt ot ebur mag hebes te 17 Figure Continuous mixing 19 Figure 4 Hydro View front 21 Figure S Moisture display err E PH Pe Ea pee Duda ese i 22 Figure 6 Help facility tenella ea decade d eed de 24 Figure 7 MaitiTher Gate ibd cane 24 Fig re 8 Trend display epe tinet ed 26 Figure 9 Selecting parameters 27 Figure 10 Changing a Value Ca
64. nput excitation supply return pa i Aes 1 20 Seet point 1 or material select output 1 21 Setpoint 2 or material select output 2 56 HYDRO VIEW USER GUIDE 00022 REV 1 06 INSTALLATION Sensor Connections Hydro Probe The Hydro Probe must be connected using the Hydronix sensor cable part no OO90A 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 Installation guidelines 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 To connect to a PC use a suitable converter see Hydro Probe II user guide 0193 for more details Route the signal cable away from any power cables The sensor cable should only be grounded near to the sensor 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 Three twisted pairs required 6 cores total cable with 22 AWG 0 35mm conductors Screen shield Braid with 65 minimum coverage plus aluminium polyester foil 500 Ohm resistor The recommended resistor is an epoxy sealed precision resistor of the following specification 500 Ohm 0 1 0 33W Maximum cable run 200m Connect
65. o View and record either the instantaneous or average value shown as appropriate for your application at the time of taking a sample Perform a desiccation or bake out test on the sample to establish the true moisture content by weighing the sample before and after drying Recommended procedures are given later in this guide in Calibration and sampling techniques Enter the results into a material table using the Hydro View Sensor Calibration page Each material calibration table allows a compensating value to be entered This is known as the Surface Saturated Dry or SSD offset and represents a value which will be subtracted from the moisture value before is it displayed or otherwise output Its purpose is to adjust the displayed moisture reading for the absorption properties of the material The Hydro View uses the two calibration values to compute a calibration line for the material of the form y mx c where y is a moisture value x is the corresponding unscaled input from the sensor m is the slope of the calibration line and cis the intercept The computed values for m and are indicated on the calibration display Further details will be found in Calibration and sampling techniques on page 42 Sensor set up menu Hydronix moisture sensors output a voltage signal which varies according to the moisture content of the material However the signal may be disturbed by the presence of other materials such as mixer blades passin
66. ome batch systems use the moisture value from one batch to correct the next sequential batch this is not adequate as there may be large batch to batch changes in moisture content In some situations this can lead to the system performance actually being worse when the moisture value is used ALWAYS ensure that the storage bins are managed correctly Running out of material during a batch may lead to errors in the reading even though out of range readings are not included in the average computation ALWAYS ensure that you are getting a meaningful input to the Hydro View there is little point wasting time performing calibrations on the system if the sensor is covered by stagnant material or is otherwise subject to inconsistent material flow Verify this first using the trend recorder display which is a convenient way of observing the material passing the probe ALWAYS use additional sensors where several gates are used you should not assume that the moisture content of the material flowing out of both gates is the same it will not be The results of several Hydro View units can be combined by use of the serial ports see Grouping channels p49 for further details NEVER attempt to use the NOW reading to correct weights the moisture content during a batch can change quite dramatically We have observed variations between 6 and 16 during a single batch the average value computed by the Hydro View on the same batch was accurate compar
67. p Parameter name Default Value Your value Notes om 100 iar 239 cate 6 Nahe pow E S Sensor calibration Parameter name Default Value Your value Notes Unscaled i p 1 Moisture 1 000 Moisture 2 SSD Parameter Default Value Set point 1 Set point 2 name 38 HYDRO VIEW USER GUIDE 00022 REV 1 06 ADVANCED USER OPTIONS AND CONFIGURATION Other parameters Parameter name Default Value Your value Notes Audible Alarm Material Mode Keypad RS232Usage Datalog 5485 Usage Disable Data Log Rate 10 1 Station number Number of Slaves 4 Input1 Use _ Input2 Use Coarse Fine Language English HYDRO VIEW USER GUIDE 00022 REV 1 06 39 SUGGESTED WORKING VALUES Suggested working values The example configurations given in this section should be used as a guide in developing your own systems However the applications of the Hydro View are not limited to these applications The examples show the minimum configurations required and in general do not show variations in the use of interfacing techniques each of which is described elsewhere The following tables give recommended working values for the three examples described in Applications of Hydro View with Hydronix moisture sensors p10 These should be treated as starting points although in practice very little
