Hydronix Hydro-Mix HT User manual

Hydro-Mix HT
Mechanical Installation Guide
To re-order quote part number:
Revision:
Revision date:
HD0766
1.2.0
June 2018

2Hydro-Mix HT Mechanical Installation Guide HD0766 Rev 1.2.0
Copyright
Neither the whole or any part of the information contained in nor the product described in this documentation may
be adapted or reproduced in any material form except with the prior written approval of Hydronix Limited,
hereinafter referred to as Hydronix.
© 2018
Hydronix Limited
7 Riverside Business Centre
Walnut Tree Close
Guildford
Surrey GU1 4UG
United Kingdom
All rights reserved
CUSTOMER RESPONSIBILITY
The customer in applying the product described in this documentation accepts that the product is a
programmable electronic system which is inherently complex and which may not be completely free of errors. In
doing so the customer therefore undertakes responsibility to ensure that the product is properly installed
commissioned operated and maintained by competent and suitably trained persons and in accordance with any
instructions or safety precautions made available or good engineering practice and to thoroughly verify the use of
the product in the particular application.
ERRORS IN DOCUMENTATION
The product described in this documentation is subject to continuous development and improvement. All
information of a technical nature and particulars of the product and its use including the information and
particulars contained in this documentation are given by Hydronix in good faith.
Hydronix welcomes comments and suggestions relating to the product and this documentation
ACKNOWLEDGEMENTS
Hydronix, Hydro-Probe, Hydro-Mix, Hydro-Skid, Hydro-View and Hydro-Control are Registered Trade Marks of
Hydronix Limited
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.
If your feedback is concerning an Atex certified product or associated service it would be very helpful for you to
give us your contact details and the model number and serial number of the product if possible. This will enable
us to contact you with any relevant safety advice should this be necessary. It is not obligatory to leave your
contact details and any information will be treated as confidential.

Hydro-Mix HT Mechanical Installation Guide HD0766 Rev 1.2.0 3
Hydronix Offices
UK Head Office
Address: 7 Riverside Business Centre
Walnut Tree Close
Guildford
Surrey
GU1 4UG
Tel: [phone]
Fax: [phone]
Email: [e-mail]
[e-mail]
Website: www.hydronix.com
North American Office
Covers North and South America, US territories, Spain and Portugal
Address: 692 West Conway Road
Suite 24, Harbor Springs
MI 47940
USA
Tel: [phone] (Toll Free)
[phone]
Fax: [phone] (Toll Free)
[phone]
European Office
Covers Central Europe, Russia and South Africa
Tel: [phone]
Fax: [phone]
French Office
Tel: [phone]

4Hydro-Mix HT Mechanical Installation Guide HD0766 Rev 1.2.0

Hydro-Mix HT Mechanical Installation Guide HD0766 Rev 1.2.0 5
Revision history
Revision No
Date
Description of Change
1.1.0
March 2017
First Release
1.1.1
April 2017
Minor formatting update
1.2.0
June 2018
Spacer Plate Installation Advice Added

6Hydro-Mix HT Mechanical Installation Guide HD0766 Rev 1.2.0

Hydro-Mix HT Mechanical Installation Guide HD0766 Rev 1.2.0 7
Table of Contents
Chapter 1 Hydro-Mix HT Installation.....................................................................................................11
1Introduction.................................................................................................................................12
2General to Flowing Material Applications...................................................................................12
3General to Mixer Applications ....................................................................................................12
4General Mounting Advice...........................................................................................................13
5Organic Material Mixers .............................................................................................................14
6Screw Conveyor.........................................................................................................................15
7Integration of Hydro-Mix HT in Ducting......................................................................................15
8Installing the Sensor...................................................................................................................17
Chapter 2 Temperature Ratings ...........................................................................................................25
1Process Temperature Range.....................................................................................................25
2Ambient Temperature Range.....................................................................................................25
3Additional Cooling ......................................................................................................................25
Chapter 3 Corrosion Protection.............................................................................................................27
1Corrosion Protection...................................................................................................................27
Chapter 4 Technical Specification ........................................................................................................29
1Technical Specifications.............................................................................................................29
Appendix A Document Cross Reference..............................................................................................31
1Document Cross Reference.......................................................................................................31

