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Hydronix Hydro-Control HC07 Operation Manual

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Hydro-Control (HC07)
Operators Guide
HD1048
1.1.0
June 2023

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Summary of Contents for Hydronix Hydro-Control HC07

  • Page 1 Hydro-Control (HC07) Operators Guide To re-order quote part number: HD1048 Revision: 1.1.0 Revision date: June 2023...
  • Page 2 CUSTOMER FEEDBACK Hydronix is continually looking to improve not only its products but also the services that we offer to our customers. If you have any suggestions about how we can do this or if you have any other feedback that would be helpful, please complete our short form at www.hydronix.com/contact/hydronix_feedback.php.
  • Page 3 Hydronix Offices UK Head Office Address: Units 11 & 12 Henley Business Park Pirbright Road Normandy Guildford Surrey GU3 2DX United Kingdom Tel: +44 1483 468900 Email: support@hydronix.com sales@hydronix.com Website: www.hydronix.com North American Office Covers North and South America, US territories, Spain, and Portugal...
  • Page 4 Hydro-Control (HC07) Operators Guide HD1048 Rev 1.1.0...
  • Page 5 Revision history Revision Software Date Description of Change Version V1.0.0 V1.1.0.0 May 2023 First Release V1.1.0 V1.1.0.0 June 2023 Minor footer and document propertied fields adjustments, error starting mix prompt and CO value added. Hydro-Control (HC07) Operators Guide HD1048 Rev 1.1.0...
  • Page 6 Hydro-Control (HC07) Operators Guide HD1048 Rev 1.1.0...

  • Page 7: Table Of Contents

    Table of Contents Chapter 1 Introduction ........................... 11 About this Manual ........................11 Introduction to the Hydro-Control ....................12 Chapter 2 Navigation ..........................13 Powering on, logging in and Powering off .................. 13 Main Menu ..........................14 Overview Screen ........................16 Recipes Screen ..........................
  • Page 8 Calibration Based Water Addition ....................88 Mixing ............................88 Chapter 14 Frequently Asked Questions ....................89 Appendix A Diagnostics ........................93 Appendix B Glossary ..........................95 Appendix C Document Cross Reference ....................97 Document Cross Reference ....................... 97 Hydro-Control (HC07) Operators Guide HD1048 Rev 1.1.0...
  • Page 9 Table of Figures Figure 1: The Hydro-Control ......................... 12 Figure 2: Hydro-Control implementation example ................12 Figure 3: Overview Screen - Default User .................... 13 Figure 4: Overview screen - user not Logged in ................... 13 Figure 5: Main Menu Bar ........................14 Figure 6: The overview screen of the Hydro-Control ................
  • Page 10 Figure 40: Recipes updated confirmation pop-up................. 46 Figure 41: The Mix Log ......................... 47 Figure 42: Mix Trace Screen ......................... 54 Figure 43: Mix Trace Data page ......................55 Figure 44: Extending the mix times for calibration ................57 Figure 45: Water Trim function pop-up window ..................

  • Page 11: Chapter 1 Introduction

    1. HD1100 – Hydro-Control (HC07) Safety Information 2. HD1074 – Hydro-Control (HC07) Installation Guide Both above documents are available to download from the www.Hydronix.com website. This manual complements the Installation Guide, which details the installation, all the system parameters and the initial setup of the Hydro-Control.

  • Page 12: Introduction To The Hydro-Control

    The Hydro-Control (HC07) is a touch-screen computer based on a Linux operating system. It has been designed to work with the Hydronix range of sensors. The unit monitors the moisture level in a process (usually in a mixer) and sends signals to adjust the water flow into the process using water valves.

  • Page 13: Chapter 2 Navigation

    The Hydro-Control is switched on by pressing the power button in the top left-hand corner of the unit. The unit will briefly display system boot-up information. A white screen with Hydronix logo will appear, followed by an automatic login message, a black screen, and another white screen with Hydronix logo.

