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Hydronix Hydro-Control VI, Installation Manual

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Chapter 3 

Electrical Installation 

 

Hydro-Control VI Installation Guide HD0455 Rev 1.9.0 

25 

4.2 

Voltage Options 

4.2.1 

Digital Input Module Types  

Hydronix 

Part No. 

OPTO-22 

Part No. 

Description 

0401 

G4IDC5 

10 - 32 VDC 
Standard DC input module 

0402 

G4IAC5 

90 – 140VAC 

0403 

G4IAC5A 

180 – 280VAC 

4.2.2 

Digital Output Module Types 

Hydronix 

Part No. 

OPTO-22 

Part No. 

Description 

0404 

G40DC5 

5 - 60VDC @ 3A (45ºC), 2A (70ºC). 

0405 

G40AC5 

12 – 140VAC @ 3A (45ºC), 2A (70ºC). 

0406 

G40AC5A  24 – 280VAC @ 3A (45ºC), 2A (70ºC). 

5  Expansion Board (Hydronix Part Number 0180) 

The Expansion Board is an optional add-on that can be used to provide additional functionality.  

The board may be added to the system at any time and enables use of the weighed water system 

and the remote recipe selection inputs. 

5.1 

Analogue Inputs 

The board has two analogue inputs that can run at 4-20mA or 0-20mA (this can use 0-10v with 

a conversion resistor as described below).  Currently only one input is used for the weigh scale 

input.  The other is reserved for future use. 

5.2 

Analogue Outputs 

The board has two analogue outputs.  These are reserved for future use. 

5.3 

Recipe selection inputs 

The board has 8 recipe selection inputs to provide recipe control using discrete, binary or BCD 

inputs.  These are configurable in the I/O Setup And Status pages and can be used to change 

the current recipe being used by the unit from an external control system or other recipe 

selection device.  These replace the Hydro-Control V remote recipe module. 

 

Summary of Contents for Hydro-Control VI

Page 1: ...Hydro Control VI Installation Guide To re order quote part number Revision Revision date HD0455 1 9 0 March 2020 ...

Page 2: ...RORS 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 ...

Page 3: ... support hydronix com sales hydronix com 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 1 888 887 4884 Toll Free 1 231 439 5000 Fax 1 888 887 4822 Toll Free 1 231 439 5001 European Office Covers Central Europe Russia and South Africa Tel 49 2563 4858 Fax 49 2563 50...

Page 4: ...4 Hydro Control VI Installation Guide HD0455 Rev 1 9 0 ...

Page 5: ...013 Figure 38 added Typical water valve set up Pipe Diameter table added Figure 42 updated 1 5 1 V2 0 0 June 2013 USB Panel Mount socket added to Box Contents List 1 6 0 V2 3 0 0 Sept 2013 Added 9 and 10 RS232 Commands 1 7 0 V2 5 0 0 April 2014 Added Control Cabinet Information RS232 Command description of serial message 14 updated 1 8 0 V2 8 0 0 October 2015 Added max mix log configuration additi...

Page 6: ...6 Hydro Control VI Installation Guide HD0455 Rev 1 9 0 ...

Page 7: ... Menu Tree 31 3 Basic Tests 32 4 Touch screen recalibration 35 5 System Parameters 36 6 Sensor Configuration 42 7 Recipe Parameters 46 Chapter 5 System Design 55 1 Water Valves 55 2 Flow Measurement 57 3 Retrofitting Systems 58 4 Mix Cycle Design 62 Chapter 6 RS232 Interface 69 1 Port Settings 69 2 RS232 Protocol Configuration 69 3 RS232 Commands HC05 HC06 Formats 70 Chapter 7 Remote Support 85 1 ...

Page 8: ...8 Hydro Control VI Installation Guide HD0455 Rev 1 9 0 ...

Page 9: ...g a voltage signal to the Analogue Input 27 Figure 16 Analogue Output Wiring Diagram 27 Figure 17 The recipe selection input wiring 28 Figure 18 The Menu Structure Of The Hydro Control VI 31 Figure 19 I O Setup And Status Page 1 33 Figure 20 I O Setup and Status Page 2 33 Figure 21 The top of the Hydro Control showing the recalibration button 35 Figure 22 An example of a calibration screen showing...

Page 10: ... 64 Figure 45 The Admix output signal during a 2 step mix cycle 65 Figure 46 The mix trace showing Auto Track settings 66 Figure 47 Auto Track parameter example for the Dry Mix phase 66 Figure 48 RS232 Remote Comms screen 69 Figure 49 Ethernet Coms Page 85 Figure 50 UltraVNC View software 86 Figure 51 Repeater Settings 87 Figure 52 The Hydro Control VI side view showing the USB ports 89 Figure 53 ...

Page 11: ... x 10 Way Connector for Power Sensor Communications 1 x 11 Way Connector for Digital Inputs 1 x 14 Way Connector for Digital Outputs 1 x Panel Mount USB Socket Kit 1 x Hydronix USB Memory Stick with Documentation Additional Contents If Expansion Board has been factory fitted 1 x 8 Way Connector for Analogue Inputs Outputs 1 x 9 Way Connector for Recipe Selection Inputs ...

