Hydronix Hydro-Probe SE User manual

Hydro-Probe SE
User Guide
To re-order quote part number: HD0278
Revision: 2.1.0
Revision date: Jan 2020

2 Hydro-Probe SE User Guide HD0278 Rev. 2.1.0
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.
© 2014
Hydronix Limited
Units 11-12,
Henley Business Park
Pirbright Road
Normandy
Surrey GU3 2DX
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-View and Hydro-Control are Registered Trade Marks of Hydronix
Limited

Hydro-Probe SE User Guide HD0278 Rev 2.1.0 3
Hydronix Offices
UK Head Office
Address: Units 11-12,
Henley Business Park
Pirbright Road
Normandy
Surrey GU3 2DX
United Kingdom
Tel: [phone]
Email: [email protected]m
[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]

4 Hydro-Probe SE User Guide HD0278 Rev. 2.1.0

Hydro-Probe SE User Guide HD0278 Rev 2.1.0 5
Revision history
Revision No Date Description of Change
2.0.0 July 2014 Major Product Update
2.1.0 Jan 2020 Address Change

6 Hydro-Probe SE User Guide HD0278 Rev. 2.1.0

Hydro-Probe SE User Guide HD0278 Rev 2.1.0 7
Table of Contents
Chapter 1 Introduction ........................................................................................................................... 11
1Introduction ................................................................................................................................. 11
2Measuring Technique ................................................................................................................. 11
3Sensor connection and configuration ......................................................................................... 12
Chapter 2 Mechanical Installation ......................................................................................................... 13
1General to all applications .......................................................................................................... 13
2Installing the Sensor ................................................................................................................... 13
3Maintenance ............................................................................................................................... 15
Chapter 3 Electrical installation and communication ............................................................................ 17
1Installation guidelines ................................................................................................................. 17
2Analogue outputs ....................................................................................................................... 17
3RS485 multi-drop connection ..................................................................................................... 19
4Digital input/output connections ................................................................................................. 20
5Connecting to a PC .................................................................................................................... 21
Chapter 4 Configuration ........................................................................................................................ 25
1Configuring the Sensor .............................................................................................................. 25
2Analogue output setup ............................................................................................................... 25
3Digital inputs/output setup .......................................................................................................... 27
4Filtering ....................................................................................................................................... 28
5Alternative Measurement Modes ............................................................................................... 29
Chapter 5 Material calibration ............................................................................................................... 31
1Introduction to material calibration ............................................................................................. 31
2Storing calibration data .............................................................................................................. 32
3Moisture (Linear) Calibration ...................................................................................................... 33
4Brix Calibration ........................................................................................................................... 38
5Quadratic calibration .................................................................................................................. 43
Chapter 6 Frequently asked questions ................................................................................................. 45
Chapter 7 Sensor diagnostics ............................................................................................................... 47
1Symptom: No output from sensor .............................................................................................. 47
2Sensor output characteristics ..................................................................................................... 47
3Symptom: Incorrect analogue output ......................................................................................... 48
4Symptom: Computer does not communicate with the sensor................................................... 48
5Symptom: Near constant material reading ................................................................................ 49
6Symptom: Inconsistent or erratic readings that do not track material ....................................... 50
Chapter 8 Technical specification ......................................................................................................... 51
1Technical Specification............................................................................................................... 51
2Connections ............................................................................................................................... 52
Appendix A Default parameters ............................................................................................................ 53
Appendix B Moisture Calibration Record Sheet.................................................................................... 55
Appendix C Brix Calibration Record Sheet ........................................................................................... 57
Appendix D Document Cross Reference .............................................................................................. 59
1Document Cross Reference ....................................................................................................... 59