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Hydro-Mix HT Mechanical Installation Guide HD0766 Rev 1.2.0 9
Table of Figures
Figure 1: The Hydro-Mix HT..................................................................................................................11
Figure 2: Flat Surface Installation (Fixing Plate and Clamp Ring Not Shown) .....................................13
Figure 3: Curved Surface Installation (Fixing Plate and Clamp Ring Not Shown)................................13
Figure 4: Twin Shaft Organic Mixer Installation....................................................................................14
Figure 5: Single Shaft Organic Mixer Installation..................................................................................14
Figure 6: Screw Conveyor Installation..................................................................................................15
Figure 7: Screw Conveyor Material Level.............................................................................................15
Figure 8: Hydronix Ducting Systems (DSAHT and DSVHT).................................................................15
Figure 9: Hydro-Mix HT Integrated in a Duct........................................................................................16
Figure 10: Sensor Installation (Fixing Plate Externally mounted).........................................................17
Figure 11: Sensor Installation (Fixing Plate Flush mounted)................................................................17
Figure 12: Hydro-Mix HT Mounting Components .................................................................................18
Figure 13: Clamp Ring Assembled and Connected to the Fixing Plate................................................19
Figure 14: Clamp Ring and Fixing Plate Attached to a Hydro-Mix HT .................................................19
Figure 15: HMHT Spacer Plates...........................................................................................................19
Figure 16: Clamp Ring with Spacer Plates attached to the Sensor......................................................20
Figure 17: Final Assembly with Fixing Plate Attached..........................................................................20
Figure 18: Minimum and Maximum Insertion........................................................................................21
Figure 19: Measuring the Insertion Depth.............................................................................................21
Figure 20: Positioning the Clamp Ring .................................................................................................22
Figure 21: Sensor Final Position...........................................................................................................22
Figure 22: Flush Mounted Fixing Plate .................................................................................................22
Figure 23: Clamp Ring (Flush Mount)...................................................................................................23
Figure 24: Flush Mounted Sensor.........................................................................................................23
Figure 25: Temperature Profile.............................................................................................................25
Figure 26: Water Cooling......................................................................................................................26
Figure 27: Hydro-Mix HT Installed with a Drip Loop.............................................................................27
Figure 28: Hydro-Mix HT with Protection Cover Installed.....................................................................27

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Hydro-Mix HT Mechanical Installation Guide HD0766 Rev 1.2.0 11
Chapter 1 Hydro-Mix HT Installation
Ø 108.0mm
269.0mm
72.0mm
Ø 90.0mm
Ceramic Disc
(Sensing Area)
Hydro-Mix HT Body
(Electronics)
Cooling Fins
Packed Contents
Hydro-Mix HT Sensor
Fixing Plate
Clamp Ring
Spacer Plates (x2)
Recommended Accessories
0975A sensor Cable (4M)
Figure 1: The Hydro-Mix HT
Available accessories:
Part No Description
4010 HMHT Fixing Plate (Supplied with sensor), Additional plates can be ordered
4020 HMHT Clamp Ring (Supplied with sensor). Additional clamps can be ordered
4030 HMHT Hydro-Mix Adapter
0975A 4m Sensor Cable
0975A-10m 10m Sensor Cable
0975A-25m 25m Sensor Cables
0116 Power Supply – 30 Watt for up to 4 sensors
0049A RS232/485 converter (DIN rail mounting)
0049B RS232/485 converter (9 pin D type to terminal block)
SIMXX USB Sensor Interface Module including cables and power supply
EAK01 Ethernet Adapter Kit including Power Supply
EPK01 Optional Ethernet Power Adapter Kit
DSAHTXX Ducting System Angled
DSVHTXX Ducting System Vertical
Hydro-Com configuration and diagnostics software is available for free to download from
www.hydronix.com

Chapter 1 Hydro-Mix HT Installation
12 Hydro-Mix HT Mechanical Installation Guide HD0766 Rev 1.2.0
1 Introduction
The Hydro-Mix HT is a flush mounted digital microwave moisture sensor designed for measuring
in flowing organic materials. The sensor can be installed in drying, ducting, mixing, and
conveying systems and is manufactured from food safe materials
The sensor reads at 25 times per second, which enables rapid detection of changes in moisture
content in the process, including determination of homogeneity in mixing processes. The sensor
can be easily connected to any control system and may be configured remotely when connected
to a PC using dedicated Hydronix software. A large number of parameters are selectable, such
as the type of output and the filtering characteristics.
2 General to Flowing Material Applications
For accurate moisture measurement the Hydro-Mix HT should be installed in a location where
the material is in contact with the ceramic disc at a controlled consistent flow rate.
Follow the advice below for good sensor positioning:
•Locate the sensor where the material flows at a consistent rate.
•When installing the sensor in a curved surface, ensure that the centre of the ceramic disc
is flush with the radius of the internal wall.
•A sampling point has to be available close to the sensor for calibration purposes.
•Avoid areas of severe turbulence in the material flow.
•Ensure the sensor is located where the material is not allowed to build up on the ceramic
disc.
•Position the sensor away from any electrical interference (See Electrical Installation
Guide HD0678).
•Position the sensor so that it is easily accessible for routine maintenance, adjustment and
cleaning.
3 General to Mixer Applications
A significant benefit of the Hydronix system is that only one sensor is required in the mixer.
However, it is important that it is positioned correctly in relation to the mixer type, material and
water inlets, and other moving parts such as blades and paddles. Although paddles or scraper
blades can be a useful mechanism to keep the sensor free from material build up, they could
cause damage to an incorrectly positioned sensor. It will be necessary to periodically check the
position as the mixer blades, paddles and floor wear away. In all installations, it is recommended
that the sensor is fitted in an area where it is away from any possible collection of ‘sitting’ water.
As the mixer floor wears, the sensor will occasionally need to be adjusted downwards in the
mixer, to maintain the correct position in relation to the mixer floor. Additionally the blades will
need to be adjusted to maintain the efficiency of the mixing action and cleanliness of the ceramic
disc.
If the sensor is allowed to protrude into the mixer it will be susceptible to damage from the mixer
blades/paddles as well as from abrasive materials becoming trapped between the paddles, mixer
floor and exposed side wall of the sensor.
NOTE: Damage caused under these circumstances will not be covered by warranty
For accurate and representative moisture measurement the sensor must be in contact with the
moving stream of material. It is equally important that no material can build up over the Ceramic
Disc to obscure the sensor readings.
Follow the advice below for good sensor positioning:
•It is a good idea to provide a small inspection lid in the mixer cover, so that during mixing,
and when the mixer is empty, the Ceramic Disc may be observed without having to raise
the main cover plate.