Page 12: ...ly 30 Watt 0175 Panel Mount USB Socket 0176 Replacement System Card Not applicable to HC06 v2 0177 Replacement Data Card Not applicable to HC06 v2 0179 Replacement Touch Screen Protective Layer 0180 Hydro Control VI Expansion Board 0170 Hydro Control VI Wall Mount Enclosure 0190 Hydro Control VI Control Cabinet ...

Page 13: ...level of moisture in a process usually in a mixer and send signals to adjust the flow of water into the process using water valves The moisture level during the process cycle is displayed on the main screen and there are intuitive and easy to use graphical tools for setting up the recipes in the system Communication with external systems can be implemented using either the built in RS232 serial po...

Page 14: ... Edition This equipment is designed to be safe under the following conditions 3 1 Precautions This unit is suitable for indoor use only If the equipment is used in a manner not specified by the manufacturer the protection provided by the equipment may be impaired The final installation should have a means to disconnect the electrical supply to the unit It should be marked as the disconnecting devi...

Page 15: ...de and top vents should not be restricted and the top access plate for the CompactFlash cards should be easily accessible The minimum clearance for the top and sides of the enclosure is 100mm It may be necessary to allow more space at the top to allow access to the top access plate with a screwdriver 3 4 IP Rating When correctly integrated into a suitable enclosure the front panel and touch screen...

Page 16: ...y prone to damage by lightning for example Tropical Regions Long cable runs between the sensor and the control panel Tall electrically conductive constructions e g aggregate bins Although the Hydro Control is fitted with Optical Isolation on the sensor input this will not prevent damage in all cases Precautions should still be taken to avoid damage by lightning in areas where there is a known risk...

Page 17: ...tions are made to the base so access needs to be allowed for the cables and connectors Space should be allowed for memory cards Not applicable to HC06 v2 to be installed through the access plate on the top of the unit USB connections are made on the right hand side of the unit viewed from the rear Sufficient space should be left to allow insertion and removal of a USB memory stick if required A mi...

Page 18: ...til the top and bottom of the bracket are level with the case To fit the top and bottom brackets insert the bracket into the slot and tighten the bolt To install the Hydro Control Cut out an aperture in the panel of the correct size See Figure 6 for a template Remove the mounting brackets from the body of the unit by releasing the screws and then unhooking the brackets Insert the Hydro Control thr...

Page 19: ... in the event of a failure There are two memory card slots and these are accessed by removing the mounting bracket on the top left corner of the Hydro Control as viewed from the rear Removing the two small screws opens the access plate over the card sockets shown in Figure 7 Figure 7 The memory card access port showing the labels of the cards As shown in Figure 7 the memory cards are mounted so th...

Page 20: ...er can be removed by carefully applying pressure to the front of the Hydro Control and sliding the sheet down slightly This will expose the corners of the sheet which can then be lifted away from the touch screen A blunt plastic tool can also be used to help lift the sheet if needed To fit a new sheet remove the sheet from the packaging taking care to keep the sheet clean and dust free Remove the ...

Page 21: ...ign OPTO Module Cover Plate Connection Label Figure 8 The rear of the Hydro Control showing two of the connectors at the bottom The diagram of the Hydro Control shown in Figure 8 shows the rear of the unit showing the labels detailing the connectors and the OPTO Modules Analogue Inputs Outputs Power supply Sensor connection Serial connection Digital Inputs Digital Outputs Remote Recipe Selection I...

Page 22: ...t indicates the Hydro Control is in an alarm state 11 12 Admix Controls the start of the admixture addition 13 14 Water Tank Fill Controls filling the water tank on a weighed water system 1 2 Input Connector Pins Name Description 15 16 Cement In Minimum 200ms pulse indicates the cement has been added 17 18 Start Resume Minimum 200ms pulse starts or resumes the Hydro Control water control cycle 19 ...

Page 23: ...ection for powering the sensor 32 24v DC 24v DC system power supply input 33 Sensor 0v 0v DC connection for powering the sensor 34 0v DC 0v DC system power supply input 35 N C 1 4 Remote Recipe Connector on optional Expansion Board Pins Name Description 36 Remote Recipe 1 Remote recipe selection inputs These are used to change the recipe in the Hydro Control via a BCD binary or digital signal 37 R...

Page 24: ... interference between the two systems 3 Communications 3 1 RS485 The RS485 connection is used for communicating with a Hydronix moisture sensor It is possible to change operating parameters and sensor diagnostics from the Hydro Control 3 2 RS232 The RS232 connection is used for connection to a batch computer or remote operator terminal to permit the remote selection of recipes 3 3 Ethernet Telnet ...

Page 25: ...e added to the system at any time and enables use of the weighed water system and the remote recipe selection inputs 5 1 Analogue Inputs The board has two analogue inputs that can run at 4 20mA or 0 20mA this can use 0 10v with a conversion resistor as described below Currently only one input is used for the weigh scale input The other is reserved for future use 5 2 Analogue Outputs The board has ...

