Hydronix Hydro-Control HC07 User manual

Hydro-Control (HC07)
Operators Guide
To re-order quote part number:
Revision:
Revision date:
HD1048
1.1.0
June 2023

2Hydro-Control (HC07) Operators Guide HD1048 Rev 1.1.0
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.
© 2023
Hydronix Limited
Units 11 & 12 Henley Business Park
Pirbright Road
Normandy
Guildford
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 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 Trademarks 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-Control (HC07) Operators Guide HD1048 Rev 1.1.0 3
Hydronix Offices
UK Head Office
Address: Units 11 & 12 Henley Business Park
Pirbright Road
Normandy
Guildford
Surrey GU3 2DX
United Kingdom
Tel: [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-Control (HC07) Operators Guide HD1048 Rev 1.1.0

Hydro-Control (HC07) Operators Guide HD1048 Rev 1.1.0 5
Revision history
Revision
No
Software
Version
Date
Description of Change
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.

6Hydro-Control (HC07) Operators Guide HD1048 Rev 1.1.0

Hydro-Control (HC07) Operators Guide HD1048 Rev 1.1.0 7
Table of Contents
Chapter 1 Introduction........................................................................................................................... 11
1About this Manual....................................................................................................................... 11
2Introduction to the Hydro-Control ............................................................................................... 12
Chapter 2 Navigation ............................................................................................................................ 13
1Powering on, logging in and Powering off..................................................................................13
2Main Menu.................................................................................................................................. 14
3Overview Screen ........................................................................................................................ 16
4Recipes Screen .......................................................................................................................... 19
5Mix Log Screen .......................................................................................................................... 20
6System Parameters Screen ....................................................................................................... 20
7Sensor Overview Screen ........................................................................................................... 21
8Settings Screen .......................................................................................................................... 21
9Hardware Screen ....................................................................................................................... 22
10 Comms Screen...................................................................................................................... 22
11 User Management Screen .................................................................................................... 22
Chapter 3 Plant Operator Controls ....................................................................................................... 27
Chapter 4 Understanding the Mix Cycle ............................................................................................... 29
1The Simple Mix Cycle................................................................................................................. 29
2Cycle with Pre-Wet Water Phase............................................................................................... 30
Chapter 5 Water Addition Modes .......................................................................................................... 33
1Preset Mode ............................................................................................................................... 33
2CALC Mode................................................................................................................................ 33
3AUTO Mode ............................................................................................................................... 34
4Selecting the Best Mode – AUTO or CALC? ............................................................................. 34
Chapter 6 Creating and Editing Recipes............................................................................................... 35
1Introduction................................................................................................................................. 35
2Creating New Recipe ................................................................................................................. 35
3Editing an Existing Recipe ......................................................................................................... 37
Chapter 7 Using the Mix Log................................................................................................................. 47
1Introduction................................................................................................................................. 47
2Information contained in the Mix Log ......................................................................................... 47
3Viewing the Mix Trace ................................................................................................................ 54
Chapter 8 Running the First Mix ........................................................................................................... 57
1The First Mix recipe parameters considerations ........................................................................ 57
2Set up the Recipe for the First Mix............................................................................................. 58
Chapter 9 Using Moisture Control......................................................................................................... 61
1Moisture Control and Homogeneity............................................................................................ 61
2CALC Mode................................................................................................................................ 62
3AUTO Mode ............................................................................................................................... 69
4Using Admixtures ....................................................................................................................... 72
5Auto-Track.................................................................................................................................. 73
6Temperature Compensation ...................................................................................................... 75
Chapter 10 Alarm Configuration ........................................................................................................... 77
1Alarms ........................................................................................................................................ 77
Chapter 11 Backup, Restore and Upgrade........................................................................................... 81
1Backing up and Restoring .......................................................................................................... 81
2Upgrading software .................................................................................................................... 82
Chapter 12 Remote Support ................................................................................................................. 85
1Establishing a remote connection .............................................................................................. 85
Chapter 13 Optimisation ....................................................................................................................... 87
1Mixer........................................................................................................................................... 87
2Ingredients.................................................................................................................................. 87
3Consistency................................................................................................................................ 88

8Hydro-Control (HC07) Operators Guide HD1048 Rev 1.1.0
4Calibration Based Water Addition .............................................................................................. 88
5Mixing ......................................................................................................................................... 88
Chapter 14 Frequently Asked Questions .............................................................................................. 89
Appendix A Diagnostics ........................................................................................................................ 93
Appendix B Glossary............................................................................................................................. 95
Appendix C Document Cross Reference .............................................................................................. 97
1Document Cross Reference....................................................................................................... 97