  • Page 14: Main Menu

    Chapter 2 Navigation Powering Off To switch the unit off, hold the power button in the top left-hand corner until the confirmation box pops up and press OK. 2 Main Menu The main menu pages are accessible by pressing the icons on the blue bar at the top of the screen. This allows access to the different areas of the Hydro-Control.
  • Page 15 Navigation Chapter 2 System Parameters Enables configuration of the system parameters, including water meter and valve setup, AUTO Mode and Auto-Track parameters, and alarm configuration (see section 6 System Parameters Screen). Sensor Overview Displays the sensor configuration screen allowing changes to the filtering and analogue output settings (see section 7 Sensor Overview Screen).

  • Page 16: Overview Screen

    Chapter 2 Navigation Log Out Enables the operator to log-out from the current user account once finished using the Hydro-Control (see section 11 User Management Screen). Overview Screen This is the main screen displaying an overview of the mix cycle and details about the batch and recipe currently in use.

  • Page 17: Figure 7: Mix Cycle Control Buttons

    Navigation Chapter 2 11. Current Recipe Number and Name and enables access to the Operators Mode recipe screen. 12. Current Recipe moisture target. 13. Current moisture value. When in air ‘EMPTY’ is indicated. 14. Process status. 15. Date and time. 16.

  • Page 18: Figure 8: Connection To Moisture Sensor Lost

    Chapter 2 Navigation Main control buttons Description Abort Aborts the Hydro-Control cycle. Enables inputting the manual trim amount (see Chapter 8, Trim section 2.3). NOTE: If a certain amount of trim is always required, personnel with supervisor access should be notified to re-calibrate the mix. The procedure for this is described in Chapter 8, section 2.8.

  • Page 19: Recipes Screen

    Navigation Chapter 2 4 Recipes Screen This is an overview list of recipes saved in the Hydro-Control. Accessing this part of the menu is described in section 2.1 Menu Buttons. Recipes can be created, selected for editing, or deleted from this screen. Figure 9: Recipes Screen The ‘Unscaled’...

  • Page 20: Mix Log Screen

    Chapter 2 Navigation 5 Mix Log Screen This is an overview list of the batches produced. Accessing this part of the menu is described in section 2.1 Menu Buttons. Figure 11: The Mix Log screen The ‘Unscaled’ button switches the display of the values shown in the mix log between % Moisture readings and sensor Unscaled readings.

  • Page 21: Sensor Overview Screen

    Navigation Chapter 2 7 Sensor Overview Screen Note: Some parameters will have been set up by the installer. All parameters are detailed in the Installation Guide (HD1074). For day-to-day operation, the operator of the system should not need to make changes in this section. 8 Settings Screen A limited functionality ‘System’...

  • Page 22: Hardware Screen

    Chapter 2 Navigation 9 Hardware Screen The parameters of this section are not used by an operator and are detailed in the Installation Guide (HD1074). 10 Comms Screen The parameters of this section are not used by an operator and are detailed in the Installation Guide (HD1074).

  • Page 23: Figure 16: Default User Accounts Configuration - No Login/Logout Button Present

    Navigation Chapter 2 Figure 16: Default User Accounts Configuration – no login/logout button present. When an additional user account (beyond the default admin account) is created in the Hydro-Control, the device requires logging in to gain access to the menu. The padlock symbol in the top menu bar signifies this.

  • Page 24: Figure 19: Login Screen - User Selection

    Chapter 2 Navigation Figure 19: Login screen - user selection After logging in, Hydro-Control will display the Overview screen. The menu access level in the top blue bar depends on the logged-in user level (see Figure 15). Once a user has logged in, the menu appears at the top of the screen, and the padlock symbol changes to unlocked.

  • Page 25: Figure 21: User Management - Editing Existing User Account

    Default username and password If user credentials become lost, attempt to login into the device using the default user account, username: Hydronix, password 0336. If the default user account password is changed and lost contact Hydronix support (support@hydronix.com). Hydro-Control (HC07) Operators Guide HD1048 Rev 1.1.0...
  • Page 26 Chapter 2 Navigation Hydro-Control (HC07) Operators Guide HD1048 Rev 1.1.0...

