Rotronic HygroFlex 1 User manual

HygroFlex
Humidity Temperature Transmitter
Instruction Manual
V 3.1

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Contents
Overview...............................................................................................................................................3
General Description..............................................................................................................................4
Power Requirements ........................................................................................................................4
Probes and Probe Inputs..................................................................................................................5
Analogue Outputs (HygroFlex 1 and HygroFlex 3) ..........................................................................7
Connection to a PC - RS232 Digital Port .........................................................................................8
HW3 Software ..................................................................................................................................8
RS485 Networking (HygroFlex 2 and HygroFlex 3) .........................................................................8
Unit System ......................................................................................................................................8
Optional Display and Keypad ...........................................................................................................9
Keypad..............................................................................................................................................9
Installation ..........................................................................................................................................10
Installation of the Transmitter Enclosure ........................................................................................10
Front cover removal........................................................................................................................10
Re-attaching the ribbon cable (cover with optional Display and Keypad)......................................11
Configuration of the Analogue Outputs ..........................................................................................16
Electrical Installation Guidelines.....................................................................................................17
Serial Network Configuration (HygroFlex 2 and HygroFlex 3 only)................................................17
HygroFlex Function Menu ..................................................................................................................19
CALCULATE (HygroFlex 2 and HygroFlex 3) ................................................................................19
DISPLAY (HygroFlex 2 and HygroFlex 3 with optional LC display)...............................................20
ADJUST M.PT (2- to 4-point adjustment against a reference environment)..................................20
ADJUST 1PT (1-point adjustment against a reference environment)............................................22
ADJUST REF (1-point adjustment against a reference probe) ......................................................23
PROBE ...........................................................................................................................................23
SETTINGS......................................................................................................................................24
SYS Status .....................................................................................................................................24
OUTPUT.........................................................................................................................................24
Errors and Status Messages ..........................................................................................................25
Test Connector for the HygroPalm Indicator......................................................................................26
Display the Probe Measurements ..................................................................................................26
Functions (except ADJUST M.PT and ADJUST 1PT)....................................................................27
Functions ADJUST M.PT and ADJUST 1PT..................................................................................27
Function ADJUST REF...................................................................................................................27
Environmental Limits ..........................................................................................................................28
Maintenance .......................................................................................................................................28
On-Site Maintenance......................................................................................................................28
Factory / Metrology Lab. Maintenance ...........................................................................................28
Specifications .....................................................................................................................................29
Appendix 3: Maintenance of the ROTRONIC probes ........................................................................32
Cleaning or Replacing the Dust Filter of the Probe........................................................................32
Periodic Calibration Check of the Probes.......................................................................................32
Appendix 4: Calibration Basics...........................................................................................................33
Temperature Calibration.................................................................................................................33
Humidity Calibration .......................................................................................................................33
Appendix 5: Humidity Definitions........................................................................................................35
Appendix 6: Dew Point Accuracy .......................................................................................................37
Appendix 7: RS232 Communication Protocol ....................................................................................38
Appendix 9: Accessories for the HygroFlex .......................................................................................42
Appendix 10: Electrical Installation Guidelines...................................................................................43

