Page 1 Hydro-Control (HC07) Installation Guide To re-order quote part number: HD1074 Revision: 1.2.0 Revision date: July 2023...
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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) Installation Guide HD1074 Rev 1.2.0...
Page 5 Revision history Revision No Software Date Description of Change Version 1.0.0 May 2023 First Release 1.1.0 June 2023 (HC06) to (HC07) adaptor plate information added 1.2.0 July 2023 Referenced documents list and mounting brackets info updated Hydro-Control (HC07) Installation Guide HD1074 Rev 1.2.0...
Page 6 Hydro-Control (HC07) Installation Guide HD1074 Rev 1.2.0...
Page 7: Table Of Contents
Installations using AC I/O ......................27 Connector pin assignments ......................28 Power Supply ..........................30 Communications ......................... 30 Expansion Board (Hydronix Part Number 7010) ................ 31 I/O Wiring Diagrams ........................32 Cables ............................37 USB Ports ........................... 37 Chapter 5 Commissioning ........................39 Navigation ..........................
Page 8 Hydro-Control (HC07) Installation Guide HD1074 Rev 1.2.0...
Page 9 Table of Figures Figure 1: The Hydro-Control screen ..................... 17 Figure 2: Example implementation of Hydro-Control ................17 Figure 3: The Hydro-Control ......................... 18 Figure 4: Rear view of the Hydro-Control ..................... 21 Figure 5: Mounting brackets........................22 Figure 6: Panel cut-out for the Hydro-Control ..................22 Figure 7: Aligning (HC06) and (HC07) panel cutouts ................
Page 10 Figure 40: Archiving page ........................51 Figure 41: The weighed water setup page .................... 52 Figure 42: Sensor overview screen navigation ..................53 Figure 43: The sensor details page ...................... 54 Figure 44: Digital I/O page ........................55 Figure 45: Analogues page ........................55 Figure 46: Signal Processing page .......................
Page 11 Figure 81: USB Ports location ......................107 Hydro-Control (HC07) Installation Guide HD1074 Rev 1.2.0...
Page 12 Hydro-Control (HC07) Installation Guide HD1074 Rev 1.2.0...
Page 13: Chapter 1 Safety Information
HC07 AC IO Board Fuse Replacement Guide EN0112 HC07 IO Board Replacement Guide All above mentioned documents are available on request or on www.Hydronix.com website. Responsibilities The safety of any system incorporating the equipment described in this documentation is the responsibility of the assembler of the system.
Page 14: Classifications And Markings
Hydro-Control (HC07) Safety Information. Intended use Hydro-Control (HC07) is intended to work with the Hydronix range of sensors to monitor the moisture level in a process and send signals to adjust the water flow into the process using water valves.
Page 15 Chapter 1 Introduction Cleaning The front panel of the Hydro-Control should be cleaned with a soft cloth. Abrasive materials and liquids must not be used. Clearance Requirements It is important to ensure that the Hydro-Control has adequate clearance for ventilation and access.
Page 16 Chapter 1 Safety Information Hydro-Control (HC07) Installation Guide HD1074 Rev 1.2.0...
Page 17: Chapter 2 Introduction
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 18: Packaging And Box Content
Chapter 2 Introduction 2 Packaging and box content Figure 3: The Hydro-Control Standard Contents: Hydro-Control (HC07) unit Antenna Kit Top/Bottom fixing brackets Side fixing brackets QR code label Declaration of Conformity Safety Information (HD1100) Additional Contents (If Expansion Board has been factory fitted): 9 Way Connector for Analogue Inputs/Outputs 9 Way Connector for Recipe Selection Inputs Hydro-Control (HC07) Installation Guide HD1074 Rev 1.2.0...
Page 19 Introduction Chapter 2 Accessories: Part No. Description 0117 Power Supply - 24V DC, 120W to power up to 16 sensors 7010 Hydro-Control (HC07) Expansion board for retrofit* 7025 Hydro-Control (HC07) System Card 0175 Panel Mount USB Socket 7010 Hydro-Control (HC07) Expansion board for retrofit 7025 Hydro-Control (HC07) System Card 7030...
Page 20 Chapter 2 Introduction Hydro-Control (HC07) Installation Guide HD1074 Rev 1.2.0...
Page 21: Chapter 3 Mechanical Installation
Chapter 3 Mechanical Installation Figure 4: Rear view of the Hydro-Control 1 Weight and Dimensions 290 mm (W) x 192 mm (H); (11.42” (W) x 7.56” (H)) Fascia: 265 mm (W) x 168 mm (H); (10.43” (W) x 6.61” (H)) Panel Cut out: Min Panel Thickness: 1 mm...
Page 22: Mounting And Installation
Chapter 3 Mechanical Installation 2 Mounting and installation The Hydro-Control is designed to be mounted in a control panel with a maximum thickness of 3mm. The unit is supplied with four mounting brackets one for each side. Figure 5: Mounting brackets Typical (new) installation To install the Hydro-Control in a cabinet with no pre-existing cut-out: •...
