Hydronix Hydro-Probe User manual

Hydro-Probe / Hydro-Probe XT
Installation Guide
To re-order quote part number:
Revision:
Revision date:
HD0675
1.5.0
January 2020

2Hydro-Probe Installation Guide HD0675 Rev 1.5.0
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
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

Hydro-Probe Installation Guide HD0675 Rev 1.5.0 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]

4Hydro-Probe Installation Guide HD0675 Rev 1.5.0

Hydro-Probe Installation Guide HD0675 Rev 1.5.0 5
Revision history
Revision No
Date
Description of Change
1.0.0
Feb 2015
First Release
1.1.0
May 2015
Cable product number changed
1.2.0
Jan 2016
Minor Formatting Update
1.3.0
March 2016
SIM02 reference added
1.3.1
July 2016
Accessories list updated
1.4.0
Nov 2017
Sensor model numbers updated
1.5.0
Jan 2020
Address Change

6Hydro-Probe Installation Guide HD0675 Rev 1.5.0

Hydro-Probe Installation Guide HD0675 Rev 1.5.0 7
Table of Contents
Chapter 1 Hydro-Probe Installation....................................................................................................... 11
1General to All Applications ......................................................................................................... 12
2Positioning the Sensor ............................................................................................................... 13
3Installing the Sensor................................................................................................................... 18
Chapter 2 Corrosion Protection............................................................................................................. 21
1Corrosion Protection................................................................................................................... 21
Chapter 3 Technical Specification ........................................................................................................ 23
1Technical Specification............................................................................................................... 23
Appendix A Document Cross Reference ..............................................................................................25
1Document Cross Reference....................................................................................................... 25

8Hydro-Probe Installation Guide HD0675 Rev 1.5.0

Hydro-Probe Installation Guide HD0675 Rev 1.5.0 9
Table of Figures
Figure 1: The Hydro-Probe Sensor ....................................................................................................... 11
Figure 2: Hydro-Probe mounting angle and material flow .................................................................... 12
Figure 3: Fitting a Deflection Plate to prevent damage......................................................................... 12
Figure 4: Overhead View of Hydro-Probe Mounted in a Bin.................................................................13
Figure 5: Mounting the Hydro-Probe in the Neck of the Bin ................................................................. 13
Figure 6: Mounting the Hydro-Probe in the Bin Wall ............................................................................14
Figure 7: Mounting the Hydro-Probe in Large Bins ..............................................................................14
Figure 8: Vibratory Feed Mounting ....................................................................................................... 15
Figure 9: Mounting the Hydro-Probe on a Conveyor Belt..................................................................... 15
Figure 10: Hydro-Probe angled at 45° to reduce build-up .................................................................... 16
Figure 11: Mounting the Hydro-Probe in an En-Masse Conveyor ........................................................16
Figure 12: Mounting the Hydro-Probe in a Screw Conveyor ................................................................ 17
Figure 13: Hydro-Probe in Ducting ....................................................................................................... 17
Figure 14: The Standard Mounting Sleeve (part no 0025) ...................................................................18
Figure 15: The Extension Mounting Sleeve (part no 0026) ..................................................................18
Figure 16: Flanged Mounting Sleeve (Part number 0024A) .................................................................19
Figure 17: Hydro-Probe installed under an Aggregate Bin ...................................................................21
Figure 18: Hydro-Probe installed in an Extension Mounting Sleeve .................................................... 21
Figure 19: Hydro-Probe installed with a Drip Loop ...............................................................................22
Figure 20: Hydro-Probe Protection Cover............................................................................................. 22

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Hydro-Probe Installation Guide HD0675 Rev 1.5.0 11
Chapter 1 Hydro-Probe Installation
Figure 1: The Hydro-Probe Sensor
Available accessories:
0023 Clamp Ring
0025 Standard Mounting Sleeve
0026 Extension Mounting Sleeve
0024A Flanged Mounting Sleeve (for vertical mounting)
0023 Clamp Ring for use with Flanged 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 (IP56, 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 Hydro-Probe Installation
12 Hydro-Probe Installation Guide HD0675 Rev 1.5.0
This Hydro-Probe/Hydro-Probe XT Installation Guide is only valid for model numbers
HP04 onwards and HPXT02 onwards. User guides for earlier Hydro-Probe model
numbers are available from www.hydronix.com
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, smooth, stream of material.
•The sensor should not obstruct the material flow.
•Position the sensor so that it is easily accessible for routine maintenance.
•To prevent damage from excessive vibration, position the sensor as far as reasonably
practical from vibrators.
•To reduce material sticking to the sensor it should be angled with the ceramic faceplate
initially set to 60° to the flow (as shown below). This is indicated on the label when the A
or B line is in line with the material flow.
•It is recommended to install a switch close to the sampling point to manually start sensor
averaging for calibration purposes. (see Electrical Installation Guide HD0678 for
connection details)
•A calibration sample point must be available as close to the sensor as possible (no more
than 150mm downstream)
600
Line A
Line B
Flow of material in
Bin/Silo/Hopper
Material flow
Figure 2: Hydro-Probe mounting angle and material flow
When filling a bin/silo/hopper using large aggregates (>12mm), the ceramic faceplate is
susceptible to damage by direct or indirect impact. To prevent this, a deflection plate should be
fitted above the sensor.
Deflection
plate
Approx.
1m
Figure 3: Fitting a Deflection Plate to prevent damage