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About the version number: this manual is valid for all instruments that display version
number 3.x, where 3.x can be 3.0, 3.1, etc. (see Function Menu, SYS STATUS).Changes in the
last digit of the version number reflect minor changes in the internal software of the
instrument that do not affect the manner in which the instrument should be operated.
Note: functions such as instrument configuration with a PC as well as the calibration of
HygroClip probes with a PC require the optional HW3 software. Instructions for using the
HW3 software are not included in this manual. These instructions are shipped separately on
the same CD ROM as the HW3 software.
Overview
The HygroFlex is a series of 3-wire humidity temperature transmitters that is available with a wide
variety of probes for use in many different industrial and scientific applications. The HygroFlex
series uses a micro-processor based design to achieve unparalleled accuracy, reliability and
versatility.
The HygroFlex is available in 3 different models:
HygroFlex 1: basic industrial transmitter with analogue outputs
relative humidity and temperature
-compatible with any ROTRONIC HygroClip digital probe 1)
-relative humidity and temperature analogue outputs
-test connector for communication with the HygroPalm indicator 2)
-software-based calibration (HygroClip probes only)
-internal service connector (RS232) for configuration with PC (units, ranges)
-two linearized analogue outputs, signal type (mA, V) configurable by means of jumpers 3)
-optional LC display and keypad 4)
1) ROTRONIC analogue probes are also accepted with some restrictions
2) allows the HygroPalm to read the transmitter or to calibrate a digital probe
3) 0..1V, 0..5V, 0..10V, 0..20 mA, 4..20 mA
4) allows direct calibration of digital probes by the transmitter and direct access to other functions
HygroFlex 2: fully digital, networkable industrial transmitter
relative humidity, dew point (or other) and temperature
-compatible with any ROTRONIC HygroClip digital probe 1)
-optional analogue input for second probe 2)
-relative humidity, temperature, dew point, wet bulb, mixing ratio, enthalpy, etc 3)
-test connector for communication with the HygroPalm indicator 4)
-software-based calibration (HygroClip probes only)
-RS232 and RS485 digital ports 5)
-optional LC display and keypad 6)
1) ROTRONIC analogue probes are also accepted with some restrictions
2) pressure probe or ROTRONIC HygroClip digital probe – some restrictions apply
3) uses either a fixed barometric pressure value or the measurements from an analogue pressure probe
for those parameters that require pressure as a computational input. The fixed pressure value can be
changed with the optional HW3 software.
4) allows the HygroPalm to read the transmitter or to calibrate a digital probe
5) The computed parameter (dew point or other) is not sent to these ports. Use of the HW3 software on
a PC allows real time computation of the dew point (or other) and facilitates both networking and
instrument configuration
6) allows direct calibration of digital probes by the transmitter and direct access to other functions

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HygroFlex 3: analogue / digital, networkable industrial transmitter
relative humidity, dew point (or other) and temperature
-compatible with any ROTRONIC HygroClip digital probe 1)
-optional input for second probe 2)
-relative humidity, temperature, dew point, wet bulb, mixing ratio, enthalpy, etc 3)
-test connector for communication with the HygroPalm indicator 4)
-software-based calibration (HygroClip probes only)
-RS232 and RS485 digital ports 5)
-three linearized analogue outputs, signal type (mA, V) configurable by means of jumpers 6)
-optional LC display and keypad 7)
1) ROTRONIC analogue probes are also accepted with some restrictions
2) pressure probe or ROTRONIC HygroClip digital probe – some restrictions apply
3) Uses either a fixed barometric pressure value or the measurements from an analogue pressure probe
for those parameters that require pressure as a computational input. The fixed pressure value can be
changed with the optional HW3 software.
4) allows the HygroPalm to read the transmitter or to calibrate a digital probe
5) The computed parameter (dew point or other) is not sent to these ports. Use of the HW3 software on
a PC allows real time computation of the dew point (or other) and facilitates both networking and
instrument configuration
6) 0..1V, 0..5V, 0..10V, 0..20 mA, 4..20 mA - corresponding to relative humidity, temperature and
computed parameter (or relative humidity of second probe)
7) allows direct calibration of digital probes by the transmitter and direct access to other functions
General Description
Power Requirements
The HygroFlex is available with a choice of two basic internal power modules:
-standard power module for operation with 12 to 35 VDC (maximum 300 mA) or with 12 to 24 VAC.
-optional power module for operation with voltages within the range of 90 to 264 VAC (50/60 Hz).
HygroFlex 1 HygroFlex 2 HygroFlex 3

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Probes and Probe Inputs
Model HygroFlex 1 HygroFlex 2 HygroFlex 3
number of probe inputs 1 1 (standard) or 2 (optional)
probe types (see below) ROTRONIC Digital
ROTRONIC
Analogue
ROTRONIC Digital
ROTRONIC Analogue
Third-Party Analogue
number of digital input channels 1 1 (input 1) + 1 (input 2 - optional)
number of analogue input channels 2 2 (input 1) + 1 (input 2 - optional)
analogue input A/D resolution 10-bit 10-bit
Unless otherwise specified when ordering, all probe inputs are factory programmed to accept a HygroClip
digital probe. Prior to using any analogue probe, the corresponding input should be re-programmed. This can
be done with the HW3 software after connecting the RS232 port to a PC (see separate HW3 manual). A
matching adapter cable is required to connect analogue probes.
HygroClip Digital Probes
The HygroFlex is primarily designed for use with the ROTRONIC HygroClip digital humidity
temperature probes. These probes permit to take full advantage of all the features and functions of
the HygroFlex such as the software based calibration.
The ROTRONIC HygroClip digital probes are highly accurate and are calibrated entirely by means
of software (no adjustment potentiometers). Because calibration and other data are stored in the
probe non-volatile memory, the probes are fully interchangeable. When a probe requires calibration
or has to be repaired, it can be replaced with another probe in a few seconds. The ROTRONIC
HygroClip digital probes are available in different configurations so as to meet the requirements of
each application:
HygroClip IW
for surface mount (area monitoring)
max. 85°C (185°F) – wire mesh filter
observe temperature limits of transmitter
electronics
HygroClip IC-1 (100mm) / IC-3 (250mm)
for through-wall installation
max. 200°C (392°F) - wire mesh filter
HygroClip IM-1 (120mm) / IM-3 (270mm)
for through-wall installation in high humidity
applications
max. 200°C (392°F) - wire mesh filter
HygroClip IE-1 (G ½”) / IE-2 (NPT ½”)
for compressed air (max. 50 bar / 725 PSI)
max. 85°C (185°F) – sintered steel filter
to avoid errors, temperature should be the
same on both sides of the mounting wall
HygroClip IC-05
for measurement in tight spaces
max. 100°C (212°F)

