Hydronix Hydro-Probe XT User manual

Hydro-Probe XT
User Guide
To re-order quote part number: HD0538
Revision: 1.6.0
Revision date: January 2020

2Hydro-Probe XT User Guide HD0538 Rev: 1.6.0
Copyright
Neither the whole nor 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.
© 2016
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 XT User Guide HD0538 Rev: 1.6.0 3
Hydronix Offices
UK Head Office
Address: Units 11-12,
Henley Business Park
Pirbright Road
Normandy
Surrey GU3 2DX
United Kingdom
Tel: [phone]
Email: [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]

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Hydro-Probe XT User Guide HD0538 Rev: 1.6.0 5
Revision history
Revision No
Date
Description of Change
1.0.0
October 2012
First Release
1.1.0
June 2013
Formatting Updates
1.2.0
August 2013
Corrosion protection section added to Chapter 2
1.3.0
February 2014
Figure 29 & 30 updated
1.4.0
April 2014
Figure 15 description updated
1.4.1
May 2014
Minor Formatting update
1.5.0
July 2016
Updated Sensor Cable part Numbers and Hydro-
Com information
1.6.0
January 2020
Address Change

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Hydro-Probe XT User Guide HD0538 Rev: 1.6.0 7
Table of Contents
Chapter 1 Introduction........................................................................................................................... 11
1Introduction................................................................................................................................. 12
2Measuring techniques ................................................................................................................ 12
3Sensor connection and configuration.........................................................................................13
Chapter 2 Mechanical Installation......................................................................................................... 15
1General to all applications .......................................................................................................... 15
2Positioning the sensor ................................................................................................................ 16
3Installing the Sensor................................................................................................................... 22
4Corrosion protection ................................................................................................................... 24
Chapter 3 Electrical Installation and Communication ........................................................................... 27
1Installation guidelines ................................................................................................................. 27
2Analogue outputs ....................................................................................................................... 27
3RS485 multi-drop connection.....................................................................................................29
4Hydronix Interface Units............................................................................................................. 30
5Digital input/output connection ................................................................................................... 30
6Connecting to a PC .................................................................................................................... 31
Chapter 4 Configuration ........................................................................................................................ 35
1Configuring the Sensor............................................................................................................... 35
2Analogue output setup ............................................................................................................... 35
3Digital inputs/output setup.......................................................................................................... 37
4Filtering....................................................................................................................................... 38
5Alternative Measurement Techniques........................................................................................ 39
Chapter 5 Sensor Integration and Calibration....................................................................................... 43
1Sensor Integration ...................................................................................................................... 43
2Sensor Calibration...................................................................................................................... 43
Chapter 6 Optimising Sensor and Process Performance ....................................................................51
1General to all Applications ......................................................................................................... 51
2Routine maintenance ................................................................................................................. 51
Chapter 7 Sensor diagnostics............................................................................................................... 53
1Sensor Diagnostics .................................................................................................................... 53
Chapter 8 Technical specification ......................................................................................................... 59
1Technical Specifications............................................................................................................. 59
Chapter 9 Frequently asked questions .................................................................................................61
Appendix A Default parameters ............................................................................................................ 63
1Default Parameters .................................................................................................................... 63
Appendix B Document Cross Reference .............................................................................................. 65
1Document Cross Reference....................................................................................................... 65

