Hydronix Hydro-Probe XT User Manual
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Hydronix Hydro-Probe XT User Manual

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Hydro-Probe XT
User Guide
HD0538
1.6.0
January 2020

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  • Page 1 Hydro-Probe XT User Guide To re-order quote part number: HD0538 Revision: 1.6.0 Revision date: January 2020...
  • Page 2 Neither the whole nor 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.
  • Page 3 +1 888 887 4822 (Toll Free) +1 231 439 5001 European Office Covers Central Europe, Russia and South Africa Tel: +49 2563 4858 Fax: +49 2563 5016 French Office Tel: +33 652 04 89 04 Hydro-Probe XT User Guide HD0538 Rev: 1.6.0 3...
  • Page 4 4 Hydro-Probe XT User Guide HD0538 Rev: 1.6.0...
  • Page 5 Figure 29 & 30 updated 1.4.0 April 2014 Figure 15 description updated 1.4.1 May 2014 Minor Formatting update 1.5.0 July 2016 Updated Sensor Cable part Numbers and Hydro- Com information 1.6.0 January 2020 Address Change Hydro-Probe XT User Guide HD0538 Rev: 1.6.0 5...
  • Page 6 6 Hydro-Probe XT User Guide HD0538 Rev: 1.6.0...

  • Page 7: Table Of Contents

    Technical Specifications ......................59 Chapter 9 Frequently asked questions ....................61 Appendix A Default parameters ......................63 Default Parameters ........................63 Appendix B Document Cross Reference ....................65 Document Cross Reference ....................... 65 Hydro-Probe XT User Guide HD0538 Rev: 1.6.0 7...
  • Page 8 8 Hydro-Probe XT User Guide HD0538 Rev: 1.6.0...
  • Page 9 Figure 4: Fitting a deflection plate to prevent damage ................15 Figure 5: Overhead view of Hydro-Probe XT mounted in a bin ............16 Figure 6: Mounting the Hydro-Probe XT in the neck of the bin ............16 Figure 7: Mounting the Hydro-Probe XT in the bin wall ................ 17 Figure 8: Mounting the Hydro-Probe XT in large bins ................
  • Page 10 10 Hydro-Probe XT User Guide HD0538 Rev: 1.6.0...

  • Page 11: Chapter 1 Introduction

    0049B RS232/485 converter (9 pin D type to terminal block) SIMxx USB Sensor Interface Module including cables and power supply Hydro-Com configuration and diagnostics software is available for free download from www.hydronix.com Hydro-Probe XT User Guide HD0538 Rev: 1.6.0 11...

  • Page 12: Introduction

    All Hydronix sensors are pre-calibrated in the factory so that they read 0 when in air and 100 when submerged in water. This is called the ‘Unscaled Reading’ and is the base value used when calibrating a sensor to the material being measured.

  • Page 13: Sensor Connection And Configuration

    For communication with a PC, Hydronix supply RS232-485 converters and a USB Sensor Interface Module (See page 31). There are two basic configurations by which the Hydro-Probe XT can be connected to a batch control system: •...
  • Page 14 Chapter 1 Introduction 14 Hydro-Probe XT User Guide HD0538 Rev: 1.6.0...

  • Page 15: Chapter 2 Mechanical Installation

    60˚ Line A Figure 3: Hydro-Probe XT mounting angle and material flow If there is a risk that high density material greater than 12mm in size may inadvertently enter the material flow it is advisable to protect the ceramic faceplate. A deflection plate should be fitted above the sensor (see Figure 4).

  • Page 16: Positioning The Sensor

    In this case, mounting the sensor under the bin can be advantageous for ease of maintenance. Figure 6: Mounting the Hydro-Probe XT in the neck of the bin 16 Hydro-Probe XT User Guide HD0538 Rev: 1.6.0...