Page 23: Figure 7: Aligning (Hc06) And (Hc07) Panel Cutouts
Mechanical Installation Chapter 3 Affixing Hydro-Control (HC07) in a (HC06) cabinet To install the Hydro-Control in a cabinet that previously housed Hydro-Control VI (HC06): • Using the Hydro-Control (HC06) to (HC07) adapter plate (part No 7050) as a template, modify the aperture in the panel to the correct size. To do this ensure that the new (HC07) cutout’s lower edge is aligned with the existing (HC06) cutout and horizontally centralised.
Page 24 Chapter 3 Mechanical Installation Hydro-Control (HC07) Installation Guide HD1074 Rev 1.2.0...
Page 25: Chapter 4 Electrical Installation
Chapter 4 Electrical Installation This chapter explains the configuration of the connectors on the Hydro-Control unit and how the wiring should be designed and installed. These connections will vary depending on the configuration and integration requirements of the system design. 1 Connecting the HC07 to an existing HC06 installation CAUTION DO NOT CONNECT existing HC06 wiring to the HC07 device!
Page 26: Figure 10: Hc06 Wiring To Hc07 Adaptor Loom
Chapter 4 Electrical Installation Making the Correct Connections The Hydro-Control (HC07) can be connected to an existing HC06 wiring installation in one of two ways: Using an HC06-to-HC07 adaptor loom (part No. 7060) Re-wiring the HC06 connector to match the HC07 pinout (see Figure 9) Figure 10: HC06 wiring to HC07 adaptor loom When the HC06-to-HC07 adaptor loom (part No.7060) is not available, the wiring configuration of the 10-pin terminal block can be changed to match the pinout of the HC07...
Page 27: Installations Using Ac I/O
Electrical Installation Chapter 4 2 Installations using AC I/O Live mains voltage danger points Danger Live Terminals IMPORTANT NOTE: When fitted with the AC I/O card (device model HC07-110) the Hydro-Control may have some of its electrical connections carrying mains voltage. This is true for terminals 1-24.
Page 28: Connector Pin Assignments
Chapter 4 Electrical Installation 3 Connector pin assignments Output Connector Pins Name Description Coarse Valve Controls the larger coarse water addition valve Fine Valve Controls the smaller fine water addition valve Pre-Wet Done Indicates the end of the Pre-Wet phase Mix Complete Indicates the Hydro-Control has completed the mix cycle Alarm...
Page 29 Electrical Installation Chapter 4 Power and Communications Connector Pins Name Description RS232 Rx RS232 data transmit line RS232 Tx RS232 data receive line RS232 Gnd RS232 ground RS485 B RS485 line B for connection to the sensor RS485 A RS485 line A for connection to the sensor Sensor 0V 0VDC connection for powering the sensor Sensor +24V...
Page 30: Power Supply
5 Communications RS485 The RS485 connection is used for communicating with a Hydronix moisture sensor. It is possible to change operating parameters and sensor diagnostics from the Hydro-Control. RS232 The RS232 connection is used for connection to a batch computer or remote operator terminal to permit the remote selection of recipes.
Page 31: Expansion Board (Hydronix Part Number 7010)
7020 110 - 240 VAC 6 Expansion Board (Hydronix Part Number 7010) The Expansion Board is an optional add-on that can be used to provide additional functionality. The board may be added to the system at any time, enabling the use of the weighed water system and the remote recipe selection inputs.
Page 32: O Wiring Diagrams
Chapter 4 Electrical Installation 7 I/O Wiring Diagrams It is recommended that any field wiring is protected by an emergency stop device that can disconnect the devices being controlled from the signal given by the Hydro-Control in the event of a fault. Wiring digital inputs The inputs function in a similar way to the coil side of a normally open relay.
Page 33: Figure 16: Connecting A Dc Input Signal To An Ac Input Card
Electrical Installation Chapter 4 Custom I/O combination This section shows suggested connections for mixed I/O requirements. 7.3.1 Connecting a DC input signal to the AC input card Figure 16 shows an example of an electrical connection when interfacing a DC input signal with Hydro-Control fitted the AC I/O card is required.
Page 34: Figure 18: Activating An Ac Device Using Dc I/O Card Output
Chapter 4 Electrical Installation 7.3.3 Activating an AC device from a DC I/O Module Hydro-Control DC I/O card output 24Vdc supply External add-on 24Vdc relay Voltage free output Figure 18: Activating an AC device using DC I/O card output 7.3.4 Activating a DC device from an AC I/O Module Hydro-Control AC I/O card output...
Page 35: Figure 21: Connecting A Loop-Powered Device