68. r results Entering the results of a calibration test allows the Hydro View to establish gain m and offset c parameters permitting the display of the absolute moisture content of the material in use The moisture content displayed by Hydro View is given by the linear scaling equation M mU c SSD where M is the moisture content U is the unscaled input value SSD is the Surface Saturated Dry offset see below m and care gain and offset parameters calculated automatically by Hydro View from 2 Mj 0 01 where U1 M4 are the unscaled input and moisture content respectively for the first sample and 02 the unscaled input and moisture content respectively for the second sample 46 HYDRO VIEW USER GUIDE 00022 REV 1 06 CALIBRATION AND SAMPLING TECHNIQUES Moisture lib Unscaled input U2 e Figure 14 Sensor calibration line HYDRO VIEW USER GUIDE D0022 REV 1 06 47 Grouping channels In some situations and particularly in high throughput batch plants it is necessary to measure the moisture content at several points simultaneously and provide an average value The Hydro View provides a convenient way of doing this by making use of its serial ports If the RS232 port is otherwise unused then the output of two sensors can be averaged by simply connecting the RS232 ports of two Hydro View units together using a cross over cable ava
69. ressing the softkey as follows aem A pop up menu will appear asking you to confirm the changes Press When a moisture content with a difference of 2 396 is available repeat from 1 above Dry Bucket method This procedure can be used on initial calibration when the silo can not be re loaded with aggregate with moisture levels with a difference of 2 396 It will provide a working system which can be fully calibrated at a later date Equipment required Plastic Bucket Dry aggregate of approximately 1 moisture enough to fill the bucket This can be dried prior to arriving on site A sample should be tested as above If not dry to 0 5 1 5 then the aggregate should be dried once more Method Place the Hydro Probe in the centre of the bucket with the ceramic facing the centre and tilted to 10 degrees The bottom of the probe should be 20mm from the base of the bucket Carefully pour the aggregate around the probe as lightly as possible Do not compact the aggregate but TAP the bucket gently on the ground twice On the Hydro View select from the main menu Unscaled input and record the Unscaled input value On the Hydro View select from the main menu Sensor calibration and enter the reading for the recorded Unscaled input into Unscaled input 1 HYDRO VIEW USER GUIDE 00022 REV 1 06 15 DRY BUCKET METHOD Dry a sample of the aggregate in the bucket and record it s moisture content enter this figure into t
70. rforms an external loop back test on the serial port You must connect transmit data to receive data to see this Displays the state of the digital inputs To use the factory test display 1 2 4 5 Remove power to the Hydro View Disconnect all wires connected the Hydro View terminals after first noting their positions Connect jumpers in the positions shown in Figure 29 If you wish to test the RS232 port you will need to use a RJ11 to 9 pin D type connecting cable available from Hydronix Re apply power and enter pass code given in Access codes p79 Select menu option Factory Test If the Hydro View is working correctly the following actions will take place on the display Analogue output voltage OUT will cycle between 0 5 and 10V Sensor input voltage IN will cycle between 0 5 and 10V at the same time as the output voltage due to the feedback wiring Output relays out 1 2 and 3 will cycle in a binary sequence 3 2 1 0 0 0 0 0 1 0 1 0 0 1 1 1 0 0 1 0 1 1 1 0 1 1 1 0 0 0 Digital input signals in 1 2 are connected back to relays 1 2 and will therefore follow the pattern above Battery Batt will display 1 if the internal Lithium battery is healthy otherwise it will display 0 64 HYDRO VIEW USER GUIDE 00022 REV 1 06 Key will display the name of the relevant key when pressed RS232 232 will scroll The quick brown fox jumps over the lazy dog INS
71. ry dry sand 0 0 2 0 10 0 8 0 Medium wet sand 4 0 8 0 6 0 T 4 0 Very wet sand 12 0 16 0 3 0 T 1 0 Two simple tests may be performed to check whether the sensor is working correctly Pressing the palm of your hand very firmly on the ceramic faceplate of the sensor will simulate the condition of very wet sand Therefore first check the open air voltage and then press your hand against the sensor which should reduce the voltage to approximately around 2 volts A more precise test for Hydro Probe sensors only uses two test blocks that may be purchased for this purpose as indicated in Figure 30 below This is an approximate test so providing that the sensor output voltage is within 1 volt of the voltage marked on the block then the sensor may be deemed to be operating satisfactorily Block 1 simulates dry material Block 2 has two faces with the black rubber face uppermost it HYDRO VIEW USER GUIDE D0022 REV 1 06 67 SENSOR INSTALLATION FAULTS simulates a medium wet material and with the black rubber face in contact with the ceramic plate simulates a very wet material APR RER R E Ine ist Block 1 Block 3 Rubber Face Down EEE Figure 30 Using test blocks 68 HYDRO VIEW USER GUIDE 00022 REV 1