Hydro-Mix HT Installation Chapter 1
Hydro-Mix HT Mechanical Installation Guide HD0766 Rev 1.2.0 13
•Ensure that the sensor is fitted away from the water and material inlets. Particular care
should be taken in keeping the sensor clear of heavy falling objects.
•When installing the sensor in a curved surface, ensure that the centre of the ceramic disc
is flush with the radius of the internal wall
•Avoid areas of severe turbulence. The best signal will be obtained where there is a
smooth flow of material over the sensor.
•The sensor should be positioned where it will see a continuous sample of the flowing
material and where the sweeping action of the blades ensures no build-up of material on
the face of the sensor.
•Position the sensor away from any electrical interference (See Electrical Installation
Guide HD0678).
•Position the sensor so that it is easily accessible for routine maintenance, adjustment and
cleaning.
4 General Mounting Advice
For installation in flat surfaces, the top of the sensor must be flush with the internal wall surface.


Internal Surface
Figure 2: Flat Surface Installation (Fixing Plate and Clamp Ring Not Shown)
When installing the sensor in a curved surface, ensure that the centre of the ceramic disc is
flush with the radius of the internal wall


Figure 3: Curved Surface Installation (Fixing Plate and Clamp Ring Not Shown)

Chapter 1 Hydro-Mix HT Installation
14 Hydro-Mix HT Mechanical Installation Guide HD0766 Rev 1.2.0
5 Organic Material Mixers
When installing in a mixer it is important that the end wall scraper arm is adjusted to ensure that
the Ceramic Disc is kept clean to avoid material build up. A build-up of material on the end wall
will indicate that the scraper arm is not correctly adjusted and this will affect the sensor reading.
5.1 Twin Shaft
It is recommended that the Hydro-Mix HT should be located in the end wall between the two
shafts. The sensor should be located at a level lower than the shafts to maintain complete
coverage of the ceramic disc.
Figure 4: Twin Shaft Organic Mixer Installation
5.2 Single Shaft
Single shaft mixers should have the sensor installed in the end wall at 30° from the centre.
30.0°
Figure 5: Single Shaft Organic Mixer Installation

Hydro-Mix HT Installation Chapter 1
Hydro-Mix HT Mechanical Installation Guide HD0766 Rev 1.2.0 15
6 Screw Conveyor
It is recommended that the sensor is installed at 30° above the base (See Figure 6).
30°
150-300mm
Sampling Point
Figure 6: Screw Conveyor Installation
It is essential that the sensor is located so that the ceramic disc is continuously covered by at
least 100mm of material (Figure 7).
100mm
100mm

Figure 7: Screw Conveyor Material Level
7 Integration of Hydro-Mix HT in Ducting
The Hydro-Mix HT can be integrated into ducting. Modifications to the ducting might be required
to achieve consistent results.
Hydronix recommends the use of the Hydronix Ducting System (DSVHT or DSAHT) when
installing the Hydro-Mix HT into ducting (Figure 8). The systems are designed for use in vertical
(DSVHT) or angled ducting (DSAHT). Contact Hydronix for further details about the available
ducting systems.
Figure 8: Hydronix Ducting Systems (DSAHT and DSVHT)