Electrical Installation Chapter 4 The wiring of the device connected to the Analogue Input will depend on whether the device has a self-powered loop or is powered by the loop itself. Device Loop Power Hydro-Control Supply Figure 21: Connecting a loop-powered device Figure 21 shows the wiring diagram for connecting an analogue device that does not have a power source.
Page 36: Figure 24: Analogue Output Wiring Diagram
Chapter 4 Electrical Installation Wiring analogue outputs The analogue outputs from the Hydro-Control are designed as a constant current source. Hydro-Control Current loop signal 0-20 mA 4-20 mA Analogue GND Figure 24: Analogue Output Wiring Diagram These are designed for future expansion. Note that all ‘-‘...
Page 37: Cables
Each of these can accept a standard USB memory stick. A panel mount USB socket with an extension cable is available from Hydronix, Part Number 0175. This has a 1.5m cable, and the panel-mounted socket needs a 28mm diameter hole with a 3mm key cut-out.
Page 38 Chapter 4 Electrical Installation Hydro-Control (HC07) Installation Guide HD1074 Rev 1.2.0...
Page 39: Chapter 5 Commissioning
Chapter 5 Commissioning 1 Navigation The Hydro-Control is a touch screen device. Navigation of the unit is achieved by touching the screen itself to activate relevant features. To access the device’s menu screens, use the buttons marked as ‘Menu bar buttons’ in Figure Menu bar buttons Figure 26: Main menu bar The menu bar enables access to the following main categories:...
Page 40 Chapter 5 Commissioning Sensor Overview Displays the sensor configuration screen allowing changes to the filtering and I/O settings. Settings Enables configuration of system time and date, units of measurement, IP address settings, and screen brightness. Software upgrade and database backup can be performed using the submenu of this section.
Page 41: Basic Tests And Configuration
‘Hardware’ screen. Sensor Testing The Hydro-Control uses an RS485 serial interface to communicate with the Hydronix moisture sensor in the mixer. Once the unit has finished loading, it will display the main screen with a message in the centre reading ‘Searching’.
Page 42: Figure 27: I/O Test Page
Chapter 5 Commissioning Digital Inputs status Digital Outputs status Figure 27: I/O test page To stop the Hydro-Control from responding to the received inputs (for example, starting a mix when the Start signal is activated), press the ‘Disable Inputs’ button and then the ‘Save’ button.
Page 43: Figure 28: Analogue Inputs Configuration
Commissioning Chapter 5 Testing Analogue Inputs The analogue inputs can be tested using the ‘Analogues’ page on the ‘Hardware’ screen (see Figure 28). Figure 28: Analogue inputs configuration The ‘Analogues’ page of the ‘Hardware’ screen shown in Figure 28 enables the configuration of the Analogue Inputs and Outputs.
Page 44: Figure 30: Remote Recipe Modes
Chapter 5 Commissioning Figure 30: Remote recipe modes Selecting the RS232 communication mode is done using a drop-down list of the ‘RS232 Mode’ field (Figure 31). Select the desired option, then press the ‘Save’ button. Configuring the RS232 communication settings is described in more detail in Chapter 7. Figure 31: RS232 communication mode selection Selecting the Admix output mode is done using a drop-down list of the ‘Admix Mode’...
Page 45: Figure 32: Admix Output Configuration
Commissioning Chapter 5 Figure 32: Admix output configuration Selecting the Water Tank Full input mode is done using a drop-down list of the ‘Water Tank Full Type’ field (Figure 33). Select the desired option, then press the ‘Save’ button. The Water Tank Full signal is used to indicate that the water weigh scale is full. If configured, the Water Tank Full signal can also be used to initiate a system shut down.
Page 46: System Parameters
Chapter 5 Commissioning 3 System Parameters The ‘System Parameters’ screen enables configuration of the system parameters, including water meter and valve setup, AUTO Mode, Auto-Track parameters, and alarm configuration. This section describes the system parameters functions, their units, range, and the default value. General At the bottom of the System Parameters subpages are two buttons: •...
Page 47: Figure 36: Water Setup Page - Timed
Commissioning Chapter 5 Figure 36: Water setup page – timed Figure 37: Water setup page - weighed Each item on the parameters page is described in the following pages. Greyed-out items are not required for the currently selected water mode. Parameter Units Default...
Page 48 Chapter 5 Commissioning 0 – 100 L Fine Inflight Water Litres/Gallons 0 – 26.4 Gallons 0 – 100 L Coarse Inflight Water Litres/Gallons 0 – 26.4 Gallons 0 – 100 s Fine Valve On Time Seconds 0 – 100 s Fine Valve Off Time Seconds Fine Valve Only...
Page 49: Figure 38: Auto Control Page
Commissioning Chapter 5 Alarms The ‘Alarms’ page of the ‘System Parameters’ screen allows each of the alarms in the system to be disabled. The parameters of this section are detailed in Chapter 10 of the Operators Guide (HD1048). Auto Control Figure 38: Auto control page Parameter Units...