72. stand even for a very short period of time will vary from top to bottom NOTE for the reasons given above collecting a few kilograms of material that is representative to 0 1 accuracy of several tonnes of material is very difficult to achieve Great care should therefore be taken when conducting these tests A variety of laboratory techniques exist The desiccation test is recommended in that it is an absolute measurement with repeatable results even when carried out by different operatives and it is not dependent on having to know the specific gravity of the material being tested As will be appreciated no matter how much care is taken in conducting these tests sampling and experimental errors will inevitably be present in each result Initially the equipment can be calibrated from one actual set of results at the level of moisture contents encountered on site in conjunction with an estimate of calibration points at 0 moisture level thus providing two separate calibration points spaced reasonably apart However improved accuracy will be obtained by taking adding a second true calibration point at a later date when site conditions allow Recommendations for best performance ALWAYS ensure that the sample of material being used for calibration is from a batch with low moisture variation This can be checked by using the minimum maximum or trend display facilities on the Hydro View and will help to prevent sampling errors affecting the res
73. t is unused The current moisture values are transmitted periodically as determined by the Data Log Rate parameter Provides two way communication between the Hydro View and another system using a simple ASCII Hex protocol The port acts as a master device for a maximum of three additional Hydro View units configured for ASCII Hex on their RS485 ports See Grouping channels p49 for further details The port will print a report of the moisture variables each time the Average hold input is turned off thus providing an end of batch report Some of these options can be selected at the same time as similar options on the RS232 port although some combinations will not be logically correct in use for example configuring both RS232 and RS485 ports as Master will produce undefined results Data log rate Determines how often data is transmitted by a port configured for Data Log operation Station number In a communications configuration involving the 5 Hex communications protocol this parameter sets the station number for this Hydro View unit acting as a slave device Number of slaves In a Master Slave system see Grouping channels p49 this parameter sets the maximum number of slaves which will be used in the system The Master station will then only attempt to communicate with the number of slave units entered avoiding wasting communications time on slave units which are not present in the system HYDRO VIEW USER GUIDE D0022
74. the incorrect reading In particular watch for mix cycles following production gaps being excessively wet which is a clear sign that the time constant is too long NEVER place the Hydro Mix sensor directly below a water or material feed into the mixer You should give the materials as much time as possible to mix before it is seen by the sensor NEVER calibrate until you are satisfied with the signal from the sensor and that the mixing times are appropriate otherwise you are wasting your time 18 HYDRO VIEW USER GUIDE 00022 REV 1 06 A BATCH MIXING SYSTEM A continuous process A typical example of a continuous process is shown in Figure 3 In this case a continuous mixer is supplied with material to be wetted to a pre set moisture content Modulating the water feed dry material flow rate or a combination of both may be used to achieve this A Hydro Skid sensor is used to monitor the output of the continuous mixer on a conveyor belt In some cases it may be convenient to use a Hydro mix sensor at the output of the mixer depending on mechanical arrangements As with many control systems of this type there is a time lag between the control action point the input to the mixer and the point at which the measurement can be made Hence the response time of the Hydro View in terms of the number of samples parameter should be set in accordance with the time constant of the system to prevent unnecessary and erratic modulation o
