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Hydronix Hydro-View HV02 User Manual

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Refer to Page 13 for Calibration Procedure when used in
Batch Weigher system Applications
Hydronix part number: D0022
Revision: 1.06
Revision date: 12 June 2007
Hydro-View
User Guide

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Summary of Contents for Hydronix Hydro-View HV02

  • Page 1 Hydro-View User Guide Refer to Page 13 for Calibration Procedure when used in Batch Weigher system Applications Hydronix part number: D0022 Revision: 1.06 Revision date: 12 June 2007...
  • Page 2 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.

  • Page 3: Table Of Contents

    Table of contents..............................3 Introduction ................................. 9 System overview..........................9 Scope of this document ........................9 Organisation of this document ......................9 Applications of Hydro-View with Hydronix moisture sensors ............10 A batch weighing system ......................11 Batch weighing calibration procedure ......................13 Calibration............................14 Dry Bucket method ..........................15 Method ............................15...
  • Page 4 Output set-up menu ........................33 Sensor diagnostic display ....................... 34 Audible Alarm..........................34 Material mode ..........................34 RS232 usage ..........................35 RS485 usage ..........................35 Data log rate............................ 35 Station number..........................35 Number of slaves ..........................35 Communications diagnostic page ....................36 Input 1 / Input 2 use ........................
  • Page 5 TABLE OF CONTENTS Continuous system sampling method..................45 Drying the samples ..........................45 Recommendations for best performance...................45 Calculating the moisture percentage ....................45 Entering results into the Hydro-View ....................46 What happens with your results ......................46 Grouping channels ............................49 Group moisture variables.........................49 Group moisture display........................49 Effect of communications errors on grouped systems ..............50 Example - a twin bin grouped system using RS232................51 Example - a four bin grouped system using RS485 ................52...
  • Page 6 Using Hydro-View serial ports ......................... 71 RS232 serial port ..........................71 RS485 serial port ..........................72 Installation of RS485 module ....................72 RS485 connections ........................72 RS485 termination........................72 Data log mode..........................73 Batch print mode ..........................74 ASCII Hex mode ..........................75 Scope ............................
  • Page 7 TABLE OF CONTENTS List of figures • Figure 1 - Batch weighing example....................11 • Figure 2 - Batch mixing system.......................17 • Figure 3 - Continuous mixing process ....................19 • Figure 4 - Hydro-View front panel ....................21 • Figure 5 - Moisture display......................22 •...
  • Page 8 This manual references older versions of Hydro-Probe Sensors which have now Note: been superseded by the Hydro-Probe II. 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 in the Hydro-Probe II User Guide.

  • Page 9: Introduction

    Hydronix range. Key features include... Hydronix sensor input including power supply source for sensor. 0-10Vdc or 4-20mA analogue output (link selected option) with working range scaled from front panel.

  • Page 10: Applications Of Hydro-View With Hydronix Moisture Sensors

    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 sensors from the Hydronix range. Applications of the sensors normally fall into one of the following categories...

  • Page 11: A Batch Weighing System

    Refer to Installation 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.
  • Page 12 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. position the sensor so that the moisture value used is representative of the batch LWAYS 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.

  • Page 13: Batch Weighing Calibration Procedure

    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.

  • Page 14: Calibration

    CALIBRATION Connect a single pole rocker switch across terminals 13 and 14 Connect a wire link across terminals 16 and 17 Hydro View Rear connector ⇒ Reconnect power to the Hydro View Calibration Read this section completely before starting any calibration. ⇒...

  • Page 15: Dry Bucket Method

    If all is correct with the data then contact Hydronix for further assistance. ⇒ Exit the calibration page by pressing the softkey as follows A pop up menu will appear asking you to confirm the changes ⇒...
  • Page 16 DRY BUCKET METHOD ⇒ Dry a sample of the aggregate in the bucket and record it’s moisture content, enter this figure into the Sensor calibration page as Moisture one. HYDRO-VIEW USER GUIDE D0022 REV 1.06...

  • Page 17: A Batch Mixing System

    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.
  • Page 18 pay attention to the sensor filter requirement. Static pan mixers in particular LWAYS 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.

  • Page 19: A Continuous Process

    General advice on this can be found in the Hydronix moisture sensor data sheets and by contacting your Hydronix supplier.
  • Page 20 Notes HYDRO-VIEW USER GUIDE D0022 REV 1.06...

  • Page 21: Hydro-View Quick Start

    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.

  • Page 22: Soft Key Legends

    MOISTURE DISPLAY PAGE Legend Name Description Soft key Allows selection of options displayed above the key which are described in Soft key legends next. • Figure 588 Moisture display Hydro-View maintains several different variables6representing the moisture content of the m Soft key legends Legend Name...

  • Page 23: Max / Min % Display

    HYDRO-VIEW QUICK START This is computed and updated continuously by the Hydro-View from ‘Now’ value 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.

  • Page 24: Help Facility

    HELP FACILITY Help facility Pressing will change the display to show the options available at any point… HYDRO-VIEW USER GUIDE D0022 REV 1.06 Figure •...