Page 50: Figure 39: System Parameters - Auto-Track
Chapter 5 Commissioning Auto-Track Figure 39: System Parameters - Auto-Track Parameter Units Default Range 0 – 100 Auto-Track Initial Mix Dev 0 – 100 Auto-Track Initial Mix Time Seconds 0 – 100 Auto-Track Pre-Wet Mix Dev 0 – 100 Auto-Track Pre-Wet Mix Time Seconds 0 –...
Page 51: Figure 40: Archiving Page
Commissioning Chapter 5 Archiving Figure 40: Archiving page Parameter Units Default Range Archiving None ON/OFF Max Mix Logs None 1-1000 The Archiving switch, when in the ON state (signified by yellow colour), will enable the Hydro-Control to save all mix log data that exceeds the Max Mix Logs limit to archive files. Once the Max Mix log limit has been reached any Mix Logs that are removed from the main database are copied to the archive file.
Page 52: Figure 41: The Weighed Water Setup Page
Chapter 5 Commissioning Figure 41: The weighed water setup page With the water tank empty, copy the ‘Weigh Scale Input’ value into the ‘Analogue Value When Empty’ field (see Figure 41). The Hydro-Control needs now to be set to use weighed water. This is done on the ‘Water Setup’...
Page 53: Sensor Overview
Commissioning Chapter 5 4 Sensor Overview With a sensor connected, the measurement parameters and settings can be changed by using the Sensor Overview screen and its subpages. This section of the manual briefly describes the options available in the subpages. For more detailed information on the available parameters, refer to the Sensor Configuration and Calibration Guide (HD0679).
Page 54: Figure 43: The Sensor Details Page
Hydronix sensors. Backup To Sensor and Restore From Sensor All Hydronix sensors utilising firmware HS0102 and above can store a copy of the sensor configuration settings in the internal memory. This facility enables the user to backup the sensor configuration so it can be restored later if required.
Page 55: Figure 44: Digital I/O Page
Commissioning Chapter 5 Digital I/O This section allows the digital input/output options to be configured. Figure 44: Digital I/O page Analogues This section allows the setup of the analogue outputs of the sensor to be adjusted. As the Hydro-Control communicates with the sensor using the RS485, the analogue outputs can be used independently of the main control itself.
Page 56: Figure 46: Signal Processing Page
Chapter 5 Commissioning Signal Processing This section enables adjusting the sensor’s signal processing parameters. It may be necessary to adjust these depending on the mixer being used to improve the stability and response of the sensor reading. Figure 46: Signal Processing page Averaging and Auto-Track This section configures the Averaging function in the sensor.
Page 57: Figure 48: Temperature Compensation Page
Commissioning Chapter 5 Temperature Compensation This section allows the temperature compensation parameters to be changed. Changing these settings when using a Hydro-Probe Orbiter and changing the Orbiter Arm may be necessary. An Engineering Note is included with relevant Orbiter Arms, which details the settings that must be entered.
Page 58: Figure 50: Factory Settings Page
Chapter 5 Commissioning Factory This page displays the current measurement calibration and enables a new calibration of the sensor to be performed. Figure 50: Factory settings page Air / Water Frequency and Amplitude calibration settings This section allows the factory calibration of the sensor to be changed. This is necessary if the sensor is a Hydro-Probe Orbiter and the arm is changed or if the sensor is a Hydro-Mix and the ceramic faceplate is replaced.
Page 59: Figure 51: Live Data Diagnostics Page
Commissioning Chapter 5 Sensor Diagnostics – Live Data 4.10 This screen shows information about the sensor. This can be used to perform basic diagnostic checks to establish if the sensor is operating correctly. Figure 51: Live Data diagnostics page Sensor Diagnostics – Hardware Test 4.11 The two analogue outputs are tested by forcing each output to a known value.
Page 60: Settings
Chapter 5 Commissioning 5 Settings This section describes the ‘Settings’ screen parameters functions. General At the bottom of the ‘Settings’ screen subpages are two buttons: • Save – This button saves changes to the system parameters. • Close – If unsaved changes are detected, the user is given the option to ‘Discard’ and return to the Overview screen or ‘Cancel’...
Page 61: Figure 54: Settings - Date/Time Page
Commissioning Chapter 5 Date/Time Figure 54: Settings - Date/Time page Settings parameter Description Date Format Sets the date format. Date / Time Sets the current time. Time Zone Sets the time zone. 5.4.1 Selecting date format The device supports four date formats. The desired format can be selected by pressing on the ‘Date Format’...