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Analogue Probes
Depending on the model and options, the HygroFlex transmitters can be used with one or two
analogue probes. Both the scale and unit of the analogue input signals can be defined with the HW3
software. For example, an analogue pressure probe may used to provide the local value of
barometric pressure for the computation of parameters such as the wet bulb temperature, mixing
ratio or enthalpy.
Use of analogue probes is subject to the following restrictions and limitations:
a) ROTRONIC analogue humidity-temperature probes with the standard temperature output signal
of – 0.5…2.0 V = -50…200°C: because the HygroFlex cannot read a negative voltage signal,
temperature measurement is generally limited to values above freezing.
b) Third-party analogue probes: single channel probes (one signal), output signal within the range
of 0 to 2.5 VDC, supply voltage: 15 VDC or less, maximum current consumption: 10 mA.
c) Resolution is limited by the 10-bit A/D converter used for the analogue inputs. This converter
provides a theoretical maximum of 1024 counts for an input voltage span of 2.5 VDC. In theory,
this gives a resolution of 2.5 / 1024 = 0.00244 V. In practice, it is not possible to get 100% of the
counts from an A/D converter and the actual resolution should be about 0.0027 V (typical). For
Probe Extension Cable AC1616/xxx
with built-in signal booster
xxx = 002 to 200
from 2 to 200 m (about 6.5ft to 656ft)
max. temperature 85°C (185°F)
HygroClip ID-EX-xxx (intrinsically safe)
for through-wall installation
xxx = 002 to 100
from 2 to 100 m cable length (about 6.5ft to 328ft)
max. temperature at sensors: 200°C (392°F)
probe length 250 mm - sintered steel filter
HygroClip IW-EX-xxx (intrinsically safe)
for surface mount (area monitoring)
xxx = 002 to 100
from 2 to 100 m cable length (about 6.5ft to 328ft)
max. temperature 40°C (104°F)
probe length 150mm
sintered steel filter
ZB1 Zenner Barrier for ID-EX and IW-EX
AC1617xxx Connecting Cable for ZB1
with built-in signal booster
xxx = 002 to 100
2 to 100m
(
about 6.5ft to 328ft
)

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example, if a probe with a temperature signal of 0..1 V = 0…100°C is being used, the signal
resolution will be about 100 x 1 x 0.0027 = 0.27°C
Analogue Outputs (HygroFlex 1 and HygroFlex 3)
Model HygroFlex 1 HygroFlex 2 HygroFlex 3
analogue outputs - relative humidity
- temperature
N/A
(digital output only)
Any three of:
- relative humidity
- temperature
- computed parameter
- user defined calculation
see note1) below
output signals 2)
configurable with
jumpers
0…1 V
0…5 V
0…10 V
0…20 mA
4…20 mA
N/A
0…1 V
0…5 V
0…10 V
0…20 mA
4…20 mA
D/A output
resolution
humidity: 12-bit
temperature: 16-bit N/A
Out 1: 12-bit
Out 2: 16-bit
Out 3: 12-bit
options
floating analogue
current outputs
(galvanic separation)
N/A
floating analogue current
outputs
16-bit D/A resolution for
Out1 allows 0.1
resolution with a span of
more than 200 units.
1) Any of the 3 analogue outputs of the HygroFlex 3 can be set to correspond to humidity
[probe 1 or 2] or temperature [probe 1 or 2] or calculated parameter [probe 1 or 2] or user
defined calculation or optional analogue probe signal (such as pressure). The HygroFlex is
set at the factory as specified when ordering. These settings can be changed at any time
with the optional HW3 software.
2) The output signals are set at the factory according to the type and range specified when ordering. A
label located on the transmitter housing shows the type of output signal for each unit.
The analogue output signals are linear and are consistent with the requirements of most data/signal
processing instrumentation (panel meter, controller, computer card, etc.).