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Hydro-Probe XT User Guide HD0538 Rev: 1.6.0 9
Table of Figures
Figure 1: The Hydro-Probe XT.............................................................................................................. 11
Figure 2: Connecting the sensor (overview) .........................................................................................13
Figure 3: Hydro-Probe XT mounting angle and material flow...............................................................15
Figure 4: Fitting a deflection plate to prevent damage..........................................................................15
Figure 5: Overhead view of Hydro-Probe XT mounted in a bin ............................................................ 16
Figure 6: Mounting the Hydro-Probe XT in the neck of the bin............................................................ 16
Figure 7: Mounting the Hydro-Probe XT in the bin wall ........................................................................17
Figure 8: Mounting the Hydro-Probe XT in large bins ..........................................................................17
Figure 9: Mounting the Hydro-Probe XT in a vibratory feeder .............................................................. 18
Figure 10: Mounting the Hydro-Probe XT on a conveyor belt ..............................................................19
Figure 11 - Mounting the Hydro-Probe XT in an en-masse conveyor .................................................. 20
Figure 12 - Mounting the Hydro-Probe XT in a screw conveyor...........................................................21
Figure 13: The standard mounting sleeve (part no 0025)..................................................................... 22
Figure 14: The extension mounting sleeve (part no 0026) ...................................................................22
Figure 15: Flanged Mounting Sleeve (Part number 0024A) .................................................................23
Figure 16: Hydro-Probe installed under an aggregate bin.................................................................... 24
Figure 17: Hydro-Probe installed in an Extension Mounting Sleeve ....................................................25
Figure 18: Hydro-Probe installed with a drip loop ................................................................................. 25
Figure 19: Deflector plate...................................................................................................................... 25
Figure 20: 0975A Sensor cable connections ........................................................................................ 28
Figure 21: RS485 multi-drop connection .............................................................................................. 29
Figure 22: Correct RS485 cable networks ............................................................................................29
Figure 23: Incorrect RS485 cabling ...................................................................................................... 29
Figure 24: Internal/external excitation of digital input 1 & 2 ..................................................................30
Figure 25: Activation of digital output 2.................................................................................................30
Figure 26: RS232/485 converter connections (0049B)......................................................................... 31
Figure 27: RS232/485 converter connections (0049A)......................................................................... 31
Figure 28: RS232/485 converter connections (Sensor Interface Module)............................................ 32
Figure 29: Ethernet Adapter Connections (EAK01) .............................................................................. 33
Figure 30: Ethernet Power Adapter Kit connections (EPK01) ..............................................................33
Figure 31: Maximum number of sensor connections dependent upon ambient temperature .............. 34
Figure 32: Guidance for setting output variables .................................................................................. 36
Figure 33: Relationship of moisture % to Unscaled values .................................................................. 40
Figure 34: Calibrations for two different materials ................................................................................ 43
Figure 35: Calibration inside the Hydro-Probe XT ................................................................................ 45
Figure 36: Calibration inside the control system ................................................................................... 46
Figure 37: Example of good material calibration................................................................................... 49
Figure 38: Examples of poor material calibration points.......................................................................50

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Hydro-Probe XT User Guide HD0538 Rev: 1.6.0 11
Chapter 1 Introduction
Figure 1: The Hydro-Probe XT
Available accessories:
Part No Description
0023 Clamp ring
0024A Flanged Mounting Sleeve (requires part number 0023)
0025 Standard mounting sleeve
0026 Extension mounting sleeve
0975A 4m sensor cable
0975A-10m 10m sensor cable
0975A-25m 25m sensor cable
0116 Power supply – 30 Watt for up to 4 sensors
0067 Terminal box (IP66, 10 terminals)
0049A RS232/485 converter (DIN rail mounting)
0049B RS232/485 converter (9 pin D type to terminal block)
SIMxx USB Sensor Interface Module including cables and power supply
Hydro-Com configuration and diagnostics software is available for free download from
www.hydronix.com

Chapter 1 Introduction
12 Hydro-Probe XT User Guide HD0538 Rev: 1.6.0
1 Introduction
The Hydro-Probe XT is a digital microwave moisture sensor. It uses high speed digital signal
processing filters and advanced measurement techniques to give a signal which gives a change
that is linear with the change in moisture in the material being measured. The sensor must be
installed into a material flow and will then give an online output of the moisture change in the
material.
The sensor has two analogue outputs which are fully configurable and can be internally
calibrated to give a direct moisture output which is compatible with any control system.
Typical applications include moisture measurement in biomass materials, grain, animal feed and
agricultural materials. The shape of the sensor makes it ideally suited to measure the moisture
content of materials in the following applications:
•Bins / Hoppers / Silos
•Conveyors
•Vibratory Feeders
Two digital inputs are available which can control the internal averaging function, allowing the
sensor measurement, taken at 25 times per second enabling rapid detection of changes in
moisture content in the process, to be averaged to enable easier use in the control system.
One of the digital inputs can be configured to provide a digital output which can provide an alarm
signal in the event of a low or high reading, and this can be used to signal a high moisture alarm
or alternatively to signal an operator that a storage bin needs to be refilled.
The Hydro-Probe XT is specially designed using suitable materials to provide many years of
reliable service even in the most arduous conditions. However, as with other sensitive electronic
devices, care should be taken not to subject the sensor to unnecessary impact damage,
particular the ceramic faceplate which, whilst being extremely resistant to abrasion, is brittle and
may be damaged if hit directly.
CAUTION – NEVER HIT THE CERAMIC
Care should be taken to ensure that the Hydro-Probe XT has been correctly
installed and in such a manner to ensure representative sampling of the
material concerned. It is essential that the sensor be installed as near as
possible to the bin gate and that the ceramic faceplate is fully inserted into the
main flow of the material. It must not be installed in stagnant material or
where material can build-up on the sensor.
All Hydronix sensors are pre-calibrated in the factory so that they read 0 when in air and 100
when submerged in water. This is called the ‘Unscaled Reading’ and is the base value used
when calibrating a sensor to the material being measured. As this normalises each sensor, if a
sensor is changed then there is no need to redo the material calibration.
After installation the sensor should be calibrated to the material (see Sensor Integration and
Calibration on Page 43). For this the sensor can be setup in two ways:
•Calibration inside sensor: Sensor is calibrated internally and outputs true moisture.
•Calibration inside control system: Sensor outputs an Unscaled reading which is
proportional to moisture. Calibration data inside the control system converts this to true
moisture
2 Measuring techniques
The Hydro-Probe XT uses the unique Hydronix digital microwave technique that provides a more
sensitive measurement compared to analogue techniques. This technique facilitates a choice of
measurement modes. The default mode is Mode V which is the most suitable mode for
agricultural and biomass materials.