  • Page 27: Chapter 3 Plant Operator Controls

    Chapter 3 Plant Operator Controls A plant operator rarely needs to adjust the device’s parameters; therefore, no access to the main menu is required in this mode. To access the plant operator controls, press the ‘Recipe’ button on the Overview Screen (see section 3 Overview Screen, arrow No. 10). Plant operator controls are available only when a user is logged in.

  • Page 28: Figure 24: Recipe Mode Screen

    Chapter 3 Plant Operator Controls Figure 24: Recipe Mode Screen If adjustments are required to maintain workability, it is advisable to adjust the amount of admixture used. If this is not possible, the Main Water Trim parameter can be used to adjust the overall amount of water added to maintain workability.

  • Page 29: Chapter 4 Understanding The Mix Cycle

    Chapter 4 Understanding the Mix Cycle To be able to optimise the system for the best performance (accuracy, repeatability, and speed), it is essential to understand the mix cycle and its phases. There are two main types of mix cycles, a simple mix cycle, and a mix cycle incorporating the Pre-Wet water phase.

  • Page 30: Cycle With Pre-Wet Water Phase

    Chapter 4 Understanding the Mix Cycle Cycle with Pre-Wet Water Phase What is Pre-Wet Water? Pre-Wet Water is a quantity of water that may be optionally added at the beginning of the mix cycle before the Dry Mix phase. Why use Pre-Wet Water? Pre-Wet Water may be used for several reasons.

  • Page 31: Figure 26: The Mix Cycle With Pre-Wet

    Understanding the Mix Cycle Chapter 4 2.4 The Mix Cycle when using Pre-Wet Water The mix cycle when using Pre-Wet Water is shown, along with a typical moisture trace, in Figure 26. Moisture As the water gets mixed As the mixer is the signal discharged the begins to...
  • Page 32 Chapter 4 Understanding the Mix Cycle The Mix Cycle when using Initial and Pre-Wet mix phases. In some mix designs, it may not be possible or take an undesirable amount of time, to obtain a stable reading in the dry or wet mix once certain materials or chemicals are added. Reasons may include: •...

  • Page 33: Chapter 5 Water Addition Modes

    Chapter 5 Water Addition Modes The Hydro-Control has been designed to operate in one of three modes of water addition: Preset Mode, AUTO Mode and CALC Mode. In all installations, the initial setup of each mix design should be done with the water addition set to Preset Mode. 1 Preset Mode No sensor signal is required to operate in this mode.

  • Page 34: Auto Mode

    Chapter 5 Water Addition Modes 3 AUTO Mode The AUTO Mode progressively adds water to the mixer to achieve a defined moisture target. The Hydro-Control controls the speed at which the water is added and slows the addition as the current moisture nears the target moisture to accurately reach the target without overshooting it.

  • Page 35: Chapter 6 Creating And Editing Recipes

    Chapter 6 Creating and Editing Recipes This chapter explains how to create a new recipe and how to edit an existing recipe. It also describes the functions of recipe parameters. For information on how to access the Recipes Screen and a description of the functionality of the buttons in the bottom part of the screen, refer to Chapter 2 Navigation, section 4: Recipes Screen.

  • Page 36: Figure 30: Copying An Existing To Create A New Recipe

    Chapter 6 Creating and Editing Recipes Creating a New Recipe Based on an Existing Recipe To create a new recipe based on a recipe existing in Hydro-Control’s database, select the recipe the new recipe will be based on selecting its name in the ‘copy from’ menu and then press the ‘Create Recipe’...

  • Page 37: Editing An Existing Recipe

    Creating and Editing Recipes Chapter 6 Recipe Parameter Description Dry Mix Time Defines the dry mix time. The amount of time to mix for, after adding the main water and before Wet Mix Time signalling that the mix is complete. 3 Editing an Existing Recipe To edit an existing recipe, select the desired recipe by pressing on it.

  • Page 38: Figure 32: Editing A Recipe - Recipe Details

    Chapter 6 Creating and Editing Recipes Recipe Details Figure 32: Editing a Recipe – Recipe Details Recipe parameter Description Recipe Name The name of the recipe displayed on the Overview Screen. Recipe Number The number of the recipe in the Hydro-Control. Batch Counter The number of the last batch made.

