Hydronix Hydro-View HV02 User manual

Hydro-View
User Guide
Refer to Page 13 for Calibration Procedure when used in
Batch Weigher system Applications
Hydronix part number: D0022
Revision: 1.06
Revision date: 12 June 2007

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.
© 1996 Hydronix Limited
7 Riverside Business Centre
Walnut Tree Close
Guildford
Surrey
GU1 4UG
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.
This documentation is intended only to assist the reader in the use of the product and therefore Hydronix
shall not be liable for any loss or damage howsoever arising from the use of information or particulars in
or any error in or omission from this documentation.
AKNOWLEDGEMENTS
Hydronix, Hydro-Probe, Hydro-Skid, Hydro-Mix, Hydro-View and Hydro-Control are Registered
Trade Marks of Hydronix Limited.
Author: R.E.B. Holland B.Eng. C.Eng. MIEE

HYDRO-VIEW USER GUIDE D0022 REV 1.06 3
Table of contents
Table of contents ................................................................................................................................................ 3
Introduction ......................................................................................................................................................... 9
System overview................................................................................................................................9
Scope of this document .....................................................................................................................9
Organisation of this document ...........................................................................................................9
Applications of Hydro-View with Hydronix moisture sensors ..........................................................10
A batch weighing system ...........................................................................................................11
Batch weighing calibration procedure ............................................................................................................. 13
Calibration........................................................................................................................................14
Dry Bucket method ..........................................................................................................................15
Method .......................................................................................................................................15
A batch mixing system ..................................................................................................................................... 17
A continuous process.................................................................................................................19
Hydro-View quick start ..................................................................................................................................... 21
Hydro-View front panel ....................................................................................................................21
Display contrast adjustment.......................................................................................................21
Keypad .......................................................................................................................................21
Soft key legends.........................................................................................................................22
Moisture display page......................................................................................................................22
Max / Min % display ...................................................................................................................23
Help facility.......................................................................................................................................24
Hydro-View main menu ...................................................................................................................24
Trend display page ..........................................................................................................................25
Changing operating values ..............................................................................................................27
Adjusting set-points .........................................................................................................................28
Material in use..................................................................................................................................29
Advanced user options and configuration....................................................................................................... 31
Sensor calibration ............................................................................................................................31
Sensor set-up menu ........................................................................................................................32

4 HYDRO-VIEW USER GUIDE D0022 REV 1.06
Output set-up menu ........................................................................................................................ 33
Sensor diagnostic display ............................................................................................................... 34
Audible Alarm.................................................................................................................................. 34
Material mode ................................................................................................................................. 34
RS232 usage .................................................................................................................................. 35
RS485 usage .................................................................................................................................. 35
Data log rate.................................................................................................................................... 35
Station number................................................................................................................................ 35
Number of slaves ............................................................................................................................ 35
Communications diagnostic page ................................................................................................... 36
Input 1 / Input 2 use ........................................................................................................................ 36
Language selection......................................................................................................................... 37
Factory default settings ................................................................................................................... 37
Sensor set-up ............................................................................................................................ 38
Output set-up............................................................................................................................. 38
Sensor calibration...................................................................................................................... 38
Set-point set-up ......................................................................................................................... 38
Other parameters ...................................................................................................................... 39
Suggested working values .............................................................................................................. 40
Sensor set-up ............................................................................................................................ 40
Output set-up............................................................................................................................. 40
Sensor calibration...................................................................................................................... 40
Set-point set-up ......................................................................................................................... 41
Other parameters ...................................................................................................................... 41
Calibration and sampling techniques .............................................................................................................. 43
Recommendations for best performance........................................................................................ 43
Equipment required......................................................................................................................... 44
Taking the samples ......................................................................................................................... 44
Batch mixer system sampling method ...................................................................................... 44