Introduction Chapter 1
Hydro-Probe XT User Guide HD0538 Rev: 1.6.0 13
3 Sensor connection and configuration
As with other Hydronix digital microwave sensors, the Hydro-Probe XT may be remotely
configured using a digital serial connection and a PC running Hydro-Com sensor configuration
and calibration software. For communication with a PC, Hydronix supply RS232-485 converters
and a USB Sensor Interface Module (See page 31).
There are two basic configurations by which the Hydro-Probe XT can be connected to a batch
control system:
•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 permits direct exchange of data and control
information between the sensor and the plant control computer. USB and Ethernet
adapter options are also available
The sensor can be configured to output a linear value of between 0-100 unscaled units with the
material calibration being performed in the control system. Alternatively it is also possible to
internally calibrate the sensor to output a real moisture value.
Figure 2: Connecting the sensor (overview)
(Drawing not to scale)
Power supply
+15V - 30 Vdc, 1A min.
2 x Analogue output
0-20mA, 4-20mA, 0-10V
Digital inputs
RS485 serial
communications

Chapter 1 Introduction
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Hydro-Probe XT User Guide HD0538 Rev: 1.6.0 15
Chapter 2 Mechanical Installation
1 General to all applications
Follow the advice below for good sensor positioning:
•The ‘sensing area’ of the sensor (ceramic faceplate) 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 may be easily accessible for routine maintenance,
adjustment and cleaning.
•Care should be taken to prevent damage from excessive vibration by positioning the
sensor as far as reasonably practical from vibrators. If fitting to a vibratory feeder, the
advice from the manufacturer of the feeder should be followed, or alternatively contact
the Hydronix support department.
•The sensor must be angled with the ceramic faceplate initially set to 60° to the flow (as
shown below) to ensure that none of the material sticks to the ceramic faceplate. This is
indicated on the label when the A or B line is perpendicular to the flow.
Line A
Line B
60˚
Figure 3: Hydro-Probe XT mounting angle and material flow
If there is a risk that high density material greater than 12mm in size may inadvertently enter the
material flow it is advisable to protect the ceramic faceplate. A deflection plate should be fitted
above the sensor (see Figure 4). The requirements of this must be determined by observation
during loading.
Deflection
plate
Approx.
1m
Figure 4: Fitting a deflection plate to prevent damage

Chapter 2 Mechanical Installation
16 Hydro-Probe XT User Guide HD0538 Rev: 1.6.0
2 Positioning the sensor
The optimum location for the sensor varies depending on the type of installation – a number of
options are detailed on the following pages. Several different mounting systems can be used to
fix the sensor as shown in Section 3.
2.1 Bin/silo/hopper mounting
The sensor may be mounted in either the neck of the bin or the wall and should be positioned
in the centre of the flow of material, as shown below.
Figure 5: Overhead view of Hydro-Probe XT mounted in a bin
2.1.1 Neck mounting
The sensor should be located on the opposite side of the gate opening and centred within
the neck. If it is fitted on the same side as the ram, it should be angled towards the centre.
•Ensure that the ceramic is not mounted closer than 150mm to any metalwork.
•Ensure the sensor does not obstruct the gate
•Ensure that the ceramic faceplate is in the main flow of material. Observe a test
batch to identify the best position. To prevent obstruction of the material where
space is limited, the sensor can be angled down to a maximum of 45° as shown
below.
•Positioning the sensor under the bin will also help where space is limited. The
sensor may require cleaning if it is used in sticky materials or if the sensor is fouled
by weeds and other foreign bodies contained in the aggregates. In this case,
mounting the sensor under the bin can be advantageous for ease of maintenance.
Figure 6: Mounting the Hydro-Probe XT in the neck of the bin