  • Page 25: Trend Display Page

    HYDRO-VIEW QUICK START The options available on the main menu by default are:- The default display when power is applied. Moisture display A graphical display of moisture and other values plotted against Trend display time. Displays the current material number and allows this to be Material in use changed.

  • Page 26: Figure 8 - Trend Display

    TREND DISPLAY PAGE • 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.

  • Page 27: Changing Operating Values

    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...

  • Page 28: Adjusting Set-Points

    ADJUSTING SET-POINTS Sometimes the parameter is not numeric but is instead one of a list of options. In this case will step through the list… • Figure 11 - Changing options Usually, the new value will not take effect until you exit from the current list to prevent invalid intermediate combinations of values from being used…...

  • Page 29: Material In Use

    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.
  • Page 30 MATERIAL IN USE Notes HYDRO-VIEW USER GUIDE D0022 REV 1.06...

  • Page 31: Advanced User Options And Configuration

    Advanced user options and configuration The menu options described in this section are only available if the relevant access code has been entered, otherwise they will appear as ... on the Hydro-View display. Access codes are listed at the end of this manual. Allows calibration values to be set from the results obtained by Sensor calibration taking laboratory samples.

  • Page 32: Sensor Set-Up Menu

    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 passing in close proximity to the sensor.

  • Page 33: Output Set-Up Menu

    ADVANCED USER OPTIONS AND CONFIGURATION Parameter Default Description Value +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 10.00V -dV Coarse 1.00 Negative coarse filter input rate limit.

  • Page 34: Sensor Diagnostic Display

    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...

  • Page 35: Rs232 Usage

    ADVANCED USER OPTIONS AND CONFIGURATION RS232 usage The RS232 port can be configured to operate in a number of different ways... RS232 port is unused. Disable The current moisture values are transmitted periodically, as determined Data Log by the Data Log Rate parameter. Provides two-way communication between the Hydro-View and another ASCII Hex system, using a simple ASCII Hex protocol.

  • Page 36: Communications Diagnostic Page

    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... •...

  • Page 37: Language Selection

    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.

  • Page 38: Sensor Set-Up

    FACTORY DEFAULT SETTINGS Sensor set-up Parameter name Default Value Your value Notes Type Samples A/H delay Sync delay 0.00 +dV Coarse 1.00 -dV Coarse 1.00 +dV Fine 0.10 -dV Fine 0.10 Minimum volts 0.5V Maximum volts 12.0V Trend step (s) Trend lower % 0.00 Trend upper %...

  • Page 39: Other Parameters

    ADVANCED USER OPTIONS AND CONFIGURATION Other parameters Parameter name Default Value Your value Notes Audible Alarm Material Mode Keypad RS232 Usage Data Log RS485 Usage Disable Data Log Rate Station number Number of Slaves Input 1 Use Ave/Hold Input 2 Use Coarse/Fine Language English...

  • Page 40: Suggested Working Values

    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 tuning should be required. These values will need to be adjusted to suit changes to interfacing arrangements which may have been employed.

  • Page 41: Set-Point Set-Up

    ADVANCED USER OPTIONS AND CONFIGURATION Set-point set-up Parameter name Batch weigher Batch mixer Continuous process Variable Low cut-off % As required As required High cut-off % As required As required Hysteresis % 0.25 As required Delay (s) Other parameters Parameter name Batch weigher Batch mixer Continuous...
  • Page 42 SUGGESTED WORKING VALUES Notes HYDRO-VIEW USER GUIDE D0022 REV 1.06...

  • Page 43: Calibration And Sampling Techniques

    A maximum recommended calibration sample limit for sand would be around 12%. attempt to calibrate a Hydronix sensor by placing it in a bucket full of material or EVER packing material on the face of the sensor.

  • Page 44: Equipment Required

    - 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:- An electronic or mechanical balance with a resolution to 0.1g...

  • Page 45: Continuous System Sampling Method

    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.

  • Page 46: Entering Results Into The Hydro-View

    ENTERING RESULTS INTO THE HYDRO-VIEW M = 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.

  • Page 47: Figure 14 - Sensor Calibration Line

    CALIBRATION AND SAMPLING TECHNIQUES Moisture Unscaled input • Figure 14 - Sensor calibration line HYDRO-VIEW USER GUIDE D0022 REV 1.06...

  • Page 49: Grouping Channels

    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 (available from Hydronix). The optional RS485 port can be used to provide an average of up to four sensors, which should satisfy most application requirements.

  • Page 50: Effect Of Communications Errors On Grouped Systems

    EFFECT OF COMMUNICATIONS ERRORS ON GROUPED SYSTEMS • 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.

  • Page 51: Example - A Twin Bin Grouped System Using Rs232

    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 D0022 REV 1.06...

  • Page 52: Example - A Four Bin Grouped System Using Rs485

    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 D0022 REV 1.06...