Chapter 1 Hydro-Mix HT Installation
16 Hydro-Mix HT Mechanical Installation Guide HD0766 Rev 1.2.0
Any material in the duct must be free flowing for the sensor to be able to measure
accurately.
Best results are achieved when:-
•The sensor head is at 40º from the material flow.
•Material flow above the sensor is ducted to provide a smooth, constant flow.
•Flow rate is controlled down-stream of the sensor thus allowing material to back-up over
the sensor and provide a constant material depth of at least 100mm.
•All ducting is smooth with no edges where the flow can be interrupted.
•A material flow rate of minimum 1kg/sec (3.54 ton/hour (long)) is used.
Figure 9 shows the Hydro-Mix HT integrated into a duct. The outlet dimensions will need to be
adjusted to suit each application to provide a suitable flow rate and a minimum of 100mm of
material above the sensor.
To achieve the required 100mm of material above the sensor and a stable flow the Hydro-Mix
HT should be installed in an overflow ducting system. This allows any additional material not
required to maintain 100mm in front of the sensor to overflow, reducing the possibility of a
blockage.
130mm
50mm
40°
X ≥ 100mm
X
50mm
≥100mm
≥150mm
Figure 9: Hydro-Mix HT Integrated in a Duct

Hydro-Mix HT Installation Chapter 1
Hydro-Mix HT Mechanical Installation Guide HD0766 Rev 1.2.0 17
8 Installing the Sensor
These instructions refer to installing the Hydro-Mix HT on a flat surface; all other
installation locations use the same mounting arrangement.
Each sensor is supplied with a Clamp Ring. When attached this allows the sensor to be
connected to the Fixing Plate which is welded externally or flush to the floor or wall of the
installation location.
The Clamp Ring facilitates the correct positioning and subsequent height adjustment of the
sensor.
Hydro-Mix HT
M8 Screw (x4)
Clamp Ring Fixing Plate
Weld
Weld
Wall/Floor
Ø 92-95mm Hole for Sensor Clearance
Figure 10: Sensor Installation (Fixing Plate Externally mounted)
When installing the Fixing Plate flush with the internal wall (Figure 11) the supplied Spacer Plates
can be used to ensure the sensor is correctly aligned.
Ø 142mm Hole for Fixing Plate
Weld Weld
Fixing Plate
Clamp Ring
Installation
Wall/Floor
Spacer Plates (x2)
Figure 11: Sensor Installation (Fixing Plate Flush mounted)

Chapter 1 Hydro-Mix HT Installation
18 Hydro-Mix HT Mechanical Installation Guide HD0766 Rev 1.2.0
8.1 Cutting the Hole for the Sensor and Installing the Fixing Plate
8.1.1 Externally Mounting the Fixing Plate
Before welding the Fixing Plate to the installation location a 92-95mm diameter hole
should be cut through the external wall and any internal wear plates.
Although the outside diameter of the sensor is 90mm it is recommended to cut a hole of
92-95mm diameter to allow for tolerances.
The Fixing Plate is then welded in position over the hole. Ensure that the Fixing Plate is
perpendicular to the internal wall.
During any welding operations the sensor must be removed.
8.1.2 Internally Mounting the Fixing Plate
To enable the Fixing Plate to be installed flush with the internal wall of the installation
location it is necessary to cut a 142mm hole through the external wall and any internal
wear plates. The supplied Spacer Plates can be used to ensure that the sensor is installed
flush with the internal wall.
Depending on the installation requirements, the Fixing Plate can be welded either from the
inside or the outside. Ensure that the Fixing Plate is flush with the internal wall.
8.2 Fitting the Clamp Ring to the Sensor (without Spacer Plates)
Fixing Plate (welded
into position)
Clamp Ring
(Attached to sensor)
M8 Fixing Screws (x4)
Clamp Screws (x2)
Figure 12: Hydro-Mix HT Mounting Components

Hydro-Mix HT Installation Chapter 1
Hydro-Mix HT Mechanical Installation Guide HD0766 Rev 1.2.0 19
Figure 13: Clamp Ring Assembled and Connected to the Fixing Plate
Figure 14: Clamp Ring and Fixing Plate Attached to a Hydro-Mix HT
8.3 Fitting the Clamp Ring using the Spacer Plates
If the Fixing Plate has been installed flush with the internal wall the Spacer Plates can be
added to the Clamp Ring to assist with the installation (Figure 15). The Spacer Plates will
guarantee that the ceramic face plate is installed flush with the Fixing Plate.
HMHT Spacer Plates (x2)
Clamp Ring
Figure 15: HMHT Spacer Plates

Chapter 1 Hydro-Mix HT Installation
20 Hydro-Mix HT Mechanical Installation Guide HD0766 Rev 1.2.0
Figure 16: Clamp Ring with Spacer Plates attached to the Sensor
Mounting Plate
Clamp Ring
Spacer Plate
Spacer Plate Fully Inserted
Sensor Flush with Mounting Plate
Figure 17: Final Assembly with Fixing Plate Attached