Hydronix Hydro-Control VI User manual

Hydro-Control VI
Installation Guide
To re-order quote part number:
Revision:
Revision date:
HD0455
1.9.0
March 2020

2 Hydro-Control VI Installation Guide HD0455 Rev 1.9.0
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.
© 2020
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 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-Control VI Installation Guide HD0455 Rev 1.9.0 3
Hydronix Offices
UK Head Office
Address: Units 11 & 12 Henley Business Park
Pirbright Road
Normandy
Guildford
Surrey GU3 2DX
United Kingdom
Tel: [phone]
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]

4 Hydro-Control VI Installation Guide HD0455 Rev 1.9.0

Hydro-Control VI Installation Guide HD0455 Rev 1.9.0 5
Revision history
Revision
No
Software
Version
Date
Description of Change
1.0.0
June 2010
First Release
1.1.0
November 2010
RS232 Command set added for Hydro-Control Iv.
1.2.0
V1.8.0
March 2011
Remote support setup added
1.3.0
V1.8.0
June 2011
Modification to Hydro-Control V Mix Log table
1.4.0
V2.0.0
December 2011
RS232 HC06 v2 Mixlog table added, additional
sections on initial mix time and auto-track
functions for initial and pre-wet mix added
1.5.0
V2.0.0
April 2013
Figure 38 added – Typical water valve set up
Pipe Diameter table added
Figure 42 updated
1.5.1
V2.0.0
June 2013
USB Panel Mount socket added to Box Contents
List
1.6.0
V2.3.0.0
Sept 2013
Added *9 and * 10 RS232 Commands
1.7.0
V2.5.0.0
April 2014
Added Control Cabinet Information.
RS232 Command description of serial message
?14 updated.
1.8.0
V2.8.0.0
October 2015
Added max mix log configuration, additional
features of HS0102, configuring IP to static,
weighed water resolution, calibrating sensors in
additional measurement modes and PLC
controlled System shut down.
1.8.1
V2.8.0.0
January 2016
Minor formatting update
1.9.0
V2.15.0.0
March 2020
Reference to HC06 v2 added (no memory cards)
Archiving function added
Address Updated

6 Hydro-Control VI Installation Guide HD0455 Rev 1.9.0

Hydro-Control VI Installation Guide HD0455 Rev 1.9.0 7
Table of Contents
Chapter 1 Introduction........................................................................................................................... 13
1Introduction to the Hydro-Control VI........................................................................................... 13
2About this manual....................................................................................................................... 14
3Safety ......................................................................................................................................... 14
Chapter 2 Mechanical Installation......................................................................................................... 17
1Weight and Dimensions ............................................................................................................. 17
2Mounting and installation ........................................................................................................... 18
3Operating Temperature .............................................................................................................. 19
4OPTO modules........................................................................................................................... 19
5Memory Cards............................................................................................................................ 19
6Touch screen protective layer .................................................................................................... 20
Chapter 3 Electrical Installation............................................................................................................. 21
1Connector pin assignments........................................................................................................ 22
2Power Supply ............................................................................................................................. 24
3Communications......................................................................................................................... 24
4Interface modules....................................................................................................................... 24
5Expansion Board (Hydronix Part Number 0180)........................................................................25
6I/O Wiring Diagrams ................................................................................................................... 26
7Cables ........................................................................................................................................ 28
8USB Ports................................................................................................................................... 28
Chapter 4 Commissioning..................................................................................................................... 31
1Screen Navigation ...................................................................................................................... 31
2Menu Tree .................................................................................................................................. 31
3Basic Tests................................................................................................................................. 32
4Touch screen recalibration......................................................................................................... 35
5System Parameters.................................................................................................................... 36
6Sensor Configuration.................................................................................................................. 42
7Recipe Parameters..................................................................................................................... 46
Chapter 5 System Design ..................................................................................................................... 55
1Water Valves .............................................................................................................................. 55
2Flow Measurement..................................................................................................................... 57
3Retrofitting Systems ................................................................................................................... 58
4Mix Cycle Design........................................................................................................................ 62
Chapter 6 RS232 Interface ................................................................................................................... 69
1Port Settings ............................................................................................................................... 69
2RS232 Protocol Configuration.................................................................................................... 69
3RS232 Commands HC05/HC06 Formats .................................................................................. 70
Chapter 7 Remote Support ................................................................................................................... 85
1Remote support using Hydronix Hydro-Control VI support server............................................. 85
2Remote support using a custom server ..................................................................................... 86
3Configure the Hydro-Control to use a static IP address............................................................. 87
Chapter 8 Backup, Restore and Upgrade............................................................................................. 89
1The System and Data Cards and USB memory stick ................................................................89
2Backing up and Restoring .......................................................................................................... 90
3Upgrading the Hydro-Control ..................................................................................................... 91
Appendix A System Parameters Record .............................................................................................. 93
Appendix B Diagnostics ........................................................................................................................ 95
Appendix C Glossary ............................................................................................................................ 99
Appendix D Document Cross Reference ............................................................................................ 101