Page 26: ...ide of a normally open relay The Hydro Control switches on the relay therefore closing the contacts for the output side Note that the AC outputs have a minimum current of 20mA Figure 11 Digital Output Wiring Diagram 6 3 Wiring analogue inputs The analogue inputs are current loop inputs taking a signal of either 0 20mA or 4 20mA This is configurable on page 2 of the I O Setup and Status pages The c...

Page 27: ...5 Connecting a voltage signal to the Analogue Input Figure 15 shows a method for connecting a 0 10v signal into the Hydro Control A series resistance of 375Ω resistance is required This can be obtained by placing two 750Ω resistors in parallel It is recommended to use resistors with a tolerance of 0 1 6 4 Wiring analogue outputs The analogue outputs from the Hydro Control are designed as a constan...

Page 28: ...wisted 4 cores total screened shielded cable with 22 AWG 0 35mm2 conductors It is recommended that a high quality cable with good braid screen and also a foil screen is used in order to minimise the possibility of interference Recommended cable types are Belden 8302 or Alpha 6373 For optimum performance and to comply with relevant safety regulations all cables including power and communications ca...

Page 29: ...t with an extension cable is available from Hydronix Part Number 0175 This has a 1 5m cable and the panel mounted socket needs a 28mm diameter hole with a 3mm key cut out The maximum panel thickness is 5 2mm and a clearance of 22mm is needed behind the panel Detailed mounting instructions are available from Hydronix ...

Page 30: ...Electrical Installation Chapter 3 30 Hydro Control VI Installation Guide HD0455 Rev 1 9 0 ...

Page 31: ...ions Select Recipe Select Control Method Enter Main Water Quantity Enter Dry Weight Enter Moisture Target Enter Main Water Trim Create Recipe Delete Recipe Edit Reipe View Mix Trace Calibrate Display Unscaled Water and System Parameters Time and Date and Alarm Settings Update Target Auto Loop Tune I O Status and Testing Analogue Setup Sensor Configuration Filter Configuration Factory Configuration...

Page 32: ...the sensor and display the reading from it in the trend display Run through the following procedure to test that the sensor is functioning properly 1 Press the Display Unscaled button This displays the incoming sensor value in terms of the unscaled units 0 in air 100 in water This is not a moisture reading and allows the basic sensor value to be seen 2 Whilst the mixer is empty with the sensor in ...

Page 33: ...u buttons will also re enable the inputs Individual outputs can be activated and deactivated by pressing on the grey circle next to the text which allows the link to the external control system input to be checked Activated outputs display with a red circle as seen from the Alarm output which is activated The Admix Signal is used to control at which point during the mix cycle the Admix output is s...

Page 34: ...page as in the previous section When the page is opened the water meter value is reset to zero 2 Weigh a container and place it underneath the water inlet to collect the water that is dosed during the testing 3 Open the Coarse Valve by pressing the icon on the display 4 Check the valve opens water flows and the water meter counts up 5 Close the Coarse Valve by pressing the icon again 6 Open the Fi...

Page 35: ...re 22 An example of a calibration screen showing the target After pressing this button the screen will change to a blank display with a small target on it similar to the one shown in Figure 22 Using a small blunt pointed object touch the screen at the area indicated until prompted to release This will be repeated a number of times after which the system will display a prompt for the calibration to...

Page 36: ...s described in the following pages Greyed out items are not required for the currently selected water mode Water Setup Parameter Units Default Range Water Mode None Metered Metered Timed Weighed Pulses Per Litre Pulses Per Litre Gallon 1 0 1 10 000 Pulses per Litre 0 2641 7 Pulses per Gallon Water Meter Timeout Seconds 5 0 100 s Fine Delivery Litres Gallons 20 0 100 L 0 26 4 Gallons Fine Valve Inf...

Page 37: ...y of water that continues to flow after the fine valve has been closed Coarse Valve Inflight is the quantity of water that continues to flow after the coarse valve has been closed This valve is used when the Pre wet phase is run in preset mode Fine Valve On Time is the amount of time it takes to turn on the fine valve This should be referenced from the valve manufacturer s data sheet Fine Valve Of...

Page 38: ...ol These system parameters can be over ridden from within each recipe System Auto Track Parameter Units Default Range Initial Mix Deviation 0 1 0 100 Initial Mix Time Seconds 10 0 100 Pre wet Mix Deviation 0 1 0 100 Pre wet Mix Time Seconds 10 0 100 Dry Mix Deviation 0 1 0 100 Dry Mix Time Seconds 10 0 100 Wet Mix Deviation 0 1 0 100 Wet Mix Time Seconds 10 0 100 The Initial Mix Deviation Initial ...

Page 39: ...System Parameters screen The System Time and Date settings are used to set the clock in the Hydro Control This is used to log times against the mix logs Pressing the Edit Time and Date button displays the following screen allowing the time and date to be set Figure 25 Changing the date and time The time can be entered by selecting the hours 0 24 and minutes 0 59 boxes The time zone can be set usin...