8 Hydro-Probe SE User Guide HD0278 Rev. 2.1.0

Hydro-Probe SE User Guide HD0278 Rev 2.1.0 9
Table of Figures
Figure 1: The Hydro-Probe SE ............................................................................................................. 10
Figure 2: Connecting the sensor (overview) ......................................................................................... 12
Figure 3: Mounting Boss ....................................................................................................................... 14
Figure 4: Mounting in a pressure vessel ............................................................................................... 14
Figure 5: The sensor installed in a storage tank ................................................................................... 14
Figure 6: Measurement chamber in-line with pipeline .......................................................................... 1 5 
Figure 7: 0975 Sensor cable connections ............................................................................................. 18
Figure 8: RS485 multi-drop connections ............................................................................................... 19
Figure 9: Multi-Drop RS485 wiring method ........................................................................................... 19
Figure 10: Internal/external excitation of digital input 1 & 2 .................................................................. 20
Figure 11: Activation of digital output 2 ................................................................................................. 20
Figure 12: RS232/485 converter connections (0049B) ......................................................................... 21
Figure 13: RS232/485 converter connections (0049A) ......................................................................... 21
Figure 14: SIM01 USB-RS485 converter connections ......................................................................... 22
Figure 15: Ethernet Adapter Connections (EAK01) .............................................................................. 2 2 
Figure 16: Ethernet Power Adapter Kit connections (EPK01) .............................................................. 23
Figure 17: Maximum number of sensor connections dependent upon ambient temperature .............. 23
Figure 18: Guidance for setting output variables .................................................................................. 25
Figure 19: Relationship of moisture % to Unscaled values .................................................................. 30
Figure 20: Calibrations for 3 different materials (Left) and typical calibration data (Right) ................... 31
Figure 21: Calibration inside the Hydro-Probe SE ................................................................................ 33
Figure 22: Calibration inside the control system ................................................................................... 33
Figure 23: Calibration Line example ..................................................................................................... 34
Figure 24: Calibrations using the SSD coefficient ................................................................................ 35
Figure 25: Example of a good material calibration ............................................................................... 37
Figure 26: Examples of poor material calibration points ....................................................................... 37
Figure 27: Hydro-Com new calibration screen ...................................................................................... 38
Figure 28: Unscaled and Brix values entered into Hydro-Com ............................................................. 39
Figure 29: Starting point selector .......................................................................................................... 39
Figure 30: Hydro-Com Brix calibration best-fit ...................................................................................... 40
Figure 31: Recalculate Seed point/Update sensor ............................................................................... 40
Figure 32: Example of a good Brix Calibration ..................................................................................... 41
Figure 33: Example of a bad Brix Calibration ....................................................................................... 41
Figure 34: Hydro-Com Configuration Tab ............................................................................................. 43
Figure 35: Example of a good quadratic calibration ............................................................................. 44
Figure 36: Examples of bad quadratic calibrations ............................................................................... 44

10 Hydro-Probe SE User Guide HD0278 Rev. 2.1.0
Figure 1: The Hydro-Probe SE
Available accessories:
0975 4m sensor cable
0975-10m 10m sensor cable
0975-25m 25m sensor cable
0116 Power supply – 30 Watt for up to 4 sensors
0067 Terminal box (IP56, 10 terminals)
0049A RS232/485 converter (DIN rail mounting)
0049B RS232/485 converter (9 pin D type to terminal block)
SIM01A USB Sensor Interface Module including cables and power supply
EAK01 Ethernet Adapter Kit
3010 Mounting Boss
3020 Gasket (1 supplied with sensor)
Hydro-Com configuration and diagnostics software is available for free download from
www.hydronix.com

Hydro-Probe SE User Guide HD0278 Rev 2.1.0 11
Chapter 1 Introduction
1 Introduction
The Hydro-Probe SE is a digital microwave moisture / Brix sensor designed for use in higher
temperature environments and pressurised vessels and to have a wear life of many years.
The Hydro-Probe SE measures the material passing in front of the ceramic faceplate. Its on-
board processing provides the options of both an analogue and a digital output which can be
easily connected to any control system. The sensor can easily be calibrated to automatically
calculate the moisture or the Brix content from the value measured and output this to the control
system.
The sensor 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.
After installation the sensor is calibrated to the material (see Chapter 5 ‘Material calibration’). For
this the sensor can be setup in two ways:
 Calibration inside sensor: Sensor is calibrated internally and outputs true moisture or
Brix.
 Calibration inside control system: Sensor outputs an Unscaled reading which is
proportional to moisture. This can then be used to control to a target figure or by having
calibration data inside the control system convert this to the true Moisture/Brix.
The Hydro-Probe SE should never be subjected to unnecessary impact damage as it
houses sensitive electronics. In particular, the ceramic faceplate, although extremely
hardwearing, is brittle and may crack if subjected to severe impact.
CAUTION – NEVER HIT THE CERAMIC
2 Measuring Technique
The Hydro-Probe SE uses the unique Hydronix digital microwave technique that provides a more
sensitive measurement compared to analogue techniques.
Measurements are taken 25 times per second and this enables rapid detection of changes in the
material.