75. the relevant module s This should be done for those units at each end of the twisted pair 72 HYDRO VIEW USER GUIDE 00022 REV 1 06 USING HYDRO VIEW SERIAL PORTS J1 J3 termination jumpers d oe HYDRONIX 1995 Figure 33 RS 485 module circuit board The RS485 module also includes RS485 line bias resistors to bias an un driven line to a known condition ONE module only in a system should have these enabled by inserting jumpers J1 and J2 normally this would be done on the unit configured as a MASTER station The RS485 module is supplied with J1 J2 and J3 installed by default Data log mode The Hydro View provides a continuous stream of data output on the relevant port which may be captured by an external device This data stream is in ASCII format and contains the NOW and AVERAGE moisture values according to the programmed data log rate The data format used is as follows lt STX gt NNN NN AAA AA lt CRLF gt where lt STX gt is the ASCII start of text character hex 02 NNN NN is the NOW moisture value in the range 99 99 to 99 99 AAA AA is the AVERAGE moisture value in the range 99 99 to 99 99 lt CRLF gt is the ASCII carriage return line feed combination hex OD hex 0A The data rate format used is 9600 baud 8 data bits no parity 1 stop bit This cannot be altered The data logging format changes when the unit
76. this section completely before starting any calibration Log into the system using access code 336 Select Unscaled Input from the main menu This display will be used to display the readings required for calibration The following operation of collecting samples may require two or more people Collecting a sample gt Open the bin gates to discharge a batch If the system does not automatically select the average function then close the switch connected to the Hydro View as the bin gate opens and open the switch as the gate closes While the batch is discharging collect two to three kilogram of aggregate which accurately represent samples of the complete batch Place this in the container or bags and seal Record the Average Unscaled Input displayed on the Hydro View before the next batch is started The Average Unscaled Input will remain frozen on the display until the start of next batch Drying the sample to calculate the moisture content Thoroughly mix the sample and remove approximately 1 Kg for drying Reseal the container Accurately weigh the this sample record this as A Dry the sample until all traces of moisture have bean removed This can be done by repeatedly weighing the sample between heating until three consecutive weightings are the same Take great care not to lose any of the sample by careless stirring Loosing only a few grains will make the test invalid Record this weight as B Calculate A B B
77. tions e g aggregate bins m High value computer equipment connected Although the Hydro View model HV02 is fitted with opto isolation on the sensor input these will not prevent damage in all cases Precautions should still be taken to avoid damage by lightning in areas where there is a known risk We would recommend the installation of suitable lightning barriers to all conductors in the sensor extension cable Ideally these would be fitted at both ends of this cable to protect both the moisture sensor and the Hydro View and equipment connected to the Hydro View Please consult your Hydronix distributor for further information regarding lightning protection on our equipment HYDRO VIEW USER GUIDE 00022 REV 1 06 63 TROUBLESHOOTING Troubleshooting Factory test display The Hydro View includes a factory test display page to assist in troubleshooting if problems are suspected with the Hydro View itself This requires a special access code see Access codes p79 and once selected it is necessary to remove power from the Hydro View to restore normal operation Since this function exercises the inputs and outputs of the Hydro View it is not recommended that this be used when the Hydro View is connected to the plant The test page performs the following operations Displays the voltage at the sensor input Cycles the voltage current on the analogue output between 0 50 and full scale Operates each output relay in turn Pe
78. tions given in this guide this equipment conforms to the requirements of Council Directive 89 336 EEC according to the following schedule Equipment type Hydro View interface unit model number 02 Manufacturer Hydronix Ltd 70 Smithbrook Kilns Cranleigh Surrey England Conformity criteria Conducted emissions EN55011 1991 Group 1 Class A Radiated emissions EN55011 1991 Group 1 Class A Radiated immunity prEN50082 2 1992 Electrostatic discharge prEN50082 2 1992 Fast transient burst immunity prEN50082 2 1992 HYDRO VIEW USER GUIDE D0022 REV 1 06 79 ELECTROMAGNETIC COMPATIBILITY DIRECTIVE 89 336 EEC Notes 80 HYDRO VIEW USER GUIDE 00022 REV 1 06 INDEX Index ACCESS 31 Ep 33 Analogue 33 59 Application batch mb ng 16 batch weighing 14 continuous 5 18 ASCII Hex protocol cete rhe 75 Average hold irse tete asa 11 Batch mixing dribble feed 16 one shot 2 22 1 16 Batch 74 12 31 43 entering results ecce 46 Iul C otc 66 25 Communi
79. to the bucket The material in the bucket should be well and thoroughly mixed immediately prior to taking a minimum of two samples for drying The samples should preferably be approximately 1Kg in weight but not less than 500gm For large aggregates it is more important to use a larger sample Dry the two samples of material and calculate the moisture content using the drying technique described later This provides a wet reading for the Hydro View calibration table 44 HYDRO VIEW USER GUIDE 00022 REV 1 06 CALIBRATION AND SAMPLING TECHNIQUES Calculate the dry reading moisture value by calculating back based on the wet reading water added and dry weight of material Enter both sets of values into the Hydro View calibration table Continuous system sampling method In this case you will need to take samples passing the face of the sensor at the same time as recording the unscaled input display It is normally impossible with this type of system to take a series of samples for mixing together before drying as it is the instantaneous value of moisture content passing the sensor which is required The preferred procedure here is to take several spot samples at different moisture contents and plot these on a graph against the corresponding unscaled input A best fit calibration line would then be obtained using a linear regression algorithm most spreadsheet programs will do this for you Two points on this li