8 Hydro-Control VI Installation Guide HD0455 Rev 1.9.0

Hydro-Control VI Installation Guide HD0455 Rev 1.9.0 9
Table of Figures
Figure 1: The Hydro-Control VI............................................................................................................. 13
Figure 2: The base of the Hydro-Control VI with the label for the Earth stud in the red circle .............14
Figure 3: The rear of the Hydro-Control showing the electrical safety symbol in the red circle ........... 15
Figure 4: The rear view of the Hydro-Control VI ...................................................................................17
Figure 5: View of the Hydro-Control VI showing the mounting brackets ..............................................18
Figure 6: The panel cut-out for the Hydro-Control VI............................................................................18
Figure 7: The memory card access port showing the labels of the cards ............................................ 19
Figure 8: The rear of the Hydro-Control showing two of the connectors at the bottom ........................ 21
Figure 9: The base of the Hydro-Control showing the connectors ....................................................... 21
Figure 10: Digital Input Wiring Diagram ................................................................................................ 26
Figure 11: Digital Output Wiring Diagram ............................................................................................. 26
Figure 12: Analogue Input Current Loop Wiring Diagram.....................................................................26
Figure 13: Connecting a loop powered device ..................................................................................... 27
Figure 14: Connecting the current loop of an externally powered device............................................. 27
Figure 15: Connecting a voltage signal to the Analogue Input ............................................................. 27
Figure 16: Analogue Output Wiring Diagram ........................................................................................ 27
Figure 17: The recipe selection input wiring ......................................................................................... 28
Figure 18: The Menu Structure Of The Hydro-Control VI ..................................................................... 31
Figure 19: I/O Setup And Status – Page 1............................................................................................ 33
Figure 20: I/O Setup and Status – Page 2 ............................................................................................ 33
Figure 21: The top of the Hydro-Control showing the recalibration button ........................................... 35
Figure 22: An example of a calibration screen showing the target ....................................................... 35
Figure 23: The System Parameters screen .......................................................................................... 36
Figure 24: The second System Parameters screen .............................................................................39
Figure 25: Changing the date and time................................................................................................. 39
Figure 26: The voltage and temperature monitor screen......................................................................40
Figure 27: The weighed water setup page............................................................................................ 41
Figure 28: The sensor configuration screen - Page 1........................................................................... 42
Figure 29: The sensor configuration screen - Page 2........................................................................... 43
Figure 30: The sensor configuration screen - Page 3........................................................................... 44
Figure 31: The sensor configuration screen - Page 4........................................................................... 45
Figure 32: The Analogue Output Test Controls .................................................................................... 45
Figure 33: The sensor configuration screen - Page 5........................................................................... 46
Figure 34: The recipe overview screen................................................................................................. 46
Figure 35: The recipe editor - page 1.................................................................................................... 47
Figure 36: The recipe editor – page 2................................................................................................... 50
Figure 37: The recipe editor – page 3................................................................................................... 52
Figure 38: Typical water valve set-up ................................................................................................... 55
Figure 39: System Block Diagram ........................................................................................................ 58

10 Hydro-Control VI Installation Guide HD0455 Rev 1.9.0
Figure 40: Example Wiring Schematic For Manual Plant Operation ....................................................59
Figure 41: System Interconnections ..................................................................................................... 61
Figure 42: The Complete Mix Cycle...................................................................................................... 62
Figure 43: The Mix cycle showing the I/O status .................................................................................. 63
Figure 44: The Admix output signal during a normal mix cycle ............................................................ 64
Figure 45: The Admix output signal during a 2-step mix cycle ............................................................. 65
Figure 46: The mix trace showing Auto-Track settings......................................................................... 66
Figure 47: Auto-Track parameter example for the Dry Mix phase........................................................ 66
Figure 48 - RS232 Remote Comms screen.......................................................................................... 69
Figure 49 - Ethernet Coms Page .......................................................................................................... 85
Figure 50 - UltraVNC View software ..................................................................................................... 86
Figure 51 - Repeater Settings ............................................................................................................... 87
Figure 52: The Hydro-Control VI side view showing the USB ports .....................................................89
Figure 53: Some of the files on the USB keydisk after extraction......................................................... 91
Figure 54: The system parameters page 2 screen ............................................................................... 92