Page 62: Figure 56: Settings - Selecting The Time Zone
Chapter 5 Commissioning 5.4.2 Selecting Time Zone To change the current time zone parameter, press on the ‘Time Zone’ field. Select the desired time zone from the drop-down menu and press the ‘Save’ button. (refer to Figure 56). Figure 56: Settings - selecting the time zone 5.4.3 Setting date and time The system ‘Date / Time’...
Page 63: Figure 57: Settings - Selecting The Day And Time
Commissioning Chapter 5 Figure 57: Settings - selecting the day and time Figure 58: Settings - selecting the month Hydro-Control (HC07) Installation Guide HD1074 Rev 1.2.0...
Page 64: Figure 59: Settings - Selecting The Year
Chapter 5 Commissioning Figure 59: Settings – selecting the year Measures Figure 60: Settings – Measures page Settings parameter Description Weight Sets unit of measure for weight. Volume Sets unit of measure for volume. Temperature Sets unit of measure for temperature. Hydro-Control (HC07) Installation Guide HD1074 Rev 1.2.0...
Page 65: Figure 61: Settings - Brightness Page
Commissioning Chapter 5 Network A detailed description of the functions available on the Network page is covered in Chapter 1 Section 9 of the Safety Information (HD1100). Brightness Figure 61: Settings – Brightness page Settings parameter Description Brightness The slider sets the screen brightness level. Hydro-Control (HC07) Installation Guide HD1074 Rev 1.2.0...
Page 66: Recipe Parameters
Chapter 5 Commissioning 6 Recipe Parameters This section describes the recipe parameters functions, their units, range and the default value. Accessing the Recipes screen and it’s subpages, as well as selecting, creating and editing recipes, is described in more detail in chapter 6 of the Operators Guide (HD1048). Recipe Details The first screen of the Recipes section stores and displays the recipe details, the water addition and the material addition/mixing times.
Page 67: Figure 63: Editing Recipe - Water Addition
Commissioning Chapter 5 Water Addition Figure 63: Editing Recipe - Water Addition Parameter Units Default Range 0 – 999 Litres Pre-Wet Water Litres/Gallons 0 – 264 Gallons 0 – 999 Litres Pre-Wet Water Limit Litres/Gallons 0 – 264 Gallons 0 – 999 Litres Main Water Litres/Gallons 0 –...
Page 68: Figure 64: Editing Recipe - Material Addition And Mixing Times
Chapter 5 Commissioning The Pre-Wet Water parameter sets the quantity of water that should be dosed into the mixer during the pre-wet phase of the mix cycle. The Pre-Wet Water Limit parameter sets the maximum amount of water that will be added, when the system is running with the pre-wet water in AUTO Mode, before the system will alarm.
Page 69 Commissioning Chapter 5 Parameter Units Default Range 0 – 32000 kg Dry Weight kg/lbs 0 – 70547 lbs 0 – 32000 kg Cement Weight kg/lbs 0 – 70547 lbs 0 – 999 s Cement Timeout Seconds 0 – 999 s Initial Mix Time Seconds 0 –...
Page 70: Figure 65: Editing Recipe - Mix Control
Chapter 5 Commissioning Mix Control Figure 65: Editing Recipe - Mix Control Parameter Units Default Range Pre-Wet Control None Preset Preset/Auto/Calculation 0 – 99.9 % Pre-Wet Target Main Water Control None Preset Preset/Auto/Calculation 0 – 99.9 % Target 0 – 99.9 % Plus Tolerance 2.75 0 –...
Page 71: Figure 66: Editing Recipe - Local Auto-Track Settings
Commissioning Chapter 5 Local Auto-Track Figure 66: Editing Recipe - local Auto-Track settings Parameter Units Default Range Auto-Track Initial Enable None Yes/No Auto-Track Pre-Wet Enable None Yes/No Local Auto-Track Enable None Yes/No Auto-Track Dry Enable None Yes/No Auto-Track Wet Enable None Yes/No 0 –...
Page 72: Figure 67: Editing Recipe - Calculation Mode Settings
Chapter 5 Commissioning Auto-Track is the facility to configure the system to measure the stability or homogeneity of the mix. If the sensor value is within a certain deviation for a set time, this function allows the mix time to finish earlier. Auto-Track Initial Enable, Auto-Track Pre-Wet Mix Enable, Auto-Track Dry Enable and Auto-Track Wet Enable parameters can be used to set whether the auto track feature is used on any of the mix phases .
Page 73: Figure 68: Editing Recipe - Auto Mode Settings
Commissioning Chapter 5 The calculation mode settings are automatically generated the recipe is calibrated from a suitable batch. These should not need to be changed. After the recipe has been calibrated, if the moisture is displayed incorrectly, then the calibration parameters can be reset to their default values by pressing the ‘Reset Calibration’...
Page 74: Figure 69: Editing Recipe - Temperature Correction Settings
Chapter 5 Commissioning Temperature Correction Settings Figure 69: Editing Recipe - Temperature Correction Settings Parameter Units Default Range 0 – 100 °C Temperature Set Point °C -9.9999 – 9.9999 Temperature Coefficient %M/°C The temperature correction settings are designed to allow system designers to compensate for the effects of hot or cold weather on the reactions in the concrete by changing the target moisture depending on the temperature.