  • Page 17: Figure 7: Mounting The Hydro-Probe Xt In The Bin Wall

    Standard Mounting Sleeve (part number: 0025) Figure 7: Mounting the Hydro-Probe XT in the bin wall If the sensor does not reach the main flow of material, then an extension mounting sleeve should be used, as shown in Figure 8.

  • Page 18: Figure 9: Mounting The Hydro-Probe Xt In A Vibratory Feeder

    Mechanical Installation Vibratory feed mounting With vibratory feeders, the sensor is normally fitted by the manufacturer – contact Hydronix for further information on positioning. It is difficult to predict where the flow of material occurs, but the location shown below is recommended.

  • Page 19: Figure 10: Mounting The Hydro-Probe Xt On A Conveyor Belt

    (See Chapter 3 for connection details). 25mm Clamp Ring and Flanged Mounting Sleeve >150mm Diverters may be used to channel the material to increase depth Flow Direction Figure 10: Mounting the Hydro-Probe XT on a conveyor belt Hydro-Probe XT User Guide HD0538 Rev: 1.6.0 19...

  • Page 20: Figure 11 - Mounting The Hydro-Probe Xt In An En-Masse Conveyor

    (see Chapter 3 for connection details) Plan View Sampling Averaging Point Switch 150-300mm 60˚ Flow Direction Side View Flow Direction 60˚ Figure 11 - Mounting the Hydro-Probe XT in an en-masse conveyor 20 Hydro-Probe XT User Guide HD0538 Rev: 1.6.0...

  • Page 21: Figure 12 - Mounting The Hydro-Probe Xt In A Screw Conveyor

    (see Chapter 3 for connection details) Input Flute removed Flow Direction Sampling point Averaging switch Output Figure 12 - Mounting the Hydro-Probe XT in a screw conveyor Hydro-Probe XT User Guide HD0538 Rev: 1.6.0 21...

  • Page 22: Installing The Sensor

    There are three mounting accessories available from Hydronix. Standard mounting sleeve (part no 0025) The Hydro-Probe XT can also be mounted vertically using the Standard Mounting Sleeve, however Hydronix would recommend using the Flanged Mounting Sleeve, see Figure 15 50mm <338mm...

  • Page 23: Figure 15: Flanged Mounting Sleeve (Part Number 0024A)

    Mechanical Installation Chapter 2 Flanged Mounting Sleeve (part no 0024A) For installations where vertical mounting is required. Use with the Hydronix Clamp Ring, part number 0023. A 100mm diameter hole is required to insert the Flanged Mounting Sleeve. Clamp Ring...

  • Page 24: Corrosion Protection

    Extension Mounting Sleeve (Part number 0026). Position the sensor in the Extension Mounting Sleeve so that the connection end is completely pushed into the sleeve preventing material coming into contact with the connector. See Figure 17 24 Hydro-Probe XT User Guide HD0538 Rev: 1.6.0...

  • Page 25: Figure 17: Hydro-Probe Installed In An Extension Mounting Sleeve

    Figure 18: Hydro-Probe installed with a drip loop Protection cover Install a cover over the top of the sensor to deflect the material away from the connector. See Figure 19 Material Protection cover Hydro-Probe Figure 19: Deflector plate Hydro-Probe XT User Guide HD0538 Rev: 1.6.0 25...
  • Page 26 It is however preferential to keep the material away from the connector as this will be the best method of stopping the possibility of corrosion. 26 Hydro-Probe XT User Guide HD0538 Rev: 1.6.0...

  • Page 27: Chapter 3 Electrical Installation And Communication

    Chapter 3 Electrical Installation and Communication Hydronix supplies cable 0975A for use with the Hydro-Probe XT and this is available in different lengths. Any extension cable should be connected to the Hydronix sensor cable using a suitable screened junction box. See Chapter 8 for cable details.

  • Page 28: Figure 20: 0975A Sensor Cable Connections

    Control Room Wiring Figure 20: 0975A Sensor cable connections Note: The cable screen is grounded at the sensor. It is important to ensure that the plant where the sensor is installed is properly grounded. 28 Hydro-Probe XT User Guide HD0538 Rev: 1.6.0...