TABLE OF CONTENTS
HYDRO-VIEW USER GUIDE D0022 REV 1.06 5
Continuous system sampling method........................................................................................45
Drying the samples ..........................................................................................................................45
Recommendations for best performance...................................................................................45
Calculating the moisture percentage ...............................................................................................45
Entering results into the Hydro-View ...............................................................................................46
What happens with your results ......................................................................................................46
Grouping channels ........................................................................................................................................... 49
Group moisture variables.................................................................................................................49
Group moisture display....................................................................................................................49
Effect of communications errors on grouped systems ....................................................................50
Example - a twin bin grouped system using RS232........................................................................51
Example - a four bin grouped system using RS485 ........................................................................52
Installation......................................................................................................................................................... 55
Power supply connections ...............................................................................................................55
Adjusting the Hydro-View mains operating voltage ...................................................................56
Field connections.............................................................................................................................56
Sensor Connections – Hydro-Probe II.............................................................................................57
Installation guidelines.................................................................................................................57
Connecting the Hydro-Probe II to the Hydro-View ....................................................................57
Sensor Connections – Hydro-Probe I..............................................................................................58
Analogue output connections.....................................................................................................59
Digital input connections ............................................................................................................60
Relay output connections...........................................................................................................61
Material selection using Digital I/O ............................................................................................61
Protection from lightning strikes.......................................................................................................63
Troubleshooting ...............................................................................................................................64
Factory test display ....................................................................................................................64
Installation problems ..................................................................................................................65
Sensor installation faults..................................................................................................................66
Sensor characteristics................................................................................................................67

6 HYDRO-VIEW USER GUIDE D0022 REV 1.06
Using Hydro-View serial ports ......................................................................................................................... 71
RS232 serial port ............................................................................................................................ 71
RS485 serial port ............................................................................................................................ 72
Installation of RS485 module ....................................................................................................72
RS485 connections ................................................................................................................... 72
RS485 termination..................................................................................................................... 72
Data log mode................................................................................................................................. 73
Batch print mode ............................................................................................................................. 74
ASCII Hex mode ............................................................................................................................. 75
Scope ........................................................................................................................................ 75
Physical connection................................................................................................................... 75
Line signalling information......................................................................................................... 75
Basic frame format .................................................................................................................... 75
Frame types .............................................................................................................................. 76
Request frame types (‘command set’) ...................................................................................... 77
Timing constraints ..................................................................................................................... 78
ASCII Hex protocol examples ................................................................................................... 78
Appendix........................................................................................................................................................... 79
Access codes .................................................................................................................................. 79
Electromagnetic Compatibility Directive - 89/336/EEC................................................................... 79
Index ................................................................................................................................................................. 81

TABLE OF CONTENTS
HYDRO-VIEW USER GUIDE D0022 REV 1.06 7
List of figures
•Figure 1 - Batch weighing example.................................................................................................11
•Figure 2 - Batch mixing system.......................................................................................................17
•Figure 3 - Continuous mixing process ............................................................................................19
•Figure 4 - Hydro-View front panel ...................................................................................................21
•Figure 5 - Moisture display..............................................................................................................22
•Figure 6 - Help facility .....................................................................................................................24
•Figure 7 - Main menu ......................................................................................................................24
•Figure 8 - Trend display ..................................................................................................................26
•Figure 9 - Selecting parameters......................................................................................................27
•Figure 10 - Changing a value..........................................................................................................27
•Figure 11 - Changing options..........................................................................................................28
•Figure 12 - Sensor diagnostic display.............................................................................................34
•Figure 13 - Communications diagnostic .........................................................................................36
•Figure 14 - Sensor calibration line ..................................................................................................47
•Figure 15 - Group moisture display.................................................................................................50
•Figure 16 - Twin bin grouped system..............................................................................................51
•Figure 17 - Four bin grouped system..............................................................................................53
•Figure 18 - Panel mounting the Hydro-View...................................................................................55
•Figure 19 - Hydro-View mains transformer.....................................................................................56
•Figure 20: Connecting the Hydro-View to a Hydro-Probe II ...........................................................57
•Figure 21 - Sensor extension cable connections............................................................................58
•Figure 22 - Hydro-View rear panel..................................................................................................58
•Figure 23 - Hydro-View main circuit board .....................................................................................59
•Figure 24 - Analogue output wiring .................................................................................................60
•Figure 25 - Digital inputs .................................................................................................................60
•Figure 26 - Internal/external excitation............................................................................................60
•Figure 27 - Relay output schematic ................................................................................................61
•Figure 28 - Material selection using digital I/O................................................................................62
•Figure 29 - Factory loop-back test wiring........................................................................................65
•Figure 30 : Using test blocks...........................................................................................................68
•Figure 31 - RS232 serial port..........................................................................................................71
•Figure 32 - RS485 interface............................................................................................................72
•Figure 33 - RS485 module circuit board .........................................................................................73

8 HYDRO-VIEW USER GUIDE D0022 REV 1.06
Note: This manual references older versions of Hydro-Probe Sensors which have now
been superseded by the Hydro-Probe II. Hydronix recommends that all new
installations should use the latest available sensor cable, which should be
connected to the Hydro-View according to the instructions in the Hydro-Probe II
User Guide.