Page 40: ... into the HC06 and a Backup is requested the archive files will be copied to the USB stick This will enable the user to keep a record of older mix logs Alarms Setup The Alarms Setup section on the System Parameters page allows each of the alarms in the system to be disabled The alarms are described in the Operators Guide in the chapter Alarm Configuration At the end of a batch if the sensor value ...

Page 41: ... Scale Input shown on the status page in Figure 27 into the field Analogue Value When Empty Now set the Hydro Control to use weighed water To do this go to the first System Parameters page shown in section 5 and set the system water mode to Weighed Once you have done this the Hydro Control will activate the Water Tank Fill output to open the valve to fill the water tank to the high level When the ...

Page 42: ...alibration This section shows the current material calibration that has been downloaded to the sensor This is updated when the recipe in the Hydro Control VI is changed The current measurement mode selected for the recipe is also displayed only with compatible sensors Analogue Outputs This section allows the setup of the Analogue Outputs on the sensor to be adjusted As the Hydro Control VI communi...

Page 43: ...en Page 2 Signal Processing This section allows the signal processing options in the sensor to be adjusted It may be necessary to adjust these depending on the mixer being used to improve the stability and response of the sensor reading Digital Inputs Outputs This section allows the digital input output options to be set If any settings are changed then they should be downloaded to the sensor usin...

Page 44: ... Automatic Calibration function This can be used to simplify the factory calibration process After the Automatic Calibration is performed it may be necessary to recalibrate the recipes To use the Automatic Calibration function make sure that the sensor faceplate is in air and press the AutoCal button After a short delay the Hydro Control will display an indication as to whether the AutoCal was suc...

Page 45: ... the current firmware version number and checksum for diagnostics purposes IO Status This section displays the current state of the digital inputs and outputs and other internal signals Comms This section displays the total communication messages between the Hydro Control and the sensor along with the error count The error count can be used to identify communication issues Analogue Output Test If ...

Page 46: ...own in Figure 33 Figure 33 The sensor configuration screen Page 5 This screen shows information about the sensor reading which can be used for diagnostic purposes 7 Recipe Parameters From the main screen pressing the menu button and then the recipe overview button will display the Recipe Overview screen 7 1 The Recipe Overview Screen Figure 34 The recipe overview screen ...

Page 47: ... 25 characters length The Recipe Number parameter is the number of the recipe in the system Recipes can be selected by number from an external batch control system by using the 8 digital recipe inputs available on the optional Hydro Control VI Expansion Board or by using the serial communications protocol They are also listed in numerical order on the recipe selector available from the start page ...

Page 48: ...sets the quantity of water that should be dosed into the mixer during the pre wet phase of the mix cycle The Pre wet Water Limit parameter sets the maximum amount of water that will be added when the system is running with the pre wet water in AUTO Mode before the system will alarm The Main Water parameter sets the quantity of water that is added to the mix during the main water addition phase of ...

Page 49: ... water before activating the Pre wet Done output and moving to the next phase The Cement Timeout parameter defines how long the Hydro Control will wait after sending the Pre wet Done signal for the batch control system to add the cement If the Cement In signal has not been received by the end of this time then it will trigger the Cement Timeout Alarm The Initial Mix Time is the time period that th...

Page 50: ...hod None Preset Preset Auto Calculation Pre wet Moisture Target 8 0 99 9 Control Method None Preset Preset Auto Calculation Moisture Target 10 0 99 9 Plus Tolerance 2 75 0 99 9 Minus Tolerance 2 75 0 99 9 The Pre wet Control Method changes the method that is used to control the pre wet water addition If the method is set to Preset then a fixed quantity of water is added defined by the parameter Pr...

Page 51: ... stability or homogeneity of the mix If the sensor value is within a certain deviation for a set time this function allows the mix time to finish earlier Parameter Units Default Range Initial Mix Enable None No Yes No Pre wet Mix Enable None No Yes No Dry Mix Enable None No Yes No Wet Mix Enable None No Yes No Local Auto Track Control None No Yes No Dry Mix Deviation 0 1 0 100 Dry Mix Time Seconds...

Page 52: ... changed After the recipe has been calibrated if the moisture is displayed incorrectly then the calibration parameters can be reset to their default values by pressing the Reset Calibration button After resetting the calibration the recipe will need to be calibrated again The calibration process is described in further detail in the Operators Guide Admix Settings Parameter Units Default Range Admi...

Page 53: ...of the current temperature from the Temperature Set Point The equation is int arg arg perature CurrentTem eSetPo Temperatur nt eCoefficie Temperatur et OldT et NewT AUTO Mode Settings Parameter Units Default Range Local Auto Control None No Yes No Proportional Gain None 5 100 100 Integral Gain None 0 100 100 Derivative Gain None 0 100 100 The Local Auto Control parameter sets the recipe to use the...