  • Page 29: Rs485 Multi-Drop Connection

    RS485 cable should run from the control room to the first sensor before linking on to any other sensors in turn. This is shown in Figure 22. Figure 22: Correct RS485 cable networks Figure 23: Incorrect RS485 cabling Hydro-Probe XT User Guide HD0538 Rev: 1.6.0 29...

  • Page 30: Hydronix Interface Units

    5 Digital input/output connection The Hydro-Probe XT has two digital inputs, the second of which can also be used as an output for a known state. Full descriptions of how the digital inputs/outputs can be configured are included in Configuration from Page 35.

  • Page 31: Connecting To A Pc

    It is highly recommended that the RS485 signals be run to the control panel even if they are unlikely to be used as this will facilitate the use of diagnostic software should the need arise. There are four types of converter supplied by Hydronix. RS232 to RS485 converter – D type (part no: 0049B) Manufactured by KK systems, this RS232 to RS485 converter is suitable for connecting up to six sensors on a network.

  • Page 32: Figure 28: Rs232/485 Converter Connections (Sensor Interface Module)

    Figure 28: RS232/485 converter connections (Sensor Interface Module) Ethernet Adapter Kit (part no: EAK01) Manufactured by Hydronix, the Ethernet adapter is suitable for connecting up to 16 sensors to a standard Ethernet network. An optional Ethernet Power Adapter Kit (EPK01) is also available which eliminates the need for additional expensive cables to be run to a remote location which does not have local power.

  • Page 33: Figure 29: Ethernet Adapter Connections (Eak01)

    Cable to Sensor (0975A) Description Colour Connector Pin RS485/A White RS485/B Black 0v DC Power Black 10/100baseT 24v DC Power CAT5e Ethernet to EPA01 10/100baseT CAT5e Figure 30: Ethernet Power Adapter Kit connections (EPK01) Hydro-Probe XT User Guide HD0538 Rev: 1.6.0 33...

  • Page 34: Figure 31: Maximum Number Of Sensor Connections Dependent Upon Ambient Temperature

    Hydro-Probe II Maximum Air Temperature °C Maximum Air Temperature °C Figure 31: Maximum number of sensor connections dependent upon ambient temperature NOTE: Operation above these limits may cause premature failure of the unit. 34 Hydro-Probe XT User Guide HD0538 Rev: 1.6.0...

  • Page 35: Chapter 4 Configuration

    Configuration 1 Configuring the Sensor The Hydro-Probe XT has a number of internal parameters which may be used to optimise the sensor for a given application. These settings are available to view and change using the Hydro- Com software. Information for all settings can be found in the Hydro-Com User Guide (HD0682).

  • Page 36: Figure 32: Guidance For Setting Output Variables

    4mA represents 0% and 20mA represents 20% These limits are set for the working range of the moisture and must be matched to the mA to moisture conversion in the batch controller. 36 Hydro-Probe XT User Guide HD0538 Rev: 1.6.0...

  • Page 37: Digital Inputs/Output Setup

    An input is activated using 15 – 30V DC into the digital input connection. The sensor power supply may be used as an excitation supply for this, or alternatively an external source may be used as in Figure 24. Hydro-Probe XT User Guide HD0538 Rev: 1.6.0 37...

  • Page 38: Filtering

    When using the sensor to measure the moisture content of a material as it is discharged from a bin or silo, there is frequently a short delay between the control signal issued to begin the batch and the material beginning to flow over the sensor. Moisture readings 38 Hydro-Probe XT User Guide HD0538 Rev: 1.6.0...

  • Page 39: Alternative Measurement Techniques

    The default measurement mode for the Hydro-Probe XT is ‘Mode V’. This mode has been designed for the best performance in agricultural, organic and biomass materials.