Hydro-Probe Installation Chapter 1
Hydro-Probe Installation Guide HD0675 Rev 1.5.0 13
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 assemblies can be used
to fix the sensor as shown on page 18.
2.1 Bin/Silo/Hopper Mounting
The sensor may be mounted in the neck or the wall of the bin so the ceramic faceplate is in
the centre of the flow, as shown below.
Figure 4: Overhead View of Hydro-Probe Mounted in a Bin
2.2 Neck Mounting
The sensor should be located on the opposite side to the door-opening and centred within the
neck. If it is fitted on the same side as the ram, it should be angled towards the centre.
Positioning the sensor under the bin will also help where space is limited.
Standard
Mounting Sleeve
Figure 5: Mounting the Hydro-Probe in the Neck of the Bin

Chapter 1 Hydro-Probe Installation
14 Hydro-Probe Installation Guide HD0675 Rev 1.5.0
2.3 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 (part no: 0025).
Figure 6: Mounting the Hydro-Probe in the Bin Wall
If the sensor does not reach the main flow of material, then an Extension Mounting Sleeve
(part no 0026) should be used, as shown below.
Figure 7: Mounting the Hydro-Probe in Large Bins
Extension
Mounting
Sleeve
Standard
Mounting Sleeve
(part no 0025)

Hydro-Probe Installation Chapter 1
Hydro-Probe Installation Guide HD0675 Rev 1.5.0 15
2.4 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.
Hydro-Probe
Figure 8: Vibratory Feed Mounting
2.5 Conveyor Belt Mounting
The sensor should be secured to a suitable fixing bar using a Flanged Mounting Sleeve
(0024A) and a Clamp Ring (0023).
•Allow a 25mm gap between the sensor and the conveyor belt with a minimum of
150mm of material depth.
•Angle the sensor ceramic at 45° to the flow of material.
•To maintain consistent material depth diverters can be added to the belt (see below).
Diverters may be used to channel the
material to increase depth
25mm
Flow
Direction
Clamp Ring and Flanged
Mounting Sleeve
>150mm
Figure 9: Mounting the Hydro-Probe on a Conveyor Belt

Chapter 1 Hydro-Probe Installation
16 Hydro-Probe Installation Guide HD0675 Rev 1.5.0
•The Hydro-Probe body can be installed at an angle of between 90° and 60° to the
conveyor belt to reduce build -up of material. It is important to maintain the 45° angle
to the material flow and the 25mm gap to the conveyor belt see Figure 10.
> 60°
Maintain
25mm gap
Figure 10: Hydro-Probe angled at 45° to reduce build-up
2.6 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 faceplate.
•The probe should be inserted so that the centre of the ceramic is in the centre of the
flow.
•The ceramic faceplate should be completely covered by a minimum of 100mm depth
of material.
Material flow
Material must cover Ceramic Faceplate
of the sensor
Side view
Sampling Point
150- 300mm
Plan View
60°
Material flow
Averaging
switch
60°
Figure 11: Mounting the Hydro-Probe in an En-Masse Conveyor

Hydro-Probe Installation Chapter 1
Hydro-Probe Installation Guide HD0675 Rev 1.5.0 17
2.7 Screw Conveyor Mounting
The sensor should be mounted either at the flight-less end of the conveyor or, if this is not
possible, the last section of the flight should be removed. 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 faceplate.
•The ceramic faceplate should be in the centre of the flow and completely covered by a
minimum of 100mm depth of material.
Output
Input
Flow
Direction
Sampling point
Averaging switch
Flight removed
Figure 12: Mounting the Hydro-Probe in a Screw Conveyor
2.8 Installing in Ducting
To achieve reliable and consistent results in ducting the Hydro-Probe requires:
•Consistent, smooth flow rate.
•The sensor face is at 60° from the material flow
For further information on achieving consistent results in ducting see document EN0078.
60º
Flow Flow
Figure 13: Hydro-Probe in Ducting

Chapter 1 Hydro-Probe Installation
18 Hydro-Probe Installation Guide HD0675 Rev 1.5.0
3 Installing the Sensor
There are three mounting accessories available from Hydronix.
3.1 Standard Mounting Sleeve (part no 0025)
<338mm
50mm
170mm
218mm
89 mm
Figure 14: The Standard Mounting Sleeve (part no 0025)
3.2 Extension Mounting Sleeve (part no 0026)
For installation in larger bins
106mm
440mm
305mm
<583mm
50mm
Bin Wall
A
B
A – Sensor is secured to the inner sleeve by 6 hex screws (use Locktite or similar) on screw threads
B – Outer sleeve welded to bin
Figure 15: The Extension Mounting Sleeve (part no 0026)

Hydro-Probe Installation Chapter 1
Hydro-Probe Installation Guide HD0675 Rev 1.5.0 19
3.3 Flanged Mounting Sleeve (part no 0024A)
For installations where vertical mounting is required, use with the Hydronix Clamp Ring, (part
number 0023). A 100mm diameter hole is required to insert the Flanged Mounting Sleeve.
126 mm
Weld
Clamp Ring
Part No: 0023
Clamp Ring
Flanged Mounting
Sleeve
110mm
16mm
Ø100mm Hole
Ø89mm
Figure 16: Flanged Mounting Sleeve (Part number 0024A)

Chapter 1 Hydro-Probe Installation
20 Hydro-Probe Installation Guide HD0675 Rev 1.5.0