80. to 1Kg although 600g is acceptable and perhaps easier to obtain Heating source The most convenient source is a single ring electric hot plate Other sources such as electric drying ovens camping gas burners or microwave ovens can be used although extreme care should be taken with the latter Heating tray or dish This should be ceramic not plastic if used with a microwave oven otherwise metal Small hand shovel For collecting samples from the flow of material Plastic bucket Ideally with plastic lid Taking the samples You should always consider how the sensor is operating when taking your samples and should collect your samples in a manner similar to the way in which the sensor sees the material Batch mixer system sampling method In this situation the preferred calibration samples would be taken from the dry materials However in many cases this can be impossible to obtain due to physical restrictions and so the following method can be used to acquire two calibration points for the Hydro View Proceed as follows Choose a suitable mix cycle to calibrate to Record the unscaled input at the end of the dry mix phase when the reading has stabilised Record the dry weight of material and the quantity of water added to the batch Record the unscaled input at the end of the wet mix again when the reading has stabilised Discharge the mix and collect several samples from different parts of the batch in
81. tuning should be required These values will need to be adjusted to suit changes to interfacing arrangements which may have been employed Sensor set up Parameter name Batch weigher Batch mixer Continuous process AlHdeay 05 0 0 Sync delay 00 000 ooo Trend lower 00 100 00 2 00 Jooo 00 Alarm Lo Alarm Hi 20 00 20 00 20 00 Output set up Parameter name Batch weigher Batch mixer Continuous process Minimum 00 Jooo 00 200 000 Calibrate 000 AVERAGE Sensor calibration Parameter name Batch weigher Batch mixer Continuous process Unscaled i p 1 Moisture 1 000 00 Unscaled i p 2 28 40 28 40 28 40 Moisture 2 11 00 11 00 11 00 SSD 000 000 00 i Depends on rotational speed of mixer This is three rotations at 2 5 seconds Depends time constants in feedback control system This will give a response time of around 10 seconds 3 Normally set to reflect the absorption properties of material in ready mix applications 40 HYDRO VIEW USER GUIDE D0022 REV 1 06 ADVANCED USER OPTIONS AND CONFIGURATION Set point set up Parameter name Batch weigher Batch mixer Continuous process High cut off N A As required Other parameters Parameter name Batch weigher Batch mixer Continuous process Data Log Rate 0 Number of Slaves 70 0 Station number 1 1 117 1 CE N 1 1 1 Ave Hold
82. uctive loads You should also ensure that such loads are fitted with suitable transient suppressors at the load to reduce electromagnetic interference The relay contacts are rated at 240Vac 500mA resistive An internal series fuse FS3 limits the TOTAL load taken by all three relays to 500mA Plug in replacement relays and fuses are available from Hydronix Material selection using Digital 1 0 This mode allows one of four material calibration tables to be selected Since this requires the use of the set point output relays these functions are automatically disabled when the mode is selected The digital input used in the diagram is input 2 but input 1 could also be used the input must be configured for material selection using the relevant item on the Main menu The electrical connections for using this method are shown in Figure 28 HYDRO VIEW USER GUIDE D0022 REV 1 06 61 SENSOR CONNECTIONS HYDRO PROBE Hydro View External wiring for internal wiring material selection 20 SWI SW2 e Figure 28 Material selection using digital 1 0 A multiplexing method is used by the Hydro View to determine the state of the two external switches SW1 and SW2 and thus to determine which material calibration table to use These switches may of course be outputs from a control system however they must be of the voltage free type for the scheme to operate correctly The diagram above shows the internal excitation s