  • Page 39: Figure 33: Editing Recipe - Water Addition

    Creating and Editing Recipes Chapter 6 Water Addition Figure 33: Editing Recipe - Water Addition Recipe parameter Description Pre-Wet Water The fixed amount of water to add during the Pre-Wet phase of the mix cycle if the Pre-Wet Water Control Method is set to Preset Mode.

  • Page 40: Figure 34: Editing Recipe - Material Addition And Mixing Times

    Chapter 6 Creating and Editing Recipes Recipe parameter Description Not used by the Hydro-Control but appears in the Recipe. This is Admix Amount the amount of admix stated in the mix design. This can be manually input for information only. Material addition/Mixing Times Figure 34: Editing Recipe - Material Addition and Mixing Times Recipe parameter...

  • Page 41: Figure 35: Editing Recipe - Mix Control

    Creating and Editing Recipes Chapter 6 Recipe parameter Description The amount of time to mix the batch after the Pre-Wet water has Dry Mix Time been added and mixed, and the Cement In signal has been received (if used). After this time, the main water is added. Wet Mix Time The amount of time to mix after the main water has been added before signalling Mix Complete.

  • Page 42: Figure 36: Editing Recipe - Local Auto-Track Settings

    Chapter 6 Creating and Editing Recipes Recipe parameter Description The limit used for the lower limit before alarms are triggered to Minus Tolerance indicate the final moisture is out of tolerance with the target defined by the Target parameter. Recipe Unscaled Mode This indicates the sensor measurement mode used for the recipe.
  • Page 43 Creating and Editing Recipes Chapter 6 Recipe parameter Description Setting enabling the Auto-Track feature for the Wet Mix phase of Auto-Track Wet Mix Enable the recipe. For more information on this feature see Chapter 8. Auto-Track Initial Mix Time When using Auto-Track control, this is the amount of time that the Initial Mix must be within the Initial Mix Deviation below to continue.

  • Page 44: Figure 37: Editing Recipe - Calculation Mode Settings

    Chapter 6 Creating and Editing Recipes Calculation Mode Settings Figure 37: Editing Recipe - Calculation Mode Settings Recipe parameter Description Pre-Wet Moisture Offset 1 Calibration coefficients for the Pre-Wet phase of the recipe. These define the relationship between the amount of moisture in Pre-Wet Moisture Gain 1 the batch and the unscaled sensor value.

  • Page 45: Figure 38: Editing Recipe - Auto Mode Settings

    Creating and Editing Recipes Chapter 6 Auto Mode Settings Figure 38: Editing Recipe - Auto Mode Settings Recipe parameter Description Local Auto Control By default the Auto Parameters in the System Parameters will be used. For difficult mixes it may be necessary to set up unique parameters for the recipe.

  • Page 46: Figure 39: Editing Recipe - Temperature Correction Settings

    Chapter 6 Creating and Editing Recipes Temperature Correction Settings Figure 39: Editing Recipe - Temperature Correction Settings Recipe parameter Description Temperature Set Point The base temperature for the temperature coefficient to work from. Temperature Coefficient The change in moisture per degree Celsius that the current temperature is different from the Temperature Set Point that is added to or subtracted from the target unscaled.

