Hydronix Hydro-MIX XT Skid User manual

Hydro-MIX XT Skid
Installation Guide
To re-order quote part number:
Revision:
Revision date:
HD0927
1.0.0
November 2020

2 Hydro-Mix XT Skid Installation Guide HD0927 Rev: 1.0.0
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

Hydro-Mix XT Skid Installation Guide HD0927 Rev: 1.0.0 3
Hydronix Offices
UK Head Office
Address: Hydronix Limited
Units 11-12
Henley Business Park
Pirbright Road
Normandy
Guildford, Surrey
GU3 2DX
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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Revision history
Revision No
Date
Description of Change
1.0.0
Nov 2020
First edition

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Hydro-Mix XT Skid Installation Guide HD0927 Rev: 1.0.0 7
Table of Contents
Chapter 1 Introduction...........................................................................................................................11
Chapter 2 Mechanical Installation.........................................................................................................13
1General to all Applications .........................................................................................................13
2Dimensions.................................................................................................................................13
3Assembly of the Hydro-Mix XT Skid...........................................................................................14
4Improving the Material Flow .......................................................................................................18
5Calibration of the Sensor............................................................................................................20
6Maintenance...............................................................................................................................20
Chapter 3 Troubleshooting....................................................................................................................21
Appendix A Document Cross Reference ..............................................................................................23
1Document Cross Reference.......................................................................................................23

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Table of Figures
Figure 1: Hydro-Mix XT Skid .................................................................................................................11
Figure 2: Hydro-Mix XT Skid Dimensions .............................................................................................13
Figure 3: Hydro-Mix XT Parts................................................................................................................14
Figure 4: Sensor Plate Setup................................................................................................................15
Figure 5: Sensor Adjustment ................................................................................................................15
Figure 6: Correct Sensor Adjustment....................................................................................................16
Figure 7: Correct Installation of the Hydro-Mix XT Skid........................................................................16
Figure 8: Height Adjustment Range......................................................................................................17
Figure 9: Adjusting the Height of the Hydro-Mix XT Skid .....................................................................17
Figure 10: Angled Conveyor Installation ...............................................................................................18
Figure 11: Material Depth Increased Using Diverters...........................................................................18
Figure 12: Material Levelling.................................................................................................................19
Figure 13: Flow Extension Plate ...........................................................................................................19
Figure 14: Sampling Point.....................................................................................................................20

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Chapter 1 Introduction
The Hydro-Mix XT Skid is a mounting device designed to enable a Hydro-Mix XT moisture sensor
to ride over the surface of flowing material on a belt conveyor. Measurements are then taken by
the flush mounted sensor as the material passes underneath.
Figure 1: Hydro-Mix XT Skid

Introduction Chapter 1
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Hydro-Mix XT Skid Installation Guide HD0927 Rev: 1.0.0 13
Chapter 2 Mechanical Installation
1 General to all Applications
The Hydro-Mix XT Skid is designed to allow a Hydro-Mix XT sensor to measure the moisture
contained in flowing material on a belt conveyor. The following is recommended when installing
the Hydro-Mix XT Skid:
•The Hydro-Mix XT Skid should be positioned to allow the ceramic face plate of the sensor
to be in constant contact with the material.
•Position the Hydro-Mix XT Skid so it is easily accessible to allow routine maintenance,
adjustment and cleaning.
•Avoid areas of severe turbulence. The optimal signal will be obtained where there is a
smooth flow of material across the sensor ceramic face plate.
•In order to calibrate the sensor, to output a moisture percentage value, it is necessary to
take a sample of the material soon after it has passed beneath the sensor. An area to the
trailing edge of the Hydro-Mix XT Skid will need to be kept free from obstructions to enable
samples to be taken (see page 20).
2 Dimensions
160mm
130mm
130mm
105mm 80mm
105mm
245mm
257mm 160mm
Figure 2: Hydro-Mix XT Skid Dimensions