83. ults ALWAYS take care when working with small samples of material not to lose any during the drying process NEVER try to calibrate using extremely wet near saturation samples of material the errors you will make in sampling such material will be very large A maximum recommended calibration sample limit for sand would be around 12 NEVER attempt to calibrate a Hydronix sensor by placing it in a bucket full of material or packing material on the face of the sensor The static readings obtained in such cases will not be representative of those obtained in the dynamic situation HYDRO VIEW USER GUIDE D0022 REV 1 06 43 EQUIPMENT REQUIRED NEVER use a calibration method which uses very small samples e g Speedy or infra red balance for calibrating coarse aggregates NEVER assume that the material flowing out of two gates in the same bin is the same moisture content and do not attempt to take a samples from the flow of both gates in an attempt to get an average value ALWAYS instead use two moisture sensors in these cases sampling the flow of each one individually otherwise you will probably be wasting the money spent on the first sensor Equipment required The following equipment is recommended for performing calibrations Your Hydronix supplier will usually have this equipment available Weighing scales An electronic or mechanical balance with a resolution to 0 1g and ideally with the facility to weigh up
84. until you exit from the current list to prevent invalid intermediate combinations of values from being used Press to exit the menu If any the values in the list have been changed then a pop up will appear requesting confirmation of the changes you have made Press and the new values will become operational or press E to abandon ail changes Adjusting set points The Hydro View control two set point output relays The set points may be programmed so that the outputs are turned ON within a specified range of moisture contents This allows the set points to be used for such purposes as Signalling an acceptable range of moisture content for example monitoring material conveyor belt using Hydro Skid sensor or checking the moisture content out of a mixer using a Hydro Mix sensor m Simple control of water addition by using the outputs to turn a water valve up to a pre set moisture reading Each set point operates independently and may be programmed with the following parameters Parameter Description used as the controlling variable turned OFF turned OFF Hysteresis The by which the moisture content must exceed the low cut off or be below the high cut off before the output relay will make an OFF to ON transition This is used to prevent jitter near to the programmed cut off points The time in seconds for which the moisture content must be within a range for any action to be taken
85. upply being used but an equivalent arrangement for external excitation is possible The multiplexing sequence performed by the Hydro View is as follows Close relay output on terminal 20 and open relay on terminal 21 Read state of SW1 on terminal 15 Open relay on terminal 20 and close relay on terminal 21 Read state of SW2 on terminal 15 Repeat from beginning as required The Hydro View requires that the state of switches SW1 and SW2 remain stable for two multiplexing cycles before it updates its internal values To avoid excessive wear on the Hydro View relay contacts this process takes about 5 seconds to complete and thus the external control system should allow sufficient time for any changes of material to be propagated to the Hydro View The material table number corresponding to the states of switches SW1 and SW2 is given by SW2 Material table Open 3 5 62 HYDRO VIEW USER GUIDE 00022 REV 1 06 INSTALLATION Protection from lightning strikes You should give some consideration to protecting the Hydronix installation from damage due to lightning and similar electrical disturbances Many installations of Hydronix equipment will be into situations which are particularly prone to damage by lightning for example m Tropical regions m Outdoor installations m Long cable runs between the sensor and instrumentation m Tall electrically conductive construc
86. ut excitation not operate power Relay outputs Incorrect settings do not operate Fuse blown Contacts welded Incorrect configuration No serial communications Sensor installation faults Enter the access code for the required facility Moisture 2 must be greater than Moisture 96 1 in calibration screen Difference must be gt 1 Check internal fuse FS2 and replace if necessary Check wiring for analogue output and digital inputs which share a common power supply Go to Output set up and select relevant output variable If using external 24V power source check common connection at terminal 16 If using internal source check that you have linked terminal 16 to 17 Check internal fuse FS2 and replace if necessary Check alarm and set point settings Check internal fuse FS3 and replace if necessary Check external wiring Replace plug in relay Check that the serial port has been enabled for the purpose you require If using RS485 verify that the optional RS485 module is installed The moisture display reading being excessively low or excessively high or not changing at all would normally suggest a fault This may be caused by m faulty interconnecting wiring most common error m blown DC fuse Hydro View m sensor in wrong position m faulty sensor m faulty Hydro View The following steps should help to locate the fault 1 Carefully check the wiring to the sensor in ac