  • Page 40: Figure 33: Relationship Of Moisture % To Unscaled Values

    Data can easily be recorded using a PC and the Hydronix Hydro-Com software, these results may then be plotted in a spreadsheet. When viewed in graph form it is often self-evident which mode gives the desired performance characteristics.
  • Page 41 When using the sensor to obtain an output signal that is calibrated to moisture (an absolute moisture measurement) it is recommended to calibrate using the different measurement modes and to compare results (see Calibration page 43). For further information please contact the Hydronix support team at support@hydronix.com Hydro-Probe XT User Guide HD0538 Rev: 1.6.0 41...
  • Page 42 Chapter 4 Configuration 42 Hydro-Probe XT User Guide HD0538 Rev: 1.6.0...

  • Page 43: Chapter 5 Sensor Integration And Calibration

    Introduction to material calibration The raw output of a Hydronix sensor is an Unscaled value ranging from 0 to 100 units. Each sensor is set so that a 0 Unscaled value relates to the measurement in air and 100 relates to water.
  • Page 44 SSD values are derived through more lengthy industry standard tests or supplied by the material supplier. Oven dried Water Absorption Value % surface moisture % moisture % (Total) (SSD offset in the sensor) (free moisture) 44 Hydro-Probe XT User Guide HD0538 Rev: 1.6.0...

  • Page 45: Figure 35: Calibration Inside The Hydro-Probe Xt

    Calibration inside the sensor will involve updating the coefficient values using the digital RS485 interface. True moisture can then be obtained from the sensor. To communicate using the RS485 interface, Hydronix has developed communications software called Hydro-Com which is free to download from www.hydronix.com.

  • Page 46: Figure 36: Calibration Inside The Control System

    • No need to learn how to use additional software. • If it is necessary to replace the sensor, a replacement Hydronix sensor can be • connected and valid results obtained immediately without connecting the sensor to a PC to update the material calibration.
  • Page 47 This gives a ‘Moisture’ and an ‘Unscaled’ value which can be plotted on a graph. With at least two points, a calibration line can be drawn. The following procedure is recommended when calibrating the Hydro-Probe XT to the material. This procedure uses the Hydro-Com utility and the calibration information is stored inside the sensor.
  • Page 48 The moisture % output from the sensor should represent true moisture of the material. This can be verified by taking further samples and checking the laboratory moisture against the sensor output. 48 Hydro-Probe XT User Guide HD0538 Rev: 1.6.0...

  • Page 49: Figure 37: Example Of Good Material Calibration

    50% mass of water. Using this method it is therefore possible to have a moisture value of more than 100%. All Hydronix calculations are based on a dry weight method unless otherwise specified. Good / bad calibration A good calibration is made by measuring samples and taking readings over the full working moisture range of the material.

  • Page 50: Figure 38: Examples Of Poor Material Calibration Points

    If the averaging facility is not used to ensure representative moisture reading for • the entire batch. Poor Moisture Calibration Data Poor Moisture Calibration Data Sensor Unscaled Output Sensor Unscaled Output Figure 38: Examples of poor material calibration points 50 Hydro-Probe XT User Guide HD0538 Rev: 1.6.0...

  • Page 51: Chapter 6 Optimising Sensor And Process Performance

    Fit the Standard Mounting Sleeve (part no 0025), the Extension Mounting Sleeve (part no 0026) or the Flanged Mounting Sleeve (part no 0024A) with Clamp Ring (part no 0023) for ease of adjustment or extraction. DO NOT HIT THE CERAMIC FACEPLATE DURING MAINTENANCE Hydro-Probe XT User Guide HD0538 Rev: 1.6.0 51...
  • Page 52 Chapter 6 Optimising Sensor and Process Performance 52 Hydro-Probe XT User Guide HD0538 Rev: 1.6.0...