Mechanical Installation Chapter 2
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3 Assembly of the Hydro-Mix XT Skid
The Hydro-Mix XT Skid requires the user to assemble the system to match their requirements.
The HMXT Skid Adjustment bars and the HMXT Skid M6 studs are pre-installed using Loctite 290
to ensure they are flush with the underside of the Sensor Plate. If they are removed Loctite 290
must be reapplied after thorough cleaning of the threads.
The Hydro-Mix XT Skid kit comprises of the following components:
1. HMXT Skid Sensor Plate
2. HMXT Skid Mounting Plate
3. HMXT Skid M12 Adjustment Bars x4
4. HMXT Skid M6 Studs x6
5. HMXT Skid Clamp Plate
6. HMXT Skid Belt Extension Plate (Optional)
7. HMXT Skid Belt Extension Mounting Plate (Optional)
8. HMXT Skid Belt Extension Clamp Plate (Optional)
9. HMXT Skid Belt Extension M12 Adjuster Bars x 2 (Optional)
10. Hydro-Mix XT Skid M12 Nuts x12
11. Hydro-Mix XT Skid Extension Plate M12 Nuts x6 (Optional)
12. M6 Nuts x18
13. M6 end caps x6
14. M10 80mm Bolts x6
15. M10 Spring washers x6
16. M10 Nuts x6
8
7
9
6
2
3
1
13
412
10
11
5
Square Bar
(User Supplied)
14 15
16
14
16
15
Figure 3: Hydro-Mix XT Parts

Chapter 2 Mechanical Installation
Hydro-Mix XT Skid Installation Guide HD0927 Rev: 1.0.0 15
3.1 Setup of the Sensor Plate
The sensor plate is designed to hold the sensor in position to ensure the ceramic face plate is
in contact with the material. The sensor is attached using the supplied M6 studs, Nuts, and End
caps (Figure 4). The M6 studs are pre-installed with Loctite 290 applied to ensure they are flush
with the underside of the Sensor Plate. If the studs are removed, Loctite 290 must be reapplied.
It is recommended to install the sensor to the sensor plate before fully assembling the Hydro-
Mix XT Skid.
M6 End Cap
M6 Nut x2
M6 Stud
M6 Nut
Figure 4: Sensor Plate Setup
3.2 Adjusting the Sensor
Once the Hydro-Mix XT has been attached to the sensor plate, the sensor positioning will need
to be adjusted
To ensure the Hydro-Mix XT can accurately detect the moisture, and to avoid damaged, the
ceramic face plate must be flush with the underside of the Hydro-Mix XT Skid. To adjust the
sensor, place the Hydro-Mix XT onto the mounting studs. Adjust the nuts on the mounting studs
until the ceramic face is completely flush with the underside of the Sensor Plate. A steel ruler,
placed across the underside of the Sensor Plate, can be used to ensure the sensor is correctly
installed. Tighten all fixings to ensure the sensor is fully secured.
Adjust M6 Nut to align
the sensor
Figure 5: Sensor Adjustment

Mechanical Installation Chapter 2
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Sensor adjusted too low Sensor flush with the underside of
the Sensor Plate
Figure 6: Correct Sensor Adjustment
3.3 Installing the Hydro-Mix XT Skid on a Conveyor Belt
The Hydro-Mix XT Skid should be installed above the conveyor attached firmly to a user
supplied suitable square bar (recommended size: 50mm x 50mm). The Hydro-Mix XT Skid is
attached to the square bar using the Mounting plate and Clamp Plate. The Hydro-Mix XT Skid
must be installed so it faces the material flow. For correct operation, the Hydro-Mix XT Skid
must be installed parallel to the conveyor belt. The square bar can be installed so it is parallel
to the belt or perpendicular.
Square Bar
(User Supplied)
Clamp Plate
Mounting Plate
M10 Bolt, Nut
and Spring
washer
M12 Nut
Figure 7: Correct Installation of the Hydro-Mix XT Skid

Chapter 2 Mechanical Installation
Hydro-Mix XT Skid Installation Guide HD0927 Rev: 1.0.0 17
Once mechanically installed as shown in Figure 7, the height of the Hydro-Skid should be
adjusted so that the underside of the Hydro-Mix XT Skid is at least 50mm from the conveyor,
this is achieved by adjusting the position of the mounting plate (Figure 8). The height
adjustment range is shown in Figure 8.
220mm
140mm
Figure 8: Height Adjustment Range
Positioning the Hydro-Skid too close to the conveyor can result in erratic sensor readings
(conveyor belt interference). As part of the installation it is important to check that the sensor
signal is stable while the belt is running as detailed below.
1. Install the Hydro-Mix XT Skid and sensor as described.
2. Connect the sensor to a suitable computer running Hydro-Com software, available free
from www.hydronix.com. A USB Sensor Interface (SIM01) or RS485/232 adapter will
be required. See the Hydro-Com user guide HD0682 for details.
3. Adjust the height of the Hydro-Mix XT Skid so that the minimum distance between the
empty conveyor belt and the underside of the Hydro-Skid is at least 50mm.
4. The Unscaled Output of the sensor should be checked to ensure that it is as close to
zero as possible. The Unscaled Output will increase if the sensor is too close to the
conveyor. Increase the height of the sensor to reduce the Unscaled output of the sensor.
5. Once the belt is running with material the Hydro-Mix XT Skid should be adjusted to allow
it to ride on the surface of the material on the belt so it removes any air gaps between
the sensor and the material, retaining the 50mm gap to the belt (Figure 9).
6. Ensure a consistent material flow beneath the sensor (Figure 9)
>50mm
Figure 9: Adjusting the Height of the Hydro-Mix XT Skid