87. ve coarse filter input rate limit Sets the maximum Range 0 01 gt 10 00V Fine 10 Positive fine filter input rate limit Range 0 01 gt 10 00V 5V 1 0 Range 0 01 10 00V Minimum Minimum sensor voltage accepted before an alarm is issued volts Used to detect broken sensor cable Range 0 5V Maximum volts Maximum 12 0V Maximum sensor voltage accepted before an alarm is volts issued Range Minimum volts gt 12 0V Trend step Sets the update interval on the trend recorder display Range 0 1 10 0 seconds Trend lower Sets the minimum moisture value displayed on the trend recorder display Range 99 99 gt 99 99 Trend upper 20 00 Sets the maximum moisture value displayed on the trend recorder display Range 99 99 gt 99 99 Alarm Lo Sets the minimum moisture value allowed before an alarm OCCUIS Range 99 99 gt 99 99 Alarm Hi 20 00 Sets the maximum moisture value allowed before an alarm OCCUIS Range 99 99 gt 99 99 Output set up menu The Hydro View 0 10V 4 20mA analogue output can be set to represent any convenient moisture content range by choosing Output set up from the main menu The parameters that may be set here are Parameter Default Description Value Minimum 0 00 The moisture value represented by an output of or 4mA 20 00 The moisture value represented by an output of 10 00V or 20 Calibrate Used to force a known value to the output for calibration of external
88. w seconds and then the display changes to the default Moisture display page shown in Figure 5 Decimal point flashes when averaging is in progress Coarse fine clipping Average moisture reading siatueindieator n Y r Average 12 1 3 x MICROWAVE TECHNOLOGY Moisture reading now Alarm pop up indicates that alarm condition exists e Figure 5 Moisture display Hydro View maintains several different variables representing the moisture content of the material in use 22 HYDRO VIEW USER GUIDE 00022 REV 1 06 HYDRO VIEW QUICK START Now value This is computed and updated continuously by the Hydro View from the readings taken by the moisture sensor This value is normally used for batch mixing type control systems in conjunction with the Hydro Mix sensor a stable value indicating that the material in the mixer is homogeneous This value would also be used in the continuous process type application Average value This is the average of the Now value beginning at an off to on transition of the Average Hold input and therefore represents the average moisture content in a batch of material The average value is continuously updated until the input is turned off at which point it is frozen until the start of the next batch This value is normally used in ready mix and similar batch weighing applications in conjunction with th
89. would be configured as for ASCII HEX on RS232 with a station address of 1 The two units would be coupled together with a cross over RS232 cable The analogue output of the master unit would be connected to the batch computer and Material storage Level sensor bin optional Hydro Probe Gate open limit switch gt gt gt Master Station 1 Analogue output to batch computer 5232 cross over cable e Figure 16 Twin bin grouped system the analogue output variable set to Group Average This variable is the batch average of the two channels which is what is required The Group Average variable automatically caters for situations where for some reason batching is performed from only one bin or gate In addition a bin level sensor input can be provided level sensor not supplied by Hydronix to prevent moisture errors in the event that one bin runs empty during a batch HYDRO VIEW USER GUIDE 00022 REV 1 06 51 EXAMPLE A FOUR BIN GROUPED SYSTEM USING RS485 Example a four bin grouped system using RS485 Figure 17 shows the maximum configuration which may be achieved with the grouping facility Although four separate bins are indicated the same situation may arise with two twin gate bins In this case the Hydro View on the lower left would
90. xpired This variable would normally be used by a batch computer performing its own time averaging Group The integration over time of the Group M2 value divided by time since Average the start of an averaging period This variable will be used in the majority of grouped applications and in general is not the same as the average of the individual unit average values since the Group M2 value observes the averaging state of individual units The group variables automatically ignore channels which are either in an alarm condition and or have a low level of material as determined by the optional level sensing inputs Group moisture display When a Hydro View unit is configured as a MASTER station you can view the group moisture variables by pressing the right hand soft key when the standard moisture display is shown This key will toggle between the standard display showing the moisture variables local to the unit and the group display showing the results of the grouping operation Indicators to the right of the group display show which slave stations are currently responding to communications requests from the master station HYDRO VIEW USER GUIDE D0022 REV 1 06 49 EFFECT OF COMMUNICATIONS ERRORS ON GROUPED SYSTEMS Decimal point flashes when averaging in progress Indicators show Group average moisture reading active slaves Group Avg 7 12 796 o Os Group M2 11 3 ALARM HYD

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