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Connection to a PC - RS232 Digital Port
The HygroFlex 1 has an internal RS232 service connector. Both the HygroFlex 2 and 3 have an
external RS232 connector (located on the connector plate). In principle, any communication
software can be used to interrogate and read the HygroFlex with the commands described in
appendix 7 (RS232 communication protocol). Use of the optional HW3 software simplifies this task.
It is important to note the following:
HygroFlex 1: use of the RS232 port (internal service connector) is limited to configuring the
instrument (units, range, etc.). Measurement data and calibration functions are not available on this
port.
HygroFlex 2 and 3: use the RS232 port to configure the transmitter, calibrate the probe and connect
the transmitter to a network. The computed parameter (dew point or other) is not part of the digital
communication (limited to %RH and temperature – in the unit selected for the transmitter).
HW3 Software
The HW3 software (optional) allows real time computation of the dew point (or other) by the PC
while providing additional functionality such as:
-RS485 networking (up to 32 units)
-full access to instrument configuration (unit system, etc.)
-calibration of the ROTRONIC HygroClip digital probes with or without HygroFlex
-data logging to a PC disk file
-graphic functions (both on and off-line)
HW3 runs on any PC with Windows 98 or NT. For more details see separate instruction manual
provided with the HW3 software.
RS485 Networking (HygroFlex 2 and HygroFlex 3)
With the optional HW3 software up to 32 HygroFlex 2 or 3 transmitters can be connected together
on a network. Any transmitter can be used either as a slave or a master, without special
configuration. Each unit must be given a unique network address with the HW3 software (0 to 31).
The master is automatically the unit that is connected to the COM port of the PC by means of the
RS232 port. See Electrical Installation for details.
Unit System
The unit system of the HygroFlex (Metric or English) is factory programmed as specified when the
instrument was ordered. The unit system can be easily be changed by the user with the optional
HW3 software.
RS232: 3 wires (including ground wire)
RS485: 2 wires
PC
(
HW3
)
CO
M P
o
r
t
Unit 0 Unit 1 Unit 31
RS232
RS485
RS485
RS485
RS232 RS232
RS232 up to 150m (490 ft) RS485 up to 1000m (3300 ft)

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Optional Display and Keypad
The LC display shows which probe input is being displayed (small indicator on top of the display)
and up to 2 parameters measured by the probe, with the associated engineering unit. When
relevant, the message line provides additional information.
SS

Keypad
Humidity and Temperature
Calculated Value and Temperature
Calculated Value and Humidity
MENU :Press this key to activate the function menu. The different
menu items appear on the LCD message line. Press this key again
to exit the menu
UP / DOWN: Press one of these keys to select the probe input
for the display and functions. When the function menu is active,
use these keys to navigate the menu, make a selection or to
change a number on the display.
ENTER: When the menu is active, press
this key to confirm a selection.
Probe Input Indicator
(1-2) from left to right
Engineering
Units
Message Line
Parameter or
Trend Indicators
8.8:8.8
8.8:8.8
To prevent unauthorized or accidental changes, access from
the keypad to the calibration functions can be blocked out
when configuring the HygroFlex with HW3. This also
prevents access to the calibration functions with the
HygroPalm calibrator.

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Installation
Each HygroFlex transmitter is shipped in an individual box, separately from the probe. The shipping
box has a label with the following information: instrument type, main specifications and serial
number. An identical label is located inside of the transmitter enclosure.
Installation of the Transmitter Enclosure
Note: see appendix 8 for the optional metal enclosure
The HygroFlex is comprised of 5 parts: mounting bracket (1), electronics housing (2), main circuit
board (3), connector plate (4) and front cover with or without optional display and keypad (5).
To attach the transmitter to a mounting surface:
1) Attach the wall plate in the position shown above to an appropriate surface using 4 screws.
2) Slide the electronics housing down on the wall plate to the mechanical stop
Front cover removal
1
2
3
4 5
V-shaped
slot
After unpacking the
HygroFlex, separate the
mounting bracket from the
back of the housing.