  • Page 53: Figure 17 - Four Bin Grouped System

    GROUPING CHANNELS • Figure 17 - Four bin grouped system HYDRO-VIEW USER GUIDE D0022 REV 1.06...
  • Page 54 EXAMPLE - A FOUR BIN GROUPED SYSTEM USING RS485 Notes HYDRO-VIEW USER GUIDE D0022 REV 1.06...

  • Page 55: Installation

    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.

  • Page 56: Adjusting The Hydro-View Mains Operating Voltage

    FIELD CONNECTIONS Adjusting the Hydro-View mains operating voltage 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 power supply assembly which is mounted on the inside of the lid.

  • Page 57: Sensor Connections - Hydro-Probe Ii

    INSTALLATION Sensor Connections – Hydro-Probe II The Hydro-Probe II must be connected using the Hydronix sensor cable (part no 0090A), available in different lengths to suit the installation. Any extension cable required should be connected to the Hydronix sensor cable using a suitable screened junction box.

  • Page 58: Sensor Connections - Hydro-Probe I

    SENSOR CONNECTIONS – HYDRO-PROBE I Sensor Connections – Hydro-Probe I 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.

  • Page 59: Analogue Output Connections

    INSTALLATION Analogue output connections The analogue output may be configured for use either as 0-10V (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.

  • Page 60: Digital Input Connections

    SENSOR CONNECTIONS – HYDRO-PROBE I • Figure 24 - Analogue output wiring Digital input connections The two digital inputs (terminals 14 & 15) share a single common terminal (16) and are arranged internally as shown in Figure 25. 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.

  • Page 61: Relay Output Connections

    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 I/O 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.

  • Page 62: Figure 28 - Material Selection Using Digital I/O

    SENSOR CONNECTIONS – HYDRO-PROBE I 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.

  • Page 63: Protection From Lightning Strikes

    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…...

  • Page 64: Troubleshooting

    3. 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. 4. Re-apply power and enter pass code given in Access codes (p79).

  • Page 65: Installation Problems

    Figure 29 - Factory loop-back test wiring Installation problems 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...

  • Page 66: Sensor Installation Faults

    SENSOR INSTALLATION FAULTS Symptom Probable cause Remedy Access code not Enter the access code for the required Cannot see entered. facility. required menu item. Incorrect order of Moisture % 2 must be greater than Unable to enter moisture value. Moisture % 1 in calibration screen. calibration values.

  • Page 67: Sensor Characteristics

    INSTALLATION fault is in the Hydro-View and may be a blown fuse – check FS1 and replace if required (see Figure 23 (p59)). Later revisions of the HV02 are fitted with re-settable fuses, so remove power for about 30 seconds and try again. 3.

  • Page 68: Figure 30 : Using Test Blocks

    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. 8.9v Block 1 5.0v 1.7v Block 2 (Rubber Face Up) Block 3 (Rubber Face Down) •...
  • Page 69 INSTALLATION Notes HYDRO-VIEW USER GUIDE D0022 REV 1.06...

  • Page 71: Using Hydro-View Serial Ports

    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.

  • Page 72: Rs485 Serial Port

    RS485 SERIAL PORT RS485 serial port The RS485 serial port provides an optically-isolated twisted-pair 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…...

  • Page 73: Data Log Mode

    USING HYDRO-VIEW SERIAL PORTS J1-J3 termination jumpers • Figure 33 - RS485 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.

  • Page 74: Batch Print Mode

    BATCH PRINT MODE AAA.AA is the group average moisture value in the range -99.99 to 99.99%. <CRLF> is the ASCII carriage return - line feed combination (hex 0D, 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.

  • Page 75: Ascii Hex Mode

    USING HYDRO-VIEW SERIAL PORTS ASCII Hex mode The 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’...

  • Page 76: Frame Types

    ASCII HEX MODE Field Format Description REQUEST 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. DATA As required by the COMMAND field.

  • Page 77: Request Frame Types ('Command Set')

    USING HYDRO-VIEW SERIAL PORTS Code Mnemonic Description BAD_DATA The data field contained data which was out of range for the specific request. 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.

  • Page 78: Timing Constraints

    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 in particular... A slave station will time out if the request frame does not complete within a period of 0.2 seconds following receipt of the STX character.

  • Page 79: Appendix

    Council Directive 89/336/EEC according to the following schedule… Equipment type: Hydro-View interface unit model number: HV02 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...
  • Page 80 ELECTROMAGNETIC COMPATIBILITY DIRECTIVE - 89/336/EEC Notes HYDRO-VIEW USER GUIDE D0022 REV 1.06...

  • Page 81: Index

    INDEX Index Access code..........31 digital ........... 36, 60 Alarm ............33 Installation ............. 55 Analogue output ........33, 59 Keypad ............21 Application Language ..........31, 37 batch mixing..........16 Lightning batch weighing .......... 11 protection barriers........63 continuous process ........18 Main menu.............
  • Page 82 Notes HYDRO-VIEW USER GUIDE D0022 REV 1.06...

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