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Hydronix Hydro-Control VI, Operator'S Manual

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Hydronix Hydro-Control VI Operator'S Manual Download Page 26

Water Addition Modes 

Chapter 5 

26     Hydro-Control VI Operators Guide HD0456 Rev 1.7.1 

3  AUTO Mode 

The AUTO Mode progressively adds water to the mixer to achieve a defined moisture target.  The 

Hydro-Control controls the speed at which the water is added and slows the addition as the current 

moisture nears the target moisture in order to accurately reach the target without overshooting it. 

Moisture

Time

Mixer

Loading

Dry Mix

Time

Main Water Addition

Wet Mix Time

Discharge

Target

Current moisture

monitored and water

added to reach the target

moisture

 

Figure 10: The moisture during AUTO Mode 

Figure 10 shows a typical moisture trace during a batch run in AUTO Mode. 

As there is no requirement for complete homogeneity during the Dry Mix Phase, the Dry Mix Time 

can be made shorter than in CALC Mode so the water can start to be added earlier in the batch. 

The system is shipped with default parameters for controlling the water addition.  To optimise the 

system these settings may require adjustment. 

To ensure that the moisture is correct and that the mix is homogeneous, it is important to allow a 

sufficient Wet Mix Time before discharging the mixer. 

4  Selecting the Best Mode – AUTO or CALC?  

The most appropriate mode for moisture control varies depending on the application.  It is important 

to understand the differences between AUTO Mode and CALC Mode in order to select the mode 

that is the most appropriate. 

•

 

Do the batch sizes vary from one batch to another?

 

If yes then AUTO Mode will work without needing to have an exact dry weight parameter 

in the recipe before a batch is made.  To use CALC Mode the dry weight recipe parameter 

would have to be updated on a batch by batch basis, either by sending it using the RS232 

port on the Hydro-Control VI, or by manually editing the recipe. 

•

  Is the water supply pressure constant? 

The AUTO Mode control method requires water to be added consistently.  If there are 

changes in flow rates due to pressure fluctuation, then the AUTO Mode will not be able to 

perform optimally. 

•

  Are mixing times critical? 

If yes then it is likely that CALC Mode may be quicker to use than AUTO Mode. 

•

  Is it possible to achieve a stable reading in the dry mix time? 

A prerequisite of CALC Mode is that the water calculation is based on a correct and stable 

dry mix reading for addition in a single dose.  If the dry mix reading is not stable enough 

then it is unlikely that CALC Mode will give the desired accuracy.  AUTO Mode does not 

need a stable signal due to water being added continuously to reach the target. 

Summary of Contents for Hydro-Control VI

Page 1: ...Hydro Control VI Operators Guide To re order quote part number Revision Revision date HD0456 1 7 1 August 2020 ...

Page 2: ...RS 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 AC...

Page 3: ...dronix 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 5016 French O...

Page 4: ...4 Hydro Control VI Operators Guide HD0456 Rev 1 7 1 ...

Page 5: ...rt Chapter added V1 3 0 V2 0 0 0 December 2011 HS0085 v2 0 0 0 extra functionality added V1 4 0 V2 5 0 0 March 2014 HS0085 v2 5 0 0 extra functionality added Reference to the Hydro Control VI Database Editor added V1 5 0 V2 8 0 0 October 2015 HS0102 sensor firmware features added V1 6 0 V2 9 0 0 August 2016 Recipe Editor Calibration Mix viewer added Mix Log details updated V1 7 0 V2 15 0 0 March 2...

Page 6: ...6 Hydro Control VI Operators Guide HD0456 Rev 1 7 1 ...

Page 7: ...7 1 The Recipe Editor 27 Chapter 7 Running the First Mix 35 1 The Recipe Wizard 35 2 Setting the Recipe for the First Mix 36 Chapter 8 Using Moisture Control 41 1 Moisture Control and Homogeneity 41 2 CALC Mode 42 3 AUTO Mode 49 4 Using Admixtures 52 5 Auto Track 54 6 Temperature Compensation 55 Chapter 9 Alarm Configuration 57 Chapter 10 Using the Mix Log 61 1 Introduction 61 2 Accessing the Mix ...

Page 8: ...8 Hydro Control VI Operators Guide HD0456 Rev 1 7 1 ...