Chapter 1 Introduction
12 Hydro-Probe SE User Guide HD0278 Rev. 2.1.0
3 Sensor connection and configuration
As with all Hydronix digital microwave sensors, the Hydro-Probe SE can be remotely configured
using a digital serial connection and a PC running Hydro-Com diagnostics software. For
communication with a PC, Hydronix supply RS232-485 converters, a USB Sensor Interface
Module and an Ethernet Adapter Kit (see Chapter 3).
The Hydro-Probe SE can be connected to a control system in three ways:
 Analogue output– A DC output is configurable to:
 4-20 mA
 0-20 mA
 0-10 V output can be achieved using the 500 Ohm resistor supplied with the sensor
cable.
 Digital control – an RS485 serial interface, USB Sensor Interface Module or Ethernet
Adapter permits direct exchange of data and control information between the sensor and
the plant control computer.
 Compatibility mode - Not used in this sensor.
The digital inputs and output enables the moisture to be averaged when material is flowing,
essential for obtaining representative moisture for process control.
Figure 2: Connecting the sensor (overview)

Hydro-Probe SE User Guide HD0278 Rev 2.1.0 13
Chapter 2 Mechanical Installation
1 General to all applications
Follow the advice below for good sensor positioning:
 The ‘sensing area’ of the sensor (ceramic face plate) should always be positioned in the
moving stream of material.
 The sensor should not obstruct the material flow.
 Avoid areas of severe turbulence. The optimal signal will be obtained where there is a
smooth flow of material over the sensor.
 Position the sensor so that it is easily accessible for routine maintenance, adjustment and
cleaning.
 To prevent damage to the sensor, position it as far as reasonably practical from sources
of vibration.
2 Installing the Sensor
The Hydro-Probe SE is fitted to the vessel using the Mounting Boss (Part number 3010). A
suitable hole will need to be cut to permit the installation of the Mounting Boss, see Figure 3 for
dimensions. The Mounting Boss should be pressure tight welded to the vessel by a competent
person in accordance with the local regulations and manufacturers’ recommendations. The
rubber gasket, supplied with the sensor, is installed between the Mounting Boss and the
Mounting Flange on the sensor to ensure that a pressure tight seal is created, see Figure 4.
Due to variations in the design of vacuum vessels it is necessary to consult the manufacturer or a
qualified person before any holes are cut or welding is attempted. During welding the sensor
must be removed to protect the electronic circuitry within it.
The optimum location for the sensor varies depending on the type of installation – a number of
options are detailed on the following pages.
Care should be taken to ensure that the Hydro-Probe SE has been correctly installed and in such
a manner to ensure representative sampling of the material concerned. It is essential that the
sensing part of the unit is fully inserted into the main flow of the material. It must not be installed
in stagnant material or where a build-up may occur.
2.1 Mounting Arrangement
An optional Hydronix manufactured Mounting Boss (Part Number 3010) is available to assist
with the installation of the Hydro-Probe SE in Pressure vessels (Figure 3). The Mounting Boss
will need to be pressure tight welded to the Vessel.
It is important to note that the material must flow over the sensing faceplate of the Hydro-
Probe SE, and that the flow must be as consistent as possible with minimal turbulence.
If installed in a pressurised environment the Mounting Boss must be installed by a competent
person in accordance with best practice. All welds should be checked for integrity.

Chapter 2 Mechanical Installation
14 Hydro-Probe SE User Guide HD0278 Rev. 2.1.0
Figure 3: Mounting Boss
2.2 Mounting in a Vessel
The Hydro-Probe SE can be installed in a vessel.
Mounting Boss
Mounting Flange
Hydro-Probe SE
M6 Bolt
Gasket
Pressure
Vessel wall
Pressure tight
weld
Figure 4: Mounting in a pressure vessel
Material
Flow
Figure 5: The sensor installed in a storage tank

Mechanical Installation Chapter 2
Hydro-Probe SE User Guide HD0278 Rev 2.1.0 15
2.3 Mounting in a pipeline measurement chamber
If the Hydro-Probe SE is to be installed in a measurement chamber in-line with a pipeline the
chamber must remain completely full at all times to achieve reliable results. A bypass line
should be installed to facilitate any maintenance of the sensor (Figure 6).
Figure 6: Measurement chamber in-line with pipeline
3 Maintenance
The sensor should be regularly inspected to ensure that material is not building up on the
ceramic faceplate. If material is encrusted on the ceramic face plate the ability of the sensor to
measure the moisture/Brix will be impaired. In the majority of cases the build-up will be removed
during routing cleaning of the vessel.
Routine cleaning systems can be used to remove encrusted material from the sensor. The
maximum temperature should be 120°C for short periods only.
A weak acid solution of Hydrochloric acid (0.5% @60°C) or an alkaline solution of Sodium
Hydroxide (15%) can be used to remove excessive material on the ceramic face plate.