Page 75: Chapter 6 System Design
Chapter 6 System Design 1 Water Valves Introduction While the Hydro-Control can work with a single water control valve, optimum performance will only be achieved with: • A coarse valve to rapidly bring the moisture level near to target • A fine valve to trim the moisture level to the target without overshoot It is essential that the valves are correctly sized and flow rates correctly adjusted with respect to the mixer capacity and efficiency.
Page 76 Chapter 6 System Design The next two tables show the recommended flow rates for different sizes of mixer. Mixer Load Coarse valve Fine valve Capacity (Kg) (m³) Flow rate On/Off % Moist Flow rate On/Off % Moist (L/sec) Time (sec) Increase (L/sec) Time (sec)
Page 77: Flow Measurement
System Design Chapter 6 Example Metric units: If a 1m mixer has only a coarse valve and the water flow rate through the valve is 10 L/s with an on/off cycle time of 1 sec, then water can only be added in 10 L steps. With a full load (~ 2200 Kg) then the smallest moisture step is approx.
Page 78: Retrofitting Systems
Chapter 6 System Design 3 Retrofitting Systems The Hydro-Control may easily be retro-fitted to any plant control system to allow an easy upgrade to enable moisture controlled water addition. Ethernet Ports Port 24v DC POWER WATER TANK FULL PAUSE/RESET START/RESUME CEMENT IN WATER TANK FILL ADMIX...
Page 79: Figure 72: Example Wiring Schematic For Manual Plant Operation
System Design Chapter 6 Basic connections Figure 71 shows the block diagram of a system. Although the simplest configuration requires only the fine valve to be connected, it is recommended that a way of measuring the amount of water dosed into the mixer is also used, either using a flow meter or using a weighed water system.
Page 80 Chapter 6 System Design Remote Recipe Selection If the recipe design in the mixer changes (for example, if a different mix of aggregates is used, a different type of cement, a different admixture, or a different colour or pigment) then, it is strongly recommended to use different recipes in the Hydro-Control for calibration and control.
Page 81: Figure 73: System Interconnections
System Design Chapter 6 Function Hydro-Control Power Supply 24v External 24v DC Power Supply 0v Sensor Power 24v Sensor Power 0v Hydronix Sensor RS485 A MIL-SPEC Connector RS485 B No Connection RS232 Gnd RS232 Serial RS232 Rx Link RS232 Tx...
Page 82: Mix Cycle Design
Chapter 6 System Design 4 Mix Cycle Design This section details the design of the mix control sequence which can contain up to three water addition steps along with associated mixing times. The mix sequence design is usually based on the type of concrete being made, the type of aggregates or the admixture addition recommendations.
Page 83: Figure 75: The Mix Cycle Showing The I/O Status
System Design Chapter 6 Simple Mix A simpler mix control sequence is to load all the raw materials into the mixer at the same time and then perform a dry mix to being to homogenise the materials. The main water is then added, and the wet mix time is run before the ‘Mix Complete’...
Page 84: Figure 76: The Admix Output Signal During A Normal Mix Cycle
Chapter 6 System Design Admix control The effect that an admixture has on the sensor signal will depend on the admixture itself and the point at which it is added to the mixer. The Hydro-Control has an output for controlling the addition of the admixture that may be configured using the Admix Signal parameter on the second page of the System Parameters.
Page 85: Figure 77: The Admix Output Signal During A 2-Step Mix Cycle
System Design Chapter 6 START MIX COMPLETE Pre-wet Main Main Wet Mix Water Dry Mix Water Dry Mix Water Cement Time Added Time Addition 1 Time Addition 2 Moisture Time Admix Type Set to: Admix Output Water Admix Admix Enable % Point set by the “Admix Enable”...
Page 86: Figure 78: The Mix Trace Showing Auto-Track Settings
Chapter 6 System Design Auto-Track Auto-Track can be used during any of the mixing phases of the mix cycle to automatically adjust the mix time depending on the homogeneity of the material in the mixer. There are four sets of parameters in the System Parameters page which control when the Auto-Track will finish the mix phases.
Page 87 System Design Chapter 6 The auto-track process is as follows: • Mix until mix phase time is less than the mixing time minus the auto-track time • Record the sensor value and start auto-track. Two green lines will appear on the graph to indicate the plus and minus tolerance of the auto-track •...
Page 88 Chapter 6 System Design Hydro-Control (HC07) Installation Guide HD1074 Rev 1.2.0...
Page 89: Chapter 7 Rs232 Interface