Page 54: ...Commissioning Chapter 4 54 Hydro Control VI Installation Guide HD0455 Rev 1 9 0 ...

Page 55: ...et up please refer to the manufactures guidelines for specific details 20 DN 5 DN Typical required clearance Refer to manufacturer for details Figure 38 Typical water valve set up 1 2 Guidelines for sizing valves and flow rates Valves should be able to turn on and off rapidly the combined on off cycle time for a 50 mm 2 valve should be no more than 2 seconds and 19 mm 3 4 valves should have combin...

Page 56: ...07 0 5 1100 4 1 0 36 0 75 1 0 07 1 0 2200 8 1 0 36 1 5 1 0 07 1 5 3300 12 1 0 36 2 25 1 0 07 2 0 4400 15 1 0 34 3 1 0 07 Mixer Capacity ft Load lbs Coarse valve Fine valve Flow rate Gal sec On Off Time sec Moist Increase Flow rate Gal sec On Off Time sec Moist Increase 10 1400 0 6 1 0 36 0 1 1 0 06 20 2800 1 2 1 0 36 0 25 1 0 07 40 5500 2 4 1 0 36 0 5 1 0 07 60 8300 3 6 1 0 36 0 75 1 0 07 80 11000...

Page 57: ... provide the same dosing accuracy but will take longer to complete a mix It is also possible to add water too fast to a mixer which creates a large ball of water which moves around the mixer with the raw material rather than being mixed in To compensate for this it is recommended to add water using a spray bar arrangement instead of from a single outlet 1 4 Leaking Water Valve Alarm If the water f...

Page 58: ...e Optional Fine Valve 21 22 Water Meter Optional 29 30 51 52 Weigh Scale Optional 49 50 Analogue I O reserved for future use 51 52 49 50 24v DC RS485 Hydro Mix or Hydro Probe Orbiter Recipe Selection Signals Binary BCD Discrete Batch Control System RS232 OR USB Ports Ethernet Port USB Key Disk for backup restore upgrade Batch control Data Telnet port23 Remote support Note if only one valve is used...

Page 59: ... Probe Orbiter Note if only one valve is used connect it to the fine valve output Field Power Supply O P I P Relay or volt free output water meter 24v 0v B A G F RS485 A RS485 B 24v 0v MIL Spec Connector Pins Figure 40 Example Wiring Schematic For Manual Plant Operation 3 2 Remote Recipe Selection If the recipe design in the mixer changes for example if a different mix of aggregates is used a diff...

Page 60: ... will accept the same connectors that the Hydro Control V uses with the same pin out Care should be taken to insert the connectors correctly so that the cut outs for the connector keys match the connectors themselves The Hydro Control VI Utility is an additional software tool that runs on a PC that can be used to convert a backup from a Hydro Control V system allowing the recipes and system parame...

Page 61: ...e AUTO Mode control loop has been simplified making it much easier to tune correctly to achieve more efficient performance For a starting point when upgrading a system divide the Proportional Gain parameter used in the Hydro Control V by 10 and set the Integral and Derivative Gain parameters to zero 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 No Connection Power Supply 0v Sensor Po...

Page 62: ...ng used It is considered best practice to increase the moisture of raw materials above their Saturated Surface Dry SSD condition wherever possible before the materials enter the mixer Using pre wet water can also reduce the amount of dust generated by the process and reduces wear on the mixer motor and gearbox The Hydro Control signals to the batching control system that the pre wet has been compl...

Page 63: ...ix Time Inputs Start Water Meter Optional Cement In Reset Outputs Coarse Valve Fine Valve Mix Complete Discharge Figure 43 The Mix cycle showing the I O status The Cement In signal is optional and may be used to control the timing of the cement addition The signal requirement can be configured in the recipe database by setting the parameter Cement Timeout to a non zero value The system will then w...

Page 64: ... the Main Water addition when the percentage of the main water dosed reaches the recipe parameter Admix Enable The total water used to calculate the percentage is the calculated amount in CALC Mode or the amount dosed in the previous batch in AUTO Mode This is used to delay the admixture addition until a set amount of water has been dosed This can be a requirement given by the manufacturer of the ...

Page 65: ... After Main Water Addition 1 the Dry Mix phase will be run a second time At the end of each of the Dry Mix phases the system will obtain an average reading of the sensor value as defined by the Averaging Time parameter in the System Parameters If this 2 step batch is used to calibrate a recipe then a second gain and offset value will be calculated for the recipe and this will be used to calculate ...

Page 66: ...not Moisture Time Dry Mix Time Dry Mix Deviation Wet Mix Time Wet Mix Deviation Dry Mix Complete Mix Complete Figure 46 The mix trace showing Auto Track settings Figure 46 shows a typical mix trace showing the Auto Track timing The Auto Track monitors the moisture and identifies the stable point for the Dry Mix and the Wet Mix times It requires the variation in the sensor value to be less than the...