Mechanical Installation Chapter 2
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3.4 Installing the Hydro-Mix XT Skid on an Angled Conveyor Belt
The Hydro-Mix XT Skid can be installed on a conveyor belt that is running at an angle. It is
recommended that the Hydro-Mix XT Skid is only operated at a maximum of 30°.
30°
30°
Figure 10: Angled Conveyor Installation
4 Improving the Material Flow
4.1 Diverters
Maintaining a minimum material depth on the conveyor belt is vital to ensure that the sensor is
in contact with the material and to remove the possibility of conveyor belt interference.
Adjustments to the flow will be required if the minimum depth is not achievable. Installation of
diverters to restrict the flow, and as a result increase the depth, can be used to maintain the
correct material flow. (Figure 11)
Material on
conveyor
Diverters
Hydro-Mix XT Skid
Diverters
>50mm
Figure 11: Material Depth Increased Using Diverters

Chapter 2 Mechanical Installation
Hydro-Mix XT Skid Installation Guide HD0927 Rev: 1.0.0 19
4.2 Levellers
Inconsistent material flow beneath the Hydro-Mix XT Skid will reduce the sensor’s ability to
measure the moisture in a particular batch. To reduce the variations in the flow, levellers or
chains can be installed above the conveyor belt (Figure 12).
Consistent material depth
Leveller or chain
Hydro-Mix XT Skid
Inconsistent material depth
Figure 12: Material Levelling
4.3 Belt Extension Plate (Part number 5125)
The Belt Extension Plate is designed to enable the Hydro-Mix XT Skid to be installed at the end
of the conveyor belt (Figure 13). This type of installation is common at the output of a horizontal
dryer where the length of the belt is very short. It is utilised to ensure the Hydro-Mix XT sensor
is always in contact with material. If the Skid is installed at the end of the belt the material will
fall away from the sensor, this will result in erroneous readings. The ceramic face of the sensor
must be fully covered to achieve accurate results. The Belt Extension Plate effectively extends
the length of the conveyor belt.
The Belt Extension Plate is installed in the same way as the Hydro-Mix XT Skid by clamping it
to a suitable square bar above the conveyor belt. The Belt Extension Plate must be installed so
it is very close to the conveyor belt but not touching. The height is adjusted using the Adjustment
bars until the Belt Extension Plate creates a level extension to the belt. The material flow over
this plate must be smooth so adjustments after installation may be required.
If the sensor is not installed at the end of the belt the Belt Extension Plate is not required.
Note: Routine checks on the Belt Extension Plate must be performed to ensure the
plate does not touch the conveyor belt. Contact between the belt and the Belt
Extension Plate could result in damage to the conveyor belt or the extension plate.
>50mm
Extension Plate
Extends the
Conveyor Belt
Figure 13: Flow Extension Plate

Mechanical Installation Chapter 2
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5 Calibration of the Sensor
On completion of the installation the Hydro-Mix XT moisture sensor will need to be calibrated to
the material. This calibration will enable the sensor to output a moisture %. To calibrate the sensor,
refer to the Sensor Configuration and Calibration Guide HD0679
5.1 Sampling Point
A sampling point close to the sensor is required to facilitate the collection of material that
represents the particular batch passing the sensor. If the sampling point is not close or is not in
line with the sensor the calibration process may not be accurate (Figure 14)
Material Flow
Maximum 300mm
Sample Point
Hydro-Mix XT Skid
Figure 14: Sampling Point
6 Maintenance
The following are recommended to help maintain the Hydro-Mix XT Skid:
•Visually inspect to confirm that the Hydro-Mix XT Skid is operating at the correct height,
especially if the material on the conveyor belt has changed. Never allow the Hydro-Mix XT
Skid to come into contact with the conveyor belt, as this will increase the wear on the
underside. Damage to the sensor caused by an incorrectly adjusted Hydro-Mix Skid will
not be covered by the warranty.
•Some materials can cause a build-up on the surface of the Hydro-Mix XT Skid, especially
if it is sticky; this will need to be monitored after installation to confirm that it does not
interfere with the sensors contact with the material.