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

Hydro-Control VI Installation Guide HD0455 Rev 1.9.0 11
Box Contents
Standard Contents:
1 x Hydro-Control VI Unit
4 x Top/Bottom fixing brackets
2 x Side fixing brackets
1 x 10 Way Connector for Power/Sensor Communications
1 x 11 Way Connector for Digital Inputs
1 x 14 Way Connector for Digital Outputs
1 x Panel Mount USB Socket Kit
1 x Hydronix USB Memory Stick with Documentation
Additional Contents (If Expansion Board has been factory fitted):
1 x 8 Way Connector for Analogue Inputs/Outputs
1 x 9 Way Connector for Recipe Selection Inputs

12 Hydro-Control VI Installation Guide HD0455 Rev 1.9.0
Accessories
Part No. Description
0116 24v DC Power Supply 30 Watt
0175 Panel Mount USB Socket
0176 Replacement System Card (Not applicable to HC06 v2)
0177 Replacement Data Card (Not applicable to HC06 v2)
0179 Replacement Touch Screen Protective Layer
0180 Hydro-Control VI Expansion Board
0170 Hydro-Control VI Wall Mount Enclosure
0190 Hydro-Control VI Control Cabinet

Hydro-Control VI Installation Guide HD0455 Rev 1.9.0 13
Chapter 1 Introduction
Figure 1: The Hydro-Control VI
1 Introduction to the Hydro-Control VI
The Hydro-Control VI is a touch screen computer based upon the Microsoft Windows XP
Embedded operating system that has been designed to work with the Hydronix range of sensors
to monitor the level of moisture in a process (usually in a mixer) and send signals to adjust the flow
of water into the process using water valves.
The moisture level during the process cycle is displayed on the main screen and there are intuitive
and easy to use graphical tools for setting up the recipes in the system.
Communication with external systems can be implemented using either the built in RS232 serial
port, Ethernet Telnet port (port23) or the optional Expansion Board. The Expansion Board also
provides two analogue inputs and two analogue outputs.

Introduction Chapter 1
14 Hydro-Control VI Installation Guide HD0455 Rev 1.9.0
2 About this manual
This manual is not a user guide. It is designed as a reference guide for engineers who are
designing, installing or commissioning a Hydro-Control VI system.
This manual complements the Operators Guide which details how to setup and calibrate recipes
in the Hydro-Control VI. In order to understand the choices of operation and consequent design
requirements it is advisable to read the Operators Guide before reading this manual.
The manual is divided into 3 sections covering the mechanical installation, the electrical installation
and the commissioning of the unit.
3 Safety
The Hydro-Control VI has been designed to meet the requirements of IEC/EN 61010-1 : 2001 and
ANSI/UL 61010-1 Second Edition.
This equipment is designed to be safe under the following conditions.
3.1 Precautions
This unit is suitable for indoor use only.
If the equipment is used in a manner not specified by the manufacturer, the
protection provided by the equipment may be impaired.
The final installation should have a means to disconnect the electrical supply to
the unit. It should be marked as the disconnecting device and be within easy reach of the
operator.
Disconnect all signals from any voltage supply before the unit is opened for any adjustment,
maintenance or repair work.
Ensure that only fuses of the correct type and rating are fitted.
Ensure that the Hydro-Control is mounted in an environment that will not cause electrical
interference.
3.2 Explanation of Symbols and Markings
It is important to understand the meaning of the various symbols and markings on the Hydro-
Control equipment as follows:
Figure 2: The base of the Hydro-Control VI with the label for the Earth stud in the red circle

Chapter 1 Introduction
Hydro-Control VI Installation Guide HD0455 Rev 1.9.0 15
The Protective Earth symbol indicates that the earth must be connected to this
point.
Figure 3: The rear of the Hydro-Control showing the electrical safety symbol in the red circle
Caution – risk of electric shock.
Caution – refer to accompanying documents.
3.3 Clearance Requirements
It is important to ensure that the Hydro-Control has adequate clearance for ventilation and
access. The side and top vents should not be restricted and the top access plate for the
CompactFlash cards should be easily accessible.
The minimum clearance for the top and sides of the enclosure is 100mm. It may be necessary
to allow more space at the top to allow access to the top access plate with a screwdriver.
3.4 IP Rating
When correctly integrated into a suitable enclosure, the front panel and touch screen are
designed to be rated to Ingression Protection (IP) rating IP66. This has the American equivalent
NEMA 4.
This IP/NEMA rating is only applicable if the unit is installed in accordance with the mechanical
mounting procedures in Chapter 2 of this installation guide.

Introduction Chapter 1
16 Hydro-Control VI Installation Guide HD0455 Rev 1.9.0
3.5 Environmental Conditions
The range of environmental conditions for which the equipment has been designed are:
•Indoor Use Only
•Altitude up to 2000m
•Temperature 0°C to 40°C (32°F to 104°F)
•Maximum relative humidity 80% for temperatures up to 31 °C decreasing linearly to
50% relative humidity at 40 °C
•Pollution Degree 3 (Electrical Equipment in industrial or farming areas, untreated rooms
and Boiler rooms)
3.6 Lightning Strikes
Consideration should be given to protecting the installation from damage caused by lightning
and similar electrical disturbances.
Many installations will be in situations that are particularly prone to damage by lightning, for
example:
•Tropical Regions.
•Long cable runs between the sensor and the control panel.
•Tall, electrically conductive constructions (e.g. aggregate bins).
Although the Hydro-Control is fitted with Optical Isolation on the sensor input, this will not
prevent damage in all cases. Precautions should still be taken to avoid damage by lightning in
areas where there is a known risk.
It is recommended to install suitable lightning barriers to all conductors in the sensor extension
cable. Ideally, these would be fitted at both ends of this cable to protect the sensor, the Hydro-
Control and any other equipment connected to it.
It is recommended to install the equipment using screened cables to the specification defined
in Chapter 3 section 7.
3.7 Cleaning
The front panel of the Hydro-Control should be cleaned with a soft cloth. Abrasive materials
and liquids must not be used.