Page 67: ...ed with Preset mode to ensure that the sensor reading is stable at the end of the dry and wet mixes When the system is running with Auto Track the average taken at the end of each of the mixing phases is the average value during the Auto Track time and not that defined by the Averaging Time value in the System Parameters This will ensure that any values used for calibration are representative of t...

Page 68: ...System Design Chapter 5 68 Hydro Control VI Installation Guide HD0455 Rev 1 9 0 ...

Page 69: ...tion The RS232 Protocol parameter sets whether the serial communications protocol used on the Hydro Control is set to the Hydro Control VI mode or the older Hydro Control V or Hydro Control IV modes If the Hydro Control VI is replacing a Hydro Control V or Hydro Control IV and the remote communications are in use then this should be set to HC05 or HC04 respectively HC06 v1 can be selected for syst...

Page 70: ...ng the mix some commands are not valid at certain phases of the mix These will be noted where appropriate The following subsections describe the different types of commands that can be used 3 1 Non Parameter Status Commands These are commands that do not correspond to the current state of the Hydro Control or any system or recipe parameters These commands are listed below Format Description Parame...

Page 71: ...b separated values 9 Download last batch from mixlog HC06 v2 format N A Any Last mix log tab separated values 10 Current Total water N A Any xx y 3 2 Mix Log Formats The Mix Log format will depend on which mode the RS232 Protocol is set to This parameter is on page 2 of the System Parameters screen and details of this can be found in Chapter 4 The data is sent as a list of values separated by the ...

Page 72: ...ure 3 Calculated Target Moisture 4 Wet Moisture 5 Water Cement ratio 6 Pre wet Water 7 Calculated Water 8 Actual Water 9 Trim Water 10 Mix Time 11 Dry Weight 12 Moisture Gain 13 Moisture Offset 14 Dry Reading Unscaled 15 Calculated Target Unscaled 16 Final Target Unscaled 17 Dry Deviation Unscaled 18 Wet Deviation Unscaled 19 Dry Deviation Moisture 20 Wet Deviation Moisture ...

Page 73: ...eviation Moisture 5 Dry Deviation Unscaled 6 Calculated Target Moisture 7 Calculated Target Unscaled 8 Wet Moisture 9 Wet Reading Unscaled 10 Wet Deviation Moisture 11 Wet Deviation Unscaled 12 Pre wet Water 13 Calculated Water 14 Automatic Trim 15 Manual Trim 16 Addition Error 17 Total Water 18 Water Cement Ratio 19 Dry Mix Time 20 Water Addition Time 21 Wet Mix Time 22 Total Time 23 Dry Weight 2...

Page 74: ...rtional Gain 32 Derivative Gain 33 Cement In Error 34 Water Meter Fault 35 Leaking Water Valve 36 No Water Required Error 37 Too Much Water Calculated Error 38 Pre wet Target Not Reached 37 Mix Too Wet Rejected 40 Mix Too Dry Rejected 41 Mix Too Wet Accepted 42 Mix Too Dry Accepted 43 Water Limit Exceeded 44 Max Dry Mix Time Reached 45 Max Wet Mix Time Reached 46 Mix Aborted 47 Sensor Fault 48 Mix...

Page 75: ...itial Mix Value Unscaled 8 Initial Mix Deviation Moisture 9 Initial Mix Deviation Unscaled 10 Pre wet Target Value Moisture 11 Pre wet Target Value Unscaled 12 Pre wet Mix Value Moisture 13 Pre wet Mix Value Unscaled 14 Pre wet Mix Deviation Moisture 15 Pre wet Mix Deviation Unscaled 16 Dry Mix Value Moisture 17 Dry Mix Value Unscaled 18 Dry Mix Deviation Moisture 19 Dry Mix Deviation Unscaled 20 ...

Page 76: ...tion Error 31 Total Water 32 Water Cement Ratio 33 Dry Mix Time 34 Water Addition Time 35 Wet Mix Time 36 Total Time 37 Dry Weight 38 Cement Weight 39 Mix Temperature 40 Pre wet Moisture Gain 41 Pre wet Moisture Offset 42 Moisture Gain 1 43 Moisture Offset 1 44 Moisture Gain 2 45 Moisture Offset 2 46 Calculation Gain 47 Calculation Offset 48 Proportional Gain 49 Integral Gain 50 Derivative Gain ...

Page 77: ...g recipe parameters The recipe values of each recipe can be set at any time except if the recipe is currently in use If the recipe is currently in use then commands to change parameters will be applied to the next mix started To read parameters the following format should be used _R_nn_pp _ denotes a space do not use the underscore character in the RS232 string nn denotes the recipe number and pp ...

Page 78: ...allons Weight 250 25 0 7 Moisture Target 65 6 5 8 Pre set Water Total Previously Pre set Final Seconds Litres US Gallons Weight 300 30 0 9 Pre wet water limit Seconds Litres US Gallons Weight 1200 120 0 13 Final Mix Time Seconds 15 15 14 Plus Tolerance 10 1 0 15 Minus Tolerance 3 0 30 17 NO LONGER USED was recipe gain N A N A N A 19 Moisture Offset None 36364 3 6364 20 Moisture Gain None 1817 0 18...