  • Page 47: Chapter 7 Using The Mix Log

    Chapter 7 Using the Mix Log This chapter describes the parameters listed in the Mix Log. For information on how to access the Mix Log Screen and a description of the functionality of the buttons in the bottom part of the screen, refer to Chapter 2 Navigation, Section 5: Mix Log Screen. 1 Introduction The Mix Log records information on mix cycles run with the Hydro-Control.
  • Page 48 Chapter 7 Using the Mix Log The ‘Unscaled’ or ‘Moisture' button can be used to toggle between % Moisture and Unscaled values. The % Moisture values have been derived from the % Moisture target set at the time of making the batch. The columns in the log summary are described in the following table: Column Units...
  • Page 49 Using the Mix Log Chapter 7 Column Units Description Pre-Wet Mix This is the Mode V deviation in the signal taken during %/US Deviation Mode V the Averaging Time or Auto-Track time at the end of the Pre-Wet Mix. Pre-Wet Mix %/US This is the Mode E deviation in the signal taken during Deviation Mode E...
  • Page 50 Chapter 7 Using the Mix Log Column Units Description This is the deviation in the signal taken during the Dry Mix Deviation* %/US Averaging Time or Auto-Track time at the end of the Dry Mix. Dry Mix Deviation %/US This is the Mode F deviation in the signal taken during Mode F the Averaging Time or Auto-Track time at the end of the Dry Mix.
  • Page 51 Using the Mix Log Chapter 7 Column Units Description Recipe Mode The sensor mode used for the recipe. Pre-Wet Water l/gal/sec/lbs/kg This is the quantity of Pre-Wet Water that was added. Main Water l/gal/sec/lbs/kg This is the quantity of Main Water that was added. Target Water l/gal/sec/lbs/kg This is the amount of water that was calculated as...
  • Page 52 Chapter 7 Using the Mix Log Column Units Description Pre-Wet Moisture This is the moisture gain used during the Pre-Wet mix Gain Pre-Wet Moisture This is the moisture offset used in the Pre-Wet mix Offset Moisture Gain 1 This is the first Moisture Gain value used to calculate the moisture for display.
  • Page 53 Using the Mix Log Chapter 7 Column Units Description A Water Meter Fault alarm was triggered during the Water Meter Fault batch. Leaking Water Valve A Leaking Water Valve alarm was triggered during the batch. Waiting For Water A Waiting For Water Tank Fill alarm was triggered Tank Fill during the batch.

  • Page 54: Viewing The Mix Trace

    Chapter 7 Using the Mix Log 3 Viewing the Mix Trace Trace page To access details for a particular batch, select one of the batches from the list and then click the ‘View Mix Trace’ button (the button is only available once a mix log is selected by pressing on its line).

  • Page 55: Figure 43: Mix Trace Data Page

    Using the Mix Log Chapter 7 Data page The Mix Trace Data page contains a list of points recorded during the batch and the amount of water the Hydro-Control added at that point (see Figure 43). Figure 43: Mix Trace Data page Hydro-Control (HC07) Operators Guide HD1048 Rev 1.1.0...
  • Page 56 Chapter 7 Using the Mix Log Hydro-Control (HC07) Operators Guide HD1048 Rev 1.1.0...

  • Page 57: Chapter 8 Running The First Mix

    Chapter 8 Running the First Mix This chapter explains how to set up a recipe and run a mix for the first time. Section 1 describes the theory behind running the first mix of a newly created recipe. The remaining sections of this chapter explain actions to prepare a mix suitable for calibration.

  • Page 58: Set Up The Recipe For The First Mix

    Chapter 8 Running the First Mix The top diagram in Figure 44 shows a mix trace for a recipe that is configured with a Dry Mix and Wet Mix time of 60 seconds. Both the Dry Mix and the Wet Mix reach stability sooner than the 60 seconds defined.

  • Page 59: Figure 45: Water Trim Function Pop-Up Window

    Running the First Mix Chapter 8 Trim the Water Manually to Reach Desired Consistency Check the consistency of the mix. If possible, observe the mix in the mixer through the inspection hatch to see if more water is needed. To add a set quantity of water, enter the amount to add and press the ‘Trim’ button within the pop-up window.

  • Page 60: Figure 46: Mix Log - Sensor Values Display Group

    Chapter 8 Running the First Mix Check the Mix Log After running the first mix, it is important to view the mix log to check that the mix times are long enough. Navigate to the Mix Log screen and select the mix to be checked from the list of mix logs (see Chapter 7 Using the Mix Log for details).

  • Page 61: Chapter 9 Using Moisture Control

    Chapter 9 Using Moisture Control This chapter describes selecting between using CALC Mode and AUTO Mode for a given recipe and configuring and optimising a recipe for that mode. 1 Moisture Control and Homogeneity The aim of moisture control is to accurately reach a chosen moisture target in the shortest time possible for a homogenous mix.