Mechanical Installation Chapter 2
Hydro-Probe XT User Guide HD0538 Rev: 1.6.0 17
2.1.2 Bin wall mounting
The sensor can be placed horizontally in the bin wall, or if the space is limited, angled
down to 45° as shown, using the standard mounting sleeve.
•The sensor should be placed in the centre of the widest side of the bin and, where
possible, mounted on the opposite side to any vibrators (where fitted).
•Ensure the sensor ceramic is not mounted closer than 150mm to any metal work.
•Ensure the sensor does not obstruct the door-opening.
•Ensure the ceramic face-plate is in the main flow of the material.
Figure 7: Mounting the Hydro-Probe XT in the bin wall
If the sensor does not reach the main flow of material, then an extension mounting sleeve
should be used, as shown in Figure 8.
Figure 8: Mounting the Hydro-Probe XT in large bins
Standard Mounting
Sleeve
(part number: 0025)
Extension
Mounting Sleeve
(part number
0026)

Chapter 2 Mechanical Installation
18 Hydro-Probe XT User Guide HD0538 Rev: 1.6.0
2.2 Vibratory feed mounting
With vibratory feeders, the sensor is normally fitted by the manufacturer – contact Hydronix
for further information on positioning. It is difficult to predict where the flow of material occurs,
but the location shown below is recommended.
Figure 9: Mounting the Hydro-Probe XT in a vibratory feeder
Hydro-Probe XT

Mechanical Installation Chapter 2
Hydro-Probe XT User Guide HD0538 Rev: 1.6.0 19
2.3 Conveyor belt mounting
The sensor should be secured to a suitable fixing bar using a Flanged Mounting Sleeve and a
Clamp Ring.
•Allow a 25mm gap between the sensor and the conveyor belt
•The minimum depth of material on the conveyor belt must be 150mm to cover the
ceramic faceplate. The sensor faceplate must always be covered in material.
•To improve the flow characteristics and level of material on the belt, it may be beneficial
to fit diverters onto the conveyor, as shown below. This can build up the material to a
deeper level for good measurement.
•To aid calibration, a manual switch may be fitted alongside the belt to switch the
average/hold digital input. This will enable the readings to be averaged over a period of
time whilst collecting samples and so giving a representative Unscaled reading for
calibration (See Chapter 3 for connection details).
Diverters may be used to channel the
material to increase depth
25mm
Flow
Direction
Clamp Ring and Flanged
Mounting Sleeve
>150mm
Figure 10: Mounting the Hydro-Probe XT on a conveyor belt

Chapter 2 Mechanical Installation
20 Hydro-Probe XT User Guide HD0538 Rev: 1.6.0
2.4 En-masse (chain) conveyor mounting
The sensor should be mounted using a Standard Mounting Sleeve in the side wall of the
conveyor.
The main body of the sensor should be mounted at an angle of 60° to the flow.
•The probe should be positioned close to the bottom of the conveyor so as much
material as possible can pass over the ceramic face
•The probe should be inserted so that the centre of the ceramic is in the centre of the
flow
•The ceramic face should be completely covered by a minimum of 100mm depth of
material at all times a measurement is required
•An accessible sampling point should be installed approximately 150mm downstream
of the sensor
•To aid calibration, a manual switch should be fitted close to the sampling point to
switch the average/hold input. This will enable the readings to be averaged over a
period of time whilst collecting samples and so give a representative Unscaled
reading for the sample collected for calibration (see Chapter 3 for connection details)
Flow
Direction
Sampling
Point
Averaging
Switch
150-300mm
Flow
Direction
Side View
Plan View
60˚
60˚
Figure 11 - Mounting the Hydro-Probe XT in an en-masse conveyor