Page 79: ... 250 25 0 35 Temp Coeff temp 200 0 2 36 Calibration Type 1 1 point 2 2 point None N A N A 41 Admix Enable after water 10 1 0 42 Admix amount US Gallons Litres 10 10 43 Mix extension enabled 1 true 0 false N A N A N A 44 Mix extension time Seconds 10 10 45 Local Auto Track Enabled 1 true 0 false N A N A N A 46 Local Auto Track time dry mix Seconds 10 10 47 Local Auto Track dry mix deviation 1 0 1 4...

Page 80: ...ocal Recipe Derivative Gain None 100 1 0 53 Auto Track Enabled 1 true 0 false N A N A N A 54 Averaging Time Seconds 10 10 55 Moisture Offset 1 None 36364 3 6364 56 Moisture Gain 1 None 1817 0 1817 57 Moisture Offset 2 None 36364 3 6364 58 Moisture Gain 2 None 1817 0 1817 59 Recipe Name None ABC ABC 60 Recipe Description None ABC ABC ...

Page 81: ...w is a list of parameters and their respective units Certain commands have been changed or are no longer used These are shown for backwards compatibility Parameter Description Units RS232 Value Actual Value 101 Water mode 0 metered 2 timed 3 weighed N A N A N A 102 Meter Flow opposite to HC05 Pulses per litre 200 0 2 103 Meter Timeout Seconds 10 10 105 Language 0 English others to be defined N A N...

Page 82: ...r in the RS232 string nn is always 0 and pp is a parameter as listed below Parameter Description Units RS232 value Actual value 6 Current active recipe None 1 1 12 Total water added last Seconds weight Litres or US Gallons 82 50 82 50 24 Time taken to reach mix complete Seconds 140 140 25 Status Byte see below N A N A 26 Moisture Reading At mix complete 7 40 7 40 27 Calculated water will be 0 unle...

Page 83: ... in 3 7 IO Status It is also possible to retrieve the current status of the Onboard IO The following command can be used to do this S1 n n can b e 0 1 or 2 If n 0 then a status word will be sent where 1 Cement In 2 Start Resume 4 Pause Reset 8 Water Meter 16 Water Tank full 32 Coarse Valve 64 Fine Valve 128 Pre wet done signal 256 Mix complete signal 512 Alarm signal 1024 Request Admix 2048 Unassi...

Page 84: ...ult 2 Water meter fault 3 Leaking water valve 4 No water required 5 Too much water calculated 6 Pre wet target no reached auto mode 7 Mix too wet 8 Mix too dry 9 Water limit exceeded 10 Maximum dry mix time reached 11 Maximum wet mix time reached 12 Sensor fault 13 Mixer blades worn 14 Waiting for water tank to fill 15 Over temp 16 Fan stopped It is also possible to accept all alarms This can be d...

Page 85: ...control the HC06 also connects to the same server using a simple client software package Control of the HC06 is then established Remote support can be configured to use either the Hydro Control VI support server provided by Hydronix or another server which an installer or local distributor may choose to set up for themselves To access the remote support configuration press followed by The communic...

Page 86: ... This can be seen on the Hydro Control VI Ethernet Comms screen shown in Figure 49 Ethernet Coms Page Instruct the user to connect the Hydro Control VI to remote support see HD0456 Operators guide for more detailed instructions Once the user is connected press connect to view the Hydro Control VI 2 Remote support using a custom server To use a custom server it is first necessary to set up a server...

Page 87: ...ould install UltraVNC viewer and set the proxy repeater address to the IP address and port number or the domain name of the custom server that the repeater is installed on 3 Configure the Hydro Control to use a static IP address The Hydro Control can be configured to use either a Static or Automatic IP address Figure 49 To configure a static IP address select Use the following IP address and enter...

Page 88: ...Remote Support Chapter 7 88 Hydro Control VI Installation Guide HD0455 Rev 1 9 0 ...

Page 89: ...Card Hydronix Replacement Part Number 0177 The Data Card holds the mix log database and system settings With the power supply off this can be removed and replaced if necessary Not applicable to HC06 v2 1 3 USB Memory Stick Figure 52 The Hydro Control VI side view showing the USB ports There are three USB ports sited on the left hand side when looking at the front of the unit A Memory Stick may be ...

Page 90: ...a memory stick into one of the USB ports 2 Press the Menu button 3 Press the System Parameters button 4 Press the Backup Restore button 5 Press the Backup button 6 When successful press OK to return to the parameters screen 2 2 Restore To restore the Hydro Control database 1 Insert a Memory Stick containing a backup of the Hydro Control into one of the USB ports The file HC06Database sdf should be...

Page 91: ...t the folder containing the software update files from the ZIP file onto a USB Memory Stick This should create a folder in the root folder of the Memory Stick called DUA which contains a number of update files as well as a device update file called hc06upgrademe dup This is shown in Figure 53 Figure 53 Some of the files on the USB keydisk after extraction Insert the USB Memory Stick into one of th...