Hydro-Control (HC07) Operators Guide HD1048 Rev 1.1.0 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 ............................................................................16
Figure 7: Mix cycle control buttons ....................................................................................................... 17
Figure 8: Connection to moisture sensor lost ....................................................................................... 18
Figure 9: Recipes Screen...................................................................................................................... 19
Figure 10: Selecting a recipe for editing ............................................................................................... 19
Figure 11: The Mix Log screen ............................................................................................................. 20
Figure 12: The Mix Log screen ............................................................................................................. 20
Figure 13: Settings Screen - the System page when logged out.......................................................... 21
Figure 14: Accessing the backup, restore and software upgrade features ..........................................21
Figure 15: Main menu access level comparison................................................................................... 22
Figure 16: Default User Accounts Configuration – no login/logout button present............................... 23
Figure 17: Additional User Accounts..................................................................................................... 23
Figure 18: Login screen ........................................................................................................................ 23
Figure 19: Login screen - user selection............................................................................................... 24
Figure 20: Adding new user account .................................................................................................... 24
Figure 21: User management - editing existing user account .............................................................. 25
Figure 22: The main menu bar when logged out. .................................................................................25
Figure 23: Recipe/Mode Screen – recipe search ................................................................................. 27
Figure 24: Recipe Mode Screen ........................................................................................................... 28
Figure 25: A simple mix cycle moisture trace explained.......................................................................29
Figure 26: The mix cycle with Pre-Wet ................................................................................................. 31
Figure 27: The moisture during CALC Mode ........................................................................................ 33
Figure 28: The moisture during AUTO Mode........................................................................................ 34
Figure 29: Creating a new recipe data input ......................................................................................... 35
Figure 30: Copying an existing to create a new recipe.........................................................................36
Figure 31: Accessing Recipe Editor – Recipe Selected .......................................................................37
Figure 32: Editing a Recipe – Recipe Details ....................................................................................... 38
Figure 33: Editing Recipe - Water Addition........................................................................................... 39
Figure 34: Editing Recipe - Material Addition and Mixing Times ..........................................................40
Figure 35: Editing Recipe - Mix Control ................................................................................................ 41
Figure 36: Editing Recipe - local Auto-Track settings...........................................................................42
Figure 37: Editing Recipe - Calculation Mode Settings ........................................................................44
Figure 38: Editing Recipe - Auto Mode Settings ...................................................................................45
Figure 39: Editing Recipe - Temperature Correction Settings .............................................................. 46

10 Hydro-Control (HC07) Operators Guide HD1048 Rev 1.1.0
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 .................................................................................... 59
Figure 46: Mix log - sensor values display group ................................................................................. 60
Figure 47: Mix trace showing homogeneity .......................................................................................... 61
Figure 48: How the deviation is calculated ........................................................................................... 61
Figure 49: The moisture during CALC Mode ........................................................................................ 62
Figure 50: Calibrating a recipe .............................................................................................................. 64
Figure 51: Summary of calibration parameters..................................................................................... 65
Figure 52: The CALC Mode Calculation ............................................................................................... 66
Figure 53: The calibration failed error message ................................................................................... 67
Figure 54: Comparison of averaging times ........................................................................................... 67
Figure 55: Comparing Measurement Modes ........................................................................................ 68
Figure 56: The moisture during AUTO Mode........................................................................................ 69
Figure 57: The effect of changing the Proportional Gain ......................................................................70
Figure 58: The effect of changing the Integral Gain ............................................................................. 71
Figure 59: The effect of changing the Derivative Gain .........................................................................71
Figure 60: The 2-step Preset Mode cycle ............................................................................................. 72
Figure 61: The calibration lines from the 2-step preset mode cycle ..................................................... 73
Figure 62: Mix trace showing the Auto-Track function.......................................................................... 74
Figure 63: System Parameters screen – alarm outputs configuration.................................................. 77
Figure 64: Unsuccessful mix start error message................................................................................. 79
Figure 65: Restoring the database........................................................................................................ 82
Figure 66: Upgrading the Software ....................................................................................................... 83
Figure 67: Connecting to Hydro-Control Remotely ............................................................................... 85
Figure 68: Logging in remotely ............................................................................................................. 86