HYDRO-VIEW USER GUIDE D0022 REV 1.06 9
Introduction
System overview
The Hydro-View provides display and control-system interface facilities in an easy-to-
apply form for a single channel of moisture measurement using any of the moisture
sensors from the Hydronix range.
Key features include...
Hydronix sensor input including power supply source for sensor.
0-10Vdc or 4-20mA analogue output (link selected option) with working range scaled
from front panel.
Graphic display provides large characters for legibility and 'chart-recorder' displays of
sensor measurements.
RS232 serial port built in for communication to external systems or printer.
Plug-in RS485 multi-drop serial port module (extra-cost option).
Two digital inputs that may be configured for batch averaging, input filtering and
material level functions.
Sensor fault or out of range alarm relay output.
Two programmable set-point relay outputs.
Panel mounting model HV02 has 146x98mm facia dimensions with 140x92mm panel
cut-out. Overall depth including IEC connector is 205mm
Scope of this document
This guide describes Hydro-View model HV02 and associated options as indicated on the
rear panel label. Earlier versions of the Hydro-View do not contain all the features of the
HV02 and you should refer instead to the appropriate guide.
Organisation of this document
This guide is organised into the following sections...
Section Readership Description
Introduction All Orientation.
Hydro-View quick
start
All How to operate the Hydro-View front panel to
select displays, change working values etc.
Advance user
options and
configuration
Engineer How to configure the Hydro-View for a particular
application.
Calibration and
sampling
techniques
Supervisor &
Engineer
How to take samples of the material in use and
obtain results for calibrating the Hydro-View unit.
Grouping
channels
Engineer How to use multiple moisture sensors to compute
average values.
Installation Engineer How to install the Hydro-View in a control panel
and connect it to your control system.
Using Hydro-View
serial ports
Engineer How to configure and operate the Hydro-View for
use with RS232 and RS485 communications.

APPLICATIONS OF HYDRO-VIEW WITH HYDRONIX MOISTURE SENSORS
10 HYDRO-VIEW USER GUIDE D0022 REV 1.06
Applications of Hydro-View with Hydronix moisture sensors
The Hydro-View is used in conjunction with any of the moisture sensors from the Hydronix
range. Applications of the sensors normally fall into one of the following categories...
Where the average moisture content of a batch of material is required, the material
passing over the sensor only once during the batch. An example of this is in the batch
weighing of materials out of a storage bin with the moisture sensor (normally a Hydro-
Probe but possibly also a Hydro-Skid) mounted in or close to the outlet of the bin. This
type of application is referred to as a Batch Weighing application in this manual.
Where the moisture content of batch of material is measured continuously with the
material being recycled over the sensor, which in this case would normally a Hydro-
Mix. An example of this is a batch mixing application, where the homogeneity of the
batch is important. This type of application is referred to as a Batch Mixing application
in this manual.
Where the moisture content of a continuous stream of material is required. The
material passes the face of the sensor only once, but the moisture value is then used
as a feedback signal in a control loop. An example of this would be a Hydro-Skid
sensor mounted on the output conveyor of a continuous mixing system. This type of
application is referred to as a Continuous process in this manual.
Each of these categories of applications would require the use of different facilities and
settings within the Hydro-View.
The selection of appropriate Hydro-View facilities and interfacing to external equipment is
essential in obtaining the best performance from your Hydronix moisture measurement
system - inappropriate choice of the operating conditions is the biggest single cause of
poor performance.
Examples of these three categories are described below. These may be used as a guide
in developing your own systems although the applications of the Hydro-View are not
limited to these applications. The examples show the minimum configurations required
and in general do not show variations in the use of interfacing techniques, which are
described elsewhere.