Chapter 2 Mechanical Installation
16 Hydro-Probe SE User Guide HD0278 Rev. 2.1.0

Hydro-Probe SE User Guide HD0278 Rev 2.1.0 17
Chapter 3 Electrical installation and communication
Hydronix supplies cable 0975 for use with the Hydro-Probe SE; this is available in different lengths.
Any extension cable required should be connected to the Hydronix sensor cable using a suitable
screened junction box. See Chapter 8 for details.
It is recommended to allow the sensor to stabilise for 15 minutes after applying power before use.
1 Installation guidelines
 Ensure that the cable is of a suitable quality (See Chapter 8 Section 2.1 for details).
 Ensure that the RS485 cable is taken back into the control panel. This can be used for
diagnostic purposes and takes the minimum of effort and cost to connect at the time of
installation.
 Route the signal cable away from any power cables.
 Check that the vessel is properly grounded.
 The sensor cable should only be grounded at the sensor end.
 Ensure that the cable screen is not connected at the control panel.
 Ensure that there is continuity of the screen through any junction boxes.
 Keep the number of cable joins to a minimum.
2 Analogue outputs
Two DC current sources generate analogue signals proportional to separately selectable
parameters (e.g. Brix, Moisture, Unscaled etc.). See Chapter 4 or the Hydro-Com User Guide
HD0273 for further details. Using the Hydro-Com software the outputs may be selected to be:
 4-20 mA
 0-20 mA (0-10 V output can be achieved using the 500 Ohm resistor supplied with the
sensor cable).

Chapter 3 Electrical installation and communication
18 Hydro-Probe SE User Guide HD0278 Rev. 2.1.0
Sensor cable (Part no 0975) connections:
Twisted Pair
Numbe
r
MIL spec
pins
Sensor connections Cable colour
1
A
+15-30V DC Red
1 B 0V Black
2 C 1st Di
g
ital input Yellow
2 -- - Black
(
Cut back
)
3 D 1st
A
nalo
g
ue Positive
(
+
)
Blue
3 E 1st
A
nalo
g
ue Return
(
-
)
Black
4 F RS485
A
White
4 G RS485 B Black
5 J 2nd Di
g
ital input Green
5 -- - Black
(
Cut back
)
6 K 2nd
A
nalo
g
ue Positive
(
+
)
Brown
6 E 2nd
A
nalo
g
ue Return
(
-
)
Black
H Screen Screen
Junct ion box
Do not connect screen
at control cabinet.
Control Room Wiring
500 Ohm resist or
for 0-10V
H
screen
Positive Return
+ -
2nd Analogue Output
2n
d
Digital
Input /
Ou t p u t
RS485B RS485A
Positive Return
+ -
1st Analogue Output
1s
t
Di gi tal
Input
0V +VE
- +
Supply (15-30V DC)
0975 t wisted pai r
Sensor Cable
K Brown E Bl ack J Green G Black F Whi te D Bl ue E Bl ack C Yellow B Black A Red
Figure 7: 0975 Sensor cable connections
Note: The cable screen is grounded at the sensor. It is important to ensure that the
plant where the sensor is installed is properly grounded.

Electrical installation and communication Chapter 3
Hydro-Probe SE User Guide HD0278 Rev 2.1.0 19
3 RS485 multi-drop connection
The RS485 serial interface enables up to 16 sensors to be connected together via a multi-drop
network see Figure 8. Each sensor should be connected using a suitable junction box, see
Chapter 8 Technical specificationfor details.
RS485 line termination will not normally be required in applications with up to 100 m of cable.
For longer lengths connect a resistor (approximately 100 Ohm) in a series with a 1000pF
capacitor across each end of the cable.
It is highly recommended that the RS485 signals be run to the control panel even if they are
unlikely to be used as this will facilitate the use of diagnostic software should the need arise in
the future.
From
other
sensors
To PC or
plant
control
device
A
B
F
G
Junction box
Do not connect screen
at control cabinet.
H
Screen
0975 twisted pair
Sensor cable
D Brown
K Black
J Green F White G Black D Blue E Black C Yellow B Black A Red
Figure 8: RS485 multi-drop connections
Figure 9: Multi-Drop RS485 wiring method

Chapter 3 Electrical installation and communication
20 Hydro-Probe SE User Guide HD0278 Rev. 2.1.0
4 Digital input/output connections
The Hydro-Probe SE has two digital inputs, the second of which can also be used as an output
for a known state. Full descriptions of how the digital inputs/outputs can be configured are
included in Chapter 4. The most common use of the digital input is for batch averaging, where it
is used to indicate the start and end of each batch. This is recommended as it provides a
representative reading of the full sample during each batch.
An input is activated using 15 – 30Vdc into the digital input connection. The sensor power supply
may be used as an excitation supply for this, or alternatively an external source may be used as
shown below.
Figure 10: Internal/external excitation of digital input 1 & 2
When the digital output is activated the sensor internally switches pin J to 0V. This can be used
to switch a relay for a signal such as ‘Vessel empty’ (see Chapter 4). Note that the maximum
current sink in this case is 500mA and in all cases over current protection should be used.
J Green
0975 twisted
pair Sensor
Cable
A Red
Digital Output switch – example using ‘Bin Empty’
signal to turn on a lamp
Active
low
output
500mA
fuse
Figure 11: Activation of digital output 2