  • Page 62: Calc Mode

    Chapter 9 Using Moisture Control 2 CALC Mode Mixer Main Water Wet Mix Dry Mix Time Discharge Loading Addition Time Moisture Average moisture Calculated reading is taken at water added the end of the Dry in one dose Mix and the quantity of water needed is calculated Time...
  • Page 63 Using Moisture Control Chapter 9 Configuring the recipe When using CALC Mode each recipe must first be calibrated. This is done by using a batch that has previously been run which is of the correct moisture and quality. The previous chapter details how to run the first batch.

  • Page 64: Figure 50: Calibrating A Recipe

    Chapter 9 Using Moisture Control The CALC Mode calibration procedure This process starts by selecting a suitable mix from the Mix Log screen. A suitable mix has the following: 1. Correct final moisture. 2. Stable dry and wet readings (low deviation values). 3.

  • Page 65: Figure 51: Summary Of Calibration Parameters

    Using Moisture Control Chapter 9 Parameter Description Target Value Enter a target for the main water addition (see NOTE below). If no dry weight has been entered into the recipe, then the Dry Weight calibration process will prompt the operator to enter one at this point.

  • Page 66: Figure 52: The Calc Mode Calculation

    Chapter 9 Using Moisture Control Optimising CALC Mode CALC Mode works by taking one average value at the end of the Dry Mix, and a second average value at the end of the Wet Mix. Using these two values and the percentage moisture change between the two points (this is the quantity of water added divided by the batch weight) it is possible to calculate the quantity of water that is needed to get from any other start point to the target moisture value.

  • Page 67: Figure 53: The Calibration Failed Error Message

    Using Moisture Control Chapter 9 It is important that there is sufficient difference between the sensor reading taken at the end of the dry mix phase and the sensor reading taken at the end of the wet mix phase to give a good moisture range for the calibration calculation.

  • Page 68: Figure 55: Comparing Measurement Modes

    Time Figure 55: Comparing Measurement Modes For advice on selecting the measurement mode contact the Hydronix support team at support@hydronix.com 2.11 Dry weights If the raw material dry weights change between batches, then this value must be updated in the recipe.

  • Page 69: Auto Mode

    Using Moisture Control Chapter 9 3 AUTO Mode Mixer Dry Mix Main Water Addition Wet Mix Time Discharge Loading Time Moisture Target Current moisture monitored and water added to reach the target moisture Time Figure 56: The moisture during AUTO Mode Introduction AUTO Mode adds water progressively to reach the moisture target defined in the recipe parameters.

  • Page 70: Figure 57: The Effect Of Changing The Proportional Gain

    Chapter 9 Using Moisture Control If required, it is possible to calibrate the recipe to display a real moisture value. The same sequence as for CALC Mode should be used (see section 2.8 above). After entering the calibration data, the Recipe will default to CALC Mode and should be set to Auto Mode. Optimising (Auto Loop Tune) Different installations will mix the water in at different rates and therefore the AUTO Mode parameters may need to be adjusted to optimise the speed and accuracy of the water addition.

  • Page 71: Figure 58: The Effect Of Changing The Integral Gain

    Using Moisture Control Chapter 9 Moisture Too High Target Correct Too Low/ No Gain Time Figure 58: The effect of changing the Integral Gain Figure 58 shows the effect of changing the Integral Gain. Integral Gain will act to increase the water flow depending on the length of time that has passed.

  • Page 72: Using Admixtures

    Chapter 9 Using Moisture Control 4 Using Admixtures Introduction In general, admixtures or colours should be dosed after the water addition has started so as not to be added on top of the dry material. Dosing simultaneously with the water aids dispersion into the mix and can help the mixing action, improve mix quality, and reduce mix cycle times.

  • Page 73: Auto-Track

    Using Moisture Control Chapter 9 Figure 61 shows the 2-Step Water Addition calibration points that are taken from the cycle shown in Figure 60. The line from point A to point C is used for the water calculation when in CALC Mode.