Hydro-Control VI Installation Guide HD0455 Rev 1.9.0 17
Chapter 2 Mechanical Installation
Figure 4: The rear view of the Hydro-Control VI
1 Weight and Dimensions
Fascia: 246 mm (W) x 190 mm (H); (9.69” (W) x 7.48” (H))
Panel Cut out: 232 mm (W) x 178 mm (H); (9.14” (W) x 7.00” (H))
Max Panel Thickness: 8 mm
Depth: 84 mm (3.54”)
Depth behind Fascia: 78 mm (3.31”)
Weight: 3.5 Kg (7.75 lb)
NOTE:
I/O connections are made to the base so access needs to be allowed for the cables and
connectors.
Space should be allowed for memory cards (Not applicable to HC06 v2) to be installed through
the access plate on the top of the unit.
USB connections are made on the right hand side of the unit (viewed from the rear). Sufficient
space should be left to allow insertion and removal of a USB memory stick, if required.
A minimum of 100mm of space should be allowed around the unit for cooling air circulation.
A ground stud is positioned at the bottom right of the unit (viewed from the rear).

Mechanical Installation Chapter 2
18 Hydro-Control VI Installation Guide HD0455 Rev 1.9.0
HC06 v1 HC06 v2
Figure 5: View of the Hydro-Control VI showing the mounting brackets
2 Mounting and installation
The unit should be mounted in a control panel (maximum thickness 8mm) using a bracket on each
side, two brackets on the top and two brackets on the bottom. To fit the side brackets, locate the
bracket in the slots on the side of the unit and slide it down until the top and bottom of the bracket
are level with the case. To fit the top and bottom brackets, insert the bracket into the slot and
tighten the bolt.
To install the Hydro-Control
•Cut out an aperture in the panel of the correct size. See Figure 6 for a template.
•Remove the mounting brackets from the body of the unit by releasing the screws and then
unhooking the brackets.
•Insert the Hydro-Control through the prepared hole.
•Re-fit the mounting brackets to the unit and tighten the screws evenly to pull the fascia
towards the control panel.
Panel or Enclosure
Cut-out for
Hydro-Control
232mm (9.14")
178mm (7.01")
Figure 6: The panel cut-out for the Hydro-Control VI

Chapter 2 Mechanical Installation
Hydro-Control VI Installation Guide HD0455 Rev 1.9.0 19
3 Operating Temperature
The unit has been designed to work in ambient air temperatures inside the cabinet of 0 – 40 °C
(32 – 104 °F).
Where ambient temperatures vary from this a temperature regulation system may need to be
installed.
4 OPTO modules
The OPTO-22 I/O modules are accessed through the removable panel on the rear of the unit. The
panel is held in place by four captive screws. When the screws are released and the panel is
removed, the OPTO modules can be individually removed and replaced using their individual
retaining screws. All power should be removed, from both the unit and the field wiring, whilst the
cover is not in place.
5 Memory Cards
Note: HC06 v2 utilises an internal SSD hard drive and does not contain removable
memory cards (Figure 5). The SSD hard drive is not removable, therefore, no user
maintenance is possible. Contact [e-mail] for assistance in the event of
a failure.
There are two memory card slots and these are accessed by removing the mounting bracket on
the top left corner of the Hydro-Control (as viewed from the rear). Removing the two small screws
opens the access plate over the card sockets (shown in Figure 7).
Figure 7: The memory card access port showing the labels of the cards
As shown in Figure 7, the memory cards are mounted so that the System Card is nearest to the
front of the unit and the Data Card is nearest to the rear. Both cards are clearly labelled. The
System Card is coloured blue and the data card is coloured beige.
The memory cards should always be inserted so that the Hydronix Logo is facing the rear of the
unit. The System Card should never be transferred between units.
If needed the System Card can be replaced with Hydronix Part Number 0176. The Card must be
replaced with the same colour card as the original factory fitted card.
Over time the memory cards can degrade in performance and so the Data Card should be replaced
every five years with Hydronix Part Number 0177.
Use Hydronix original parts to ensure compatibility and continuing reliability of the unit.
Memory
Cards

Mechanical Installation Chapter 2
20 Hydro-Control VI Installation Guide HD0455 Rev 1.9.0
6 Touch screen protective layer
The touch screen has a thin sheet of plastic which protects it. The sheet is not glued in place, but
held around the edged by the bezel on the front of the Hydro-Control. If the protector gets worn or
dirty it can be replaced with Hydronix Part Number 0179.
The touch screen protective layer can be removed by carefully applying pressure to the front of the
Hydro-Control and sliding the sheet down slightly. This will expose the corners of the sheet which
can then be lifted away from the touch screen. A blunt plastic tool can also be used to help lift the
sheet if needed.
To fit a new sheet, remove the sheet from the packaging taking care to keep the sheet clean and
dust free. Remove the protective covering from the rear (shiny) surface of the touch screen
protector and then carefully fit the new protector over the screen so that the anti-glare (dull) front
surface faces away from the touch screen.