Chapter 7 RS232 Interface 1 Port Settings RS232 The RS232 port settings should be set up as follows • Baud Rate – 9600 • Data Bits – 8 • Parity – None • Stop Bits – 1 • Handshaking – None Ethernet The Ethernet port can also be configured to utilise the RS232 protocol.
Page 90: Rs232 Commands Hc05/Hc06/Hc07 Formats
Chapter 7 RS232 Interface If the Hydro-Control (HC07) is replacing an older Hydro-Control device, refer to the table below to configure the serial protocol settings correctly: Device being replaced Serial protocol setting to be used None (new install) HC07 Hydro-Control VI (HC06 v1 mix log format) HC06 v1 Hydro-Control VI (HC06 v2 mix log format) HC06 v2...
Page 91 RS232 Interface Chapter 7 Non-Parameter/Status Commands These are commands that do not correspond to the current state of the Hydro-Control or any system or recipe parameters. These commands are listed below Format Description Parameter Range Valid Period Response >R1=nn Selects recipe nn as the next recipe nn = any valid integer Standby If the requested recipe does not...
Page 92 Chapter 7 RS232 Interface Mix Log Formats The Mix Log format will depend on which mode the RS232 Protocol is set to. This parameter is on page 2 of the System Parameters screen and details of this can be found in Chapter 5. The data is sent as a list of values separated by the tab character (ASCII Code 9).
Page 93 RS232 Interface Chapter 7 3.2.2 Hydro-Control VI (HC06) Format v1 Value Description Batch/Recipe/Control Method Dry % Moisture Dry Reading Unscaled Dry Deviation % Moisture Dry Deviation Unscaled Calculated Target % Moisture Calculated Target Unscaled Wet % Moisture Wet Reading Unscaled Wet Deviation % Moisture Wet Deviation Unscaled Pre-Wet Water...
Page 94 Chapter 7 RS232 Interface Moisture Gain 1 Moisture Offset 1 Moisture Gain 2 Moisture Offset 2 Calculation Gain Calculation Offset Proportional Gain Derivative Gain Cement In Error Water Meter Fault Leaking Water Valve No Water Required Error Too Much Water Calculated Error Pre-Wet Target Not Reached Mix Too Wet Rejected Mix Too Dry Rejected...
Page 95 RS232 Interface Chapter 7 3.2.3 Hydro-Control VI (HC06) Format v2 Value Description Batch/Recipe/Prewet Control Method Control Method Auto-track Initial Enable Auto-track Pre-wet Enable Auto-track Dry Enable Auto-track Wet Enable Initial Mix Value (% Moisture) Initial Mix Value (Unscaled) Initial Mix Deviation (% Moisture) Initial Mix Deviation (Unscaled) Pre-Wet Target Value (%Moisture) Pre-Wet Target Value (Unscaled)
Page 96 Chapter 7 RS232 Interface Wet Mix Deviation (Unscaled) Pre-Wet Water Calculated Water Auto Trim Water Manual Trim Water Addition Error Total Water Water/Cement Ratio Dry Mix Time Water Addition Time Wet Mix Time Total Time Dry Weight Cement Weight Mix Temperature Pre-Wet Moisture Gain Pre-wet Moisture Offset Moisture Gain 1...
Page 97 RS232 Interface Chapter 7 Cement In Error Water Meter Fault Leaking Water Valve No Water Required Too Much Water Calculated Pre-wet Target Not Reached Mix Too Wet Rejected Mix Too Dry Rejected Mix Too Wet Accepted Mix Too Dry Accepted Water Limit Exceeded Max Dry Mix Time Reached Max Wet Mix Time Reached...
Page 98 Chapter 7 RS232 Interface Below is a list of parameters and their respective units. Certain commands have been changed or are no longer used. These are shown for backwards compatibility. Command 40 onwards are new commands for the HC06. Parameter Description Units RS232 Value...
Page 99 RS232 Interface Chapter 7 Seconds, weight, Water Trim Litres or US Gallons Batch Counter None Pre-wet Mix (was Seconds Pre-wet delay) Pre-wet Target Pre-wet mode (0 = None auto, 1 = preset) Cement Weight Kg or lbs 2000 2000 Temperature °C or °F 25.0 Temp.
Page 100 Chapter 7 RS232 Interface Local Recipe None Proportional Gain Local Recipe None Derivative Gain Auto-Track Enabled (1= true, 0 = false) Averaging Time Seconds Moisture Offset 1 None -36364 -3.6364 Moisture Gain 1 None 1817 0.1817 Moisture Offset 2 None -36364 -3.6364 Moisture Gain 2...
Page 101 RS232 Interface Chapter 7 Reading and writing system parameters The system values of each recipe can be set at any time. To read parameters the following format should be used: • #_R_nn_pp “_” denotes a space, do not use the underscore character in the RS232 string, “nn” will always be 0 and “pp”...
Page 102 Chapter 7 RS232 Interface System Derivative gain None System Dry mix Auto-Track Time Seconds System Dry mix Auto-Track Deviation System Wet mix Auto-Track Time Seconds System Wet mix Auto-Track Deviation Mixer Status Commands To obtain the status of the system the following command can be given: •...
Page 103 RS232 Interface Chapter 7 • 32 – Wet Mix • 64 – Mix Complete • 128 – Paused It is also possible to get combinations of status (such as pause and wet mix) in this case 32+128 = 160 would be returned Mixer Control Commands To issue start, pause, resume and reset commands to the unit the following command can be used:...