  • Page 74: Figure 62: Mix Trace Showing The Auto-Track Function

    Chapter 9 Using Moisture Control Recipe Dry Mix Time Auto-track Moisture Dry Mix Deviation Auto-Track Dry Mix Auto-Track Time Dry Mix Time Auto-track Dry Mix Time starts Finishes Figure 62: Mix trace showing the Auto-Track function Figure 62 shows the mix trace for a Dry Mix phase using the Auto-Track feature. The Auto-Track feature is enabled at the point Dry Mix Time –...

  • Page 75: Temperature Compensation

    Using Moisture Control Chapter 9 6 Temperature Compensation In environments where there are large changes in temperature it can be necessary to change the viscosity of the mix. It is advisable to do this by varying the amount of admixture in the mix. In this circumstance it is advisable to calibrate the recipe when the least amount of admix is required (usually at the coolest part of the day).
  • Page 76 Chapter 9 Using Moisture Control Hydro-Control (HC07) Operators Guide HD1048 Rev 1.1.0...

  • Page 77: Chapter 10 Alarm Configuration

    Chapter 10 Alarm Configuration This chapter describes the system alarms. Alarms are messages displayed on the device’s screen that assist in managing, monitoring, and controlling the mixing process. 1 Alarms When an alarm is triggered, a visual prompt is displayed, indicating the nature of the problem. The Alarm output is also activated to signal to the batch control system that a problem exists.
  • Page 78 Chapter 10 Alarm Configuration Water Meter Fault This alarm is triggered if a water valve has been opened and the water meter has not pulsed within the time set by the ‘Water Meter Timeout’ parameter defined in the System Parameters pages.

  • Page 79: Figure 64: Unsuccessful Mix Start Error Message

    Alarm Configuration Chapter 10 Water Limit Exceeded In AUTO Mode this alarm is triggered if the water addition has reached the ‘Water Limit’ parameter defined in the recipe. Check: The recipe ‘Water Limit’ parameter is high enough. • The AUTO Mode tuning should be adjusted not to overshoot the target value. •...
  • Page 80 Chapter 10 Alarm Configuration Attempting to use the device with the ‘Sensor Fault’ alarm disabled will result in the red ‘Enable Sensor Fault Alarm’ button to appear on the Overview screen. Press the button to re-enable the alarm function. Further information on cabling can be found in the sensor user guides. Mixer Blades Worn This alarm notifies the operator about mixer blades needing adjustment.

  • Page 81: Chapter 11 Backup, Restore And Upgrade

    Chapter 11 Backup, Restore and Upgrade This chapter describes how to back up and restore the internal database. Performing a software upgrade is also described in this chapter. Having access to the device’s database is extremely useful when diagnosing system performance-related problems. A USB memory stick may be used for backing up and restoring recipes, system parameters and mix log files.

  • Page 82: Upgrading Software

    2 Upgrading software Hydro-Control’s software can be upgraded using a USB memory stick. The newest version of the software can be downloaded from www.Hydronix.com. To access the Software Upgrade function, navigate to the ‘Settings’ screen and then to the ‘System’ page (see Figure 14).

  • Page 83: Figure 66: Upgrading The Software

    Backup, Restore and Upgrade Chapter 11 Figure 66: Upgrading the Software An ‘Update in Progress – System will Reboot’ message will appear. The Hydro-Control will automatically reboot and revert to the Overview screen. The memory stick can only be removed after the device has fully restarted. IMPORTANT NOTE: DO NOT REMOVE THE USB MEMORY STICK OR DISCONNECT POWER DURING THE UPGRADE PROCEDURE.
  • Page 84 Chapter 11 Backup, Restore and Upgrade Hydro-Control (HC07) Operators Guide HD1048 Rev 1.1.0...

  • Page 85: Chapter 12 Remote Support

    Chapter 12 Remote Support A remote connection can be established with a Hydro-Control unit utilising Ethernet connectivity. An engineer using a PC in a remote location can connect to the Hydro-Control to view, control, and change the device's configuration. As the engineer at the remote location makes changes, the operator will see what changes are being made and what screens are accessed.

  • Page 86: Figure 68: Logging In Remotely

    Chapter 12 Remote Support Figure 68: Logging in remotely Hydro-Control (HC07) Operators Guide HD1048 Rev 1.1.0...