  • Page 53: Chapter 7 Sensor Diagnostics

    Chapter 7 Sensor diagnostics The following tables list the most common faults found when using the sensor. If you are unable to diagnose the problem from this information, please contact Hydronix technical support. 1 Sensor Diagnostics Symptom: No output from sensor...
  • Page 54 Sensor is found at Try an alternative sensor has the same sensor individually an address. RS485-RS232/USB address number Renumber this if available sensor and repeat for all the sensors on the network 54 Hydro-Probe XT User Guide HD0538 Rev: 1.6.0...
  • Page 55 & check reading (a) change over a Hydro-Com configuration with ceramic face open reasonable range diagnostics and (b) with hand pressed firmly on ceramic face. Activate Average /Hold input if required Hydro-Probe XT User Guide HD0538 Rev: 1.6.0 55...
  • Page 56 Average/Hold input for the application behaviour OFF and changing with the input ON Inadequate ground Metalwork and cable Ground potential Ensure equipotential connections ground connections differences must be bonding of metalwork minimized 56 Hydro-Probe XT User Guide HD0538 Rev: 1.6.0...
  • Page 57 Filtered Unscaled Output (values shown are approximate) RS485 4-20mA 0-20 mA 0-10 V Compatibility mode Sensor exposed to air 4 mA 0 mA >10V Hand on sensor 75-85 15-17 mA 16-18 mA 7.5-8.5 V 3.6-2.8V Hydro-Probe XT User Guide HD0538 Rev: 1.6.0 57...
  • Page 58 Chapter 7 Sensor diagnostics 58 Hydro-Probe XT User Guide HD0538 Rev: 1.6.0...

  • Page 59: Chapter 8 Technical Specification

    One configurable digital input 15 – 30 V DC activation One configurable digital input/output – input specification 15 – 30 V DC, output specification: open collector output, maximum current 500 mA (over current protection required). Hydro-Probe XT User Guide HD0538 Rev: 1.6.0 59...
  • Page 60 Chapter 8 Technical specification 60 Hydro-Probe XT User Guide HD0538 Rev: 1.6.0...

  • Page 61: Chapter 9 Frequently Asked Questions

    Use an ‘Average Unscaled’ value for your calibration. The averaging period can be set either with the ‘Average/Hold’ input, or using ‘Remote Averaging’. See Hydro-Com User Guide (HD0682) for more information. Hydro-Probe XT User Guide HD0538 Rev: 1.6.0 61...
  • Page 62 The ceramic should be mounted at an angle which allows material to pass continuously. The Hydro-Probe XT sensor has two lines, marked A and B on the rear plate label. Correct alignment is where either line A or line B is horizontal, indicating that the ceramic is at the correct angle as suggested on Page 15.

  • Page 63: Appendix A Default Parameters

    0.00 High limit (us) 100.00 Low limit (us) 0.00 Freq. Co Ampl. Co Electronics temp. coeff 0.0059 0.0637 Resonator temp. coeff Set by test Set by test Material temp. coeff 0.00000 0.00000 Hydro-Probe XT User Guide HD0538 Rev: 1.6.0 63...
  • Page 64 Temperature Compensation The temperature compensation settings are individual to the unit and set in the factory during manufacturing. These should not be changed. event that these settings required please contact Hydronix support@hydronix.com. 64 Hydro-Probe XT User Guide HD0538 Rev: 1.6.0...

  • Page 65: Appendix B Document Cross Reference

    Document Number Title HD0682 Hydro-Com User Guide HD0303 USB Sensor Interface Module User Guide EN0071 Engineering Note – Sensor Default Parameters Hydro-Probe XT User Guide HD0538 Rev: 1.6.0 65...
  • Page 66 Appendix B Document Cross Reference 66 Hydro-Probe XT User Guide HD0538 Rev: 1.6.0...
  • Page 67 Standard Mounting Sleeve ......22 Filters Suitable Applications........12 Slew Rate ..........38 Total Moisture ..........44 USB Sensor Interface Module ...... 32 Vibratory Feeders ......... 18 Water Absorption Value ........ 44 Hydro-Probe XT User Guide HD0538 Rev: 1.6.0 67...

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