Page 9: ...igure 17 How the deviation is calculated 41 Figure 18 The moisture during CALC Mode 42 Figure 19 The CALC Mode Calculation 46 Figure 20 The calibration failed error message 47 Figure 21 Comparison of averaging times 47 Figure 23 The moisture during AUTO Mode 49 Figure 24 The effect of changing the Proportional Gain 50 Figure 25 The effect of changing the Integral Gain 51 Figure 26 The effect of ch...

Page 10: ...10 Hydro Control VI Operators Guide HD0456 Rev 1 7 1 ...

Page 11: ... monitors the 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 Overview 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 ...

Page 12: ...ecipes in and using the Hydro Control VI to make concrete Hydro Control VI navigation Designing the mix cycle Setting up a recipe Running the first mix Using moisture control to automatically add water Chapter 2 describes how to navigate around the Hydro Control VI and introduces the system Chapter 4 introduces the mix cycle and Chapter 5 explains the difference between the water addition modes Ch...

Page 13: ...ter valves are energised 2 Displays Water Added during the current phase and Total Water added to the batch 3 Displays the Flow Rate and current Temperature of the process 4 Displays the current Recipe number in use The Batch number increments with each batch made for each Recipe Mode indicates the control mode in operation for the given Recipe Preset AUTO or CALC 5 Dialog box allowing quick acces...

Page 14: ...ut There are three levels of access in the Hydro Control VI Plant Operator Access to the Overview Screen only Chapter 3 describes Plant Operator controls Supervisor Access barred to setting up user accounts sensor configuration and system parameters Administrator Full access rights To Login from the Overview screen 1 Press the Log In Button 2 Enter the user name and password by pressing each textb...

Page 15: ...e mix cycle and view details about the batch and recipe currently in use Recipe Overview Displays the user defined recipes stored in the system and allows the user to create edit and delete recipes Mix Log Displays a list of previously run batches and allows the user to view information about the previous batches and also to calibrate the system from a batch IO Setup Allows configuration and test ...

Page 16: ...u button and then pressing the Recipe Overview button A list of available recipes is then displayed and can be selected by pressing on them To scroll around the list you can use the up and down arrows 1 on the right hand side of the screen You can also use the Find Recipe button 2 to go directly to a known recipe number Figure 4 The Recipe Overview Screen To create a recipe press the Create Recipe...

Page 17: ...n also be filtered using the Display Group option to reduce the number of columns that are displayed 1 View Mix Trace displays more detailed information about the batch selected as well as a graph showing the sensor reading during the batch There is also an option to calibrate the recipe using the batch as a template More information on the calibration process is given in Chapter 10 2 Display Unsc...

Page 18: ...Navigation Chapter 2 18 Hydro Control VI Operators Guide HD0456 Rev 1 7 1 ...

Page 19: ...e system will find the desired recipe In Preset mode it is not possible to adjust moisture targets as the system will add only fixed amounts of water In AUTO or CALC mode it is not possible to adjust the water values as the water addition is controlled to the water target See Chapter 5 for an explanation of the different water addition modes If it becomes necessary to adjust the water addition sli...

Page 20: ...Plant Operator Controls Chapter 3 20 Hydro Control VI Operators Guide HD0456 Rev 1 7 1 ...

Page 21: ... water is added after which the Wet Mix Time commences At the end of the Wet Mix Time the cycle is finished and the Mix Complete signal is activated This signals to the batch control PLC to discharge the mixer Load mixer Dry Mix Time Main Water Addition Wet Mix Time Discharge Mixer Mix Phase From PLC To PLC START MIX COMPLETE Signal increases from mixer empty reading As materials start to mix the ...

Page 22: ...en the material and reduce the mixing power useful in mixers that are not capable of mixing all dry materials together 4 To wet the aggregates to bring them above their Water Absorption Value WAV also known as the SSD Saturated Surface Dry point typical for lightweight or synthetic aggregates Example case If the water needed to produce a repeatable concrete mix varies between 55 and 68 litres depe...