  • Page 87: Chapter 13 Optimisation

    Chapter 13 Optimisation The moisture reading from a sensor can only indicate what is happening in the mixer. The speed of reading, or the time taken to reach a steady reading when the materials are homogeneous, reflects the mixer's effectiveness. By taking some simple precautions, the overall performance can be considerably improved, and the cycle time reduced with consequent financial savings.

  • Page 88: Consistency

    Chapter 13 Optimisation 3 Consistency A sensor measures moisture, not consistency. Many factors affect consistency but may not affect moisture content. These might include: Aggregate grading (coarse/fine ratio) • Aggregate/cement ratio • Admixture dosage dispersion • Ambient temperature • • Water/cement ratio •...

  • Page 89: Chapter 14 Frequently Asked Questions

    We had a lightning strike, and now the unit doesn’t work correctly, can I do any onsite repairs? It is not possible to do any repairs onsite, and any attempts of onsite repairs will invalidate any warranty outstanding. In such cases the equipment should be sent back to Hydronix for repair. _ _ _ I ordered a 110v AC unit but the label on the back shows a 24v DC power input.
  • Page 90 Chapter 14 Frequently Asked Questions Can I still run in calculation mode without recalibrating if I change my mix design? Any change in the mix design may need a different calibration and so should be run with a separate Hydro-Control recipe. This might include changes in pigment (colour), ratios of aggregates, cement supplier or type of admixture.
  • Page 91 The mix log is a very useful tool for diagnosing problems with the controller. It is also useful to know the recipe, system, and control parameters. These can be transferred onto a USB Memory Stick by doing a Backup (see Chapter 11). The file can be emailed to Hydronix as an aid for diagnostics.
  • Page 92 Chapter 14 Frequently Asked Questions Hydro-Control (HC07) Operators Guide HD1048 Rev 1.1.0...

  • Page 93: Appendix A Diagnostics

    The following tables list the most common faults found when using the controller that can possibly be diagnosed by a qualified operator. In case of difficulties experienced in diagnosing the problem, contact the system administrator or Hydronix technical support on +44 1483 468900 or by email: support@hydronix.com.
  • Page 94 Appendix A Diagnostics Hydro-Control (HC07) Operators Guide HD1048 Rev 1.1.0...

  • Page 95: Appendix B Glossary

    Appendix B Glossary Analogue Output The analogue outputs are continuously variable voltages or currents that can be configured to output the sensor’s moisture or unscaled output to a batch control system using an analogue input module. Automatic Calibration (AutoCal) To simplify fitting a new sensor arm to a Hydro-Probe Orbiter, the sensor can be automatically calibrated.
  • Page 96 Appendix B Glossary Pre-Wet Water This is the water that is added at the start of the process before any dry mixing is done. Probe See Sensor. RS485 This is the serial communication protocol that the sensors use to communicate digitally with the control system.

  • Page 97: Appendix C Document Cross Reference

    Appendix C Document Cross Reference 1 Document Cross Reference This section lists all other documents that are referred to in this User Guide. It is beneficial to have a copy available when reading this guide. Document Number Title HD1074 Hydro-Control (HC07) Installation Guide HD1100 Hydro-Control (HC07) Safety Information Hydro-Control (HC07) Operators Guide HD1048 Rev 1.1.0...
  • Page 98 Appendix C Document Cross Reference Hydro-Control (HC07) Operators Guide HD1048 Rev 1.1.0...
  • Page 99 Index Admixtures ............ 72 Consistency ..........87 2-Step Water Addition ....... 73 Deviation ............61 Amount ............40 Diagnostics Enable ............39 Controller ........... 93 Alarms ............77 Dribble Feed ....... See Auto Mode Cement In ..........77 Dry Mix (Dry Mix) .......... 57 Leaking Water Valve .........
  • Page 100 Index Error! Reference source not found. Mix Control ..........41 Restore ............81 Mixing Times ..........40 Sensor Performance ........87 Recipe Details ........19, 38 Signal stability ..........88 Temperature Correction Settings ....46 Slump ........See Consistency Water Addition ........... 39 Spray Bars ............

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