Page 92: ...s page 2 screen Press the Upgrade button and the system will prompt to reboot After rebooting the Hydro Control will automatically update and then reboot and restart itself The Memory Stick must not be removed until the upgrade has been completed and the main screen is shown DO NOT REMOVE POWER DURING THE UPGRADE PROCEDURE ...

Page 93: ...1 Water Meter Timeout Seconds 5 Fine Delivery Litres Gallons 20 Fine Valve Inflight Litres Gallons 0 Coarse Valve Inflight Litres Gallons 0 Fine Valve On Time Seconds 0 5 Fine Valve Off Time Seconds 0 5 Use Fine Valve Only None No Averaging Time Seconds 10 Cycle Loops None 1 System Auto Control Setup Parameter Units Default Commissioned Value Proportional Gain None 5 Integral Gain None 0 Derivativ...

Page 94: ...1 Initial Mix Time Seconds 10 Pre wet Mix Deviation 0 1 Pre wet Mix Time Seconds 10 Dry Mix Deviation 0 1 Dry Mix Time Seconds 10 Wet Mix Deviation 0 1 Wet Mix Time Seconds 10 General Settings Parameter Units Default Commissioned Value Language None English Remote Communications Parameter Units Default Commissioned Value RS232 Protocol None HC06 Admix Signal None Admix Enable ...

Page 95: ...ged Pins are bent and can be bent to normal to make electrical contact Check sensor configuration by connecting to a PC Internal failure or incorrect configuration Connect the sensor to a PC using the Hydro Com software and a suitable RS485 converter Digital RS485 connection is working Digital RS485 connection is not working Sensor should be returned to Hydronix for repair Symptom Incorrect sensor...

Page 96: ...oller OPTO module colour Red DC module typically up to 60v DC Black AC module typically up to 110v AC Contact Hydronix for correct OPTO module rating Wiring fault When the OPTO switches on the OPTO LED should light up Check wiring whilst the OPTO is on See User Guide for more details Force relay to switch on and check wiring Go to Menu I O Setup and Status Select output and switch on Blown fuse Re...

Page 97: ...oltage across the input terminals of the OPTO i e for DC input module 0v connected to terminal and 24v connected to terminal When voltage is applied LED turns on Hydro Control must be powered for this Swap module with the same input range module if one is available and re apply power across the terminals Symptom Faulty display contrast Possible explanation Check Required result Action required on ...

Page 98: ...powers off and then press it again to restart Correct startup If Blue Screen persists then the System Card will need replacing Contact Hydronix for further information Symptom Orange dialog Write Filter Error Possible explanation Check Required result Action required on failure Caused by the write filter being in the wrong state Restart the unit and see if the box reappears Correct startup Replace...

Page 99: ... Dry Mix Time This is the time taken for the Dry Mix the first mix that occurs after the pre wet water has been added The Dry Mix Time can be short for AUTO Mode but should be longer if using CALC Mode If a two step addition is selected then the dry mix time is done twice once after any pre wet water is added and the second after the first main water addition this is stopped when the water additio...

Page 100: ...ue of the sensor which changes linearly with the amount of moisture in the material being measured The unscaled value is pre set to read 0 in air and 100 in water USB The Universal Serial Bus is an interface that can be used to attach external devices such as memory sticks to the Hydro Control Wet Mix Time This is the time taken for the wet mix phase This is the mixing phase that occurs at the end...

Page 101: ...u may find it beneficial to have a copy available when reading to this guide Document Number Title HD0456 Hydro Control VI Operators Guide HD0679 Hydronix Moisture Sensor Configuration and Calibration Guide HD0678 Hydronix Moisture Sensor Electrical Installation Guide HD0676 Hydro Mix Installation Guide HD0677 Hydro Probe Orbiter Installation Guide HD0044 Hydro Control IV Installation and Referenc...

Page 102: ...Document Cross Reference Appendix D 102 Hydro Control VI Installation Guide HD0455 Rev 1 9 0 ...

Page 103: ...ltage Options 25 I O Wiring Diagrams 26 Internal Temperature and Voltages 40 Introduction 13 Mechanical Installation Mounting 18 Mechanical Installation Dimensions 17 Memory Cards Data Card 19 89 System Card 19 89 Memory Stick 89 Menu Tree 31 Mix Cycle Complete Cycle 62 Design 62 Simple Mix 63 Mix Diagrams Dry mix cycle 63 Mix cycle with admix 64 Pre wet mix cycle 62 New Installation Testing 32 Op...

Page 104: ...tup 40 AUTO Control Settings 38 Auto Track Settings 38 General Settings 40 Language 40 Unit Information 40 Water Settings 36 System Parameters Record 93 Temperature Compensation 53 Tests 32 I O 32 Sensor 32 Valves 34 Water Meter 34 Weighed Water 41 Touch Screen Protective Layer 20 Recalibration 35 Upgrade Firmware 91 Hydro Control V 60 USB 89 USB Ports 28 Valves See Water Valves Water Addition Mod...

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