Page 104 Chapter 7 RS232 Interface If nn = 2, 4 tab delimited integers will be sent representing the current readings for the 2 analogue inputs and 2 analogue outputs. 4 tab delimited 0’s will be sent if no Expansion Board is present. Alarm Status It is possible to find out what type of alarm is currently active this can be achieved by sending the command below:...
Page 105: Chapter 8 Remote Support
Chapter 8 Remote Support 1 Accessing the Hydro-Control remotely Setting up a remote connection to the Hydro-Control is described in detail in Chapter 12 of the Hydro-Control (HC07) Operators Guide (HD1048). Hydro-Control (HC07) Installation Guide HD1074 Rev 1.2.0...
Page 106 Chapter 8 Remote Support Hydro-Control (HC07) Installation Guide HD1074 Rev 1.2.0...
Page 107: Chapter 9 Backup, Restore And Upgrade
Hydro-Control’s USB ports. In case if the access to the device’s built-in USB Ports is restricted or obstructed, a suitable USB extension with a panel mounted socket should be installed (Hydronix Part Number 0175). USB Ports Figure 81: USB Ports location...
Page 108 Chapter 9 Backup, Restore and Upgrade Hydro-Control (HC07) Installation Guide HD1074 Rev 1.2.0...
Page 109: Appendix A System Parameters Record
Appendix A System Parameters Record Water Setup Parameter Units Default Commissioned Value Water Mode None Metered Pulses Per Litre Pulses Per Litre/Gallon Water Meter Timeout Seconds Fine Delivery Litres/Gallons Fine Valve Inflight Litres/Gallons Coarse Valve Inflight Litres/Gallons Fine Valve On Time Seconds Fine Valve Off Time Seconds...
Page 110 Appendix A System Parameters Record System Auto-Track Parameter Units Default Commissioned Value Auto-Track Initial Mix Dev Auto-Track Initial Mix Time Seconds Auto-Track Pre-Wet Mix Dev Auto-Track Pre-Wet Mix Time Seconds Auto-Track Dry Dev Auto-Track Dry Mix Time Seconds Auto-Track Wet Dev Auto-Track Wet Mix Time Seconds General Settings...
Page 111: Appendix B Diagnostics
Diagnostics The following tables list the most common faults found when using the controller. In case of difficulties experienced in diagnosing the problem, please contact Hydronix technical support on +44 (0) 1483 468900 or by email: support@hydronix.com. Symptom: Displays shows ‘Searching For Sensor’ - no output from the sensor...
Page 112 + terminal. Symptom: Faulty display contrast Possible explanation Check Required result Action required Faulty internal power Contact Hydronix for repair supply to backlight. details. Backlight has failed Contact Hydronix for repair details. Hydro-Control (HC07) Installation Guide HD1074 Rev 1.2.0...
Page 113: Appendix C Glossary
Appendix C 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 (Auto-Cal) To simplify fitting a new sensor arm to a Hydro-Probe Orbiter, the sensor can be automatically calibrated.
Page 114 Appendix C Glossary Moisture The water held in and around the material. Moisture is defined as a percentage using the weight of the water and the weight of the material it is with. Although the material weight can either be dry weight or wet weight the standard for the concrete industry is to use the dry weight.
Page 115: Appendix D Document Cross Reference
Document Number Title HD1048 Hydro-Control (HC07) Operators Guide HD1100 Hydro-Control (HC07) Safety information HD0679 Hydronix Moisture Sensor Configuration and Calibration Guide HD0678 Hydronix Moisture Sensor Electrical Installation Guide HD0676 Hydro-Mix Mechanical Installation Guide HD0677 Hydro-Probe Orbiter Installation Guide HD1061...
Page 116 Appendix D Document Cross Reference Hydro-Control (HC07) Installation Guide HD1074 Rev 1.2.0...
Page 117 Index Admix Control ..........80 Mix Cycle Alarms Complete Cycle ......... 78 Leaking Water Valve ......... 73 Design ............78 Analogue Input Simple Mix ..........79 Weighed water .......... 47 Mix Diagrams Wiring ............30 Dry mix cycle ..........79 Analogue Output Mix cycle with admix .........
Page 118 Index Water Meter ..........38 Water Valves ..........71 Weighed Water .......... 47 Example Sizing ......... 73 Upgrade Guidelines ..........71 Hydro-Control V ......... 76 Weighed Water ..........47 USB Ports............33 Weight ............19 Valves ........See Water Valves Wiring Water Addition Mode Analogue Inputs ........

Hydronix Hydro-Control HC07 Installation Manual

Chapter 1 Safety Information

Chapter 2 Introduction

Chapter 3 Mechanical Installation

Chapter 4 Electrical Installation

Chapter 5 Commissioning

Chapter 6 System Design

Chapter 7 RS232 Interface

Chapter 8 Remote Support

Chapter 9 Backup, Restore and Upgrade

Appendix A System Parameters Record

Appendix B Diagnostics

Appendix C Glossary

Appendix D Document Cross Reference

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