Page 23: ...l Signals Optional Cement Dosing Pre wet Mix Time As the materials mix with the water the signal starts to stabilise Figure 8 The mix cycle with pre wet The Hydro Control VI starts its cycle when the Start signal is received The first phase is the addition of the Pre wet Water followed by the mix time defined in the parameter Pre wet Mix Time The Pre Wet Done output then goes high and if enabled t...

Page 24: ...ntrol VI can be configured to calculate an amount of water to add based on a reading with either just aggregates or aggregates and water added Once water has been added to a fixed moisture content it is then optional whether an additional calculation is made to add the main water or whether a pre set amount of water scaled for changes in the dry weight is added Calibrating recipes is covered in mo...

Page 25: ... exact quantity of water required to reach the moisture target in the recipe using calibration data and the dry weight of the materials in the mixer Moisture Time Mixer Loading Dry Mix Time Main Water Addition Wet Mix Time Discharge Calculated water added in one dose Average moisture reading is taken at the end of the Dry Mix and the quantity of water needed is calculated Figure 9 The moisture dur...

Page 26: ... the Best Mode AUTO or CALC The most appropriate mode for moisture control varies depending on the application It is important to understand the differences between AUTO Mode and CALC Mode in order to select the mode that is the most appropriate Do the batch sizes vary from one batch to another If yes then AUTO Mode will work without needing to have an exact dry weight parameter in the recipe befo...

Page 27: ...number of the recipe in the Hydro Control VI Batch Number This is the number of the last batch made Recipe Name This is the name of the recipe which is displayed on the Overview Screen 1 2 Water Addition Recipe parameter Description 2 Step Addition This enables the two step addition mode which splits the main water addition into two stages During the second stage the Admixture signal is activated ...

Page 28: ...isture correction this value should be sent from the batch control system to allow the calculation to be done to the best accuracy Cement Weight This is the weight of the cement added and if entered the Hydro Control log will contain the water cement ratio for a particular batch Cement Timeout This is the amount of time that the system will wait after issuing a pre wet done signal before alarming ...

Page 29: ...ee settings Preset Auto and Calc These methods are discussed in Chapter 5 Control Method This parameter defines the way in which the main water addition is controlled It has three settings Preset Auto and Calc These methods are discussed in Chapter 5 Moisture Target If the main Control Method is set to Auto or Calc then this setting defines the moisture target as a moisture percentage that the aut...

Page 30: ...o continue If the sensor signal has not stabilised within this window by the end of the Initial Mix Time the system will prompt the operator to continue regardless of whether it has stabilised or not Initial Mix Deviation This is the maximum deviation that the sensor signal must be within in order for the system to continue Pre wet Mix Time When using Auto track control this is the amount of time ...

Page 31: ...set 1 Pre wet Moisture Gain 1 These are the calibration coefficients for the pre wet phase of the recipe These define the relationship between the amount of moisture in the batch and the unscaled sensor value These are automatically calculated when you calibrate a recipe Moisture Offset 1 Moisture Gain 1 These are the calibration coefficients for the recipe These define the relationship between th...

Page 32: ...ode to adjust the rate that the water is added to the mixer This defines the initial speed of the water into the mixer Integral Gain This parameter is used by the control mode to adjust the rate that the water is added to the mixer This adjusts the rate of the water addition based on the amount of time the addition has taken This can be used to correct an offset at the end of the water addition wi...

Page 33: ...ture for the temperature coefficient to work from Temperature Coefficient This is the change in moisture per degree Celsius that the current temperature is different from the Temperature Set Point that is added to or subtracted from the target unscaled This is used to allow the concrete to vary depending on the temperature to allow for the increased rate of hydration in hotter atmospheres ...

Page 34: ...Editing Recipes Chapter 6 34 Hydro Control VI Operators Guide HD0456 Rev 1 7 1 ...

Page 35: ...e as a template This is a quick way of copying parameters from one recipe to another Auto Recipe Number Select to automatically assign the next available recipe number Recipe Number Use this to enter a user defined recipe number if the above parameter is not ticked Cement Timeout This is the amount of time after the Pre wet Done signal has been given before the Hydro Control triggers an alarm that...

Page 36: ...en the reading stabilises this indicates a homogenous mix When using CALC Mode it is important to obtain stable dry and wet mix readings to use for calibrating the water calculation After calibration is complete the wet mix time can be reduced depending on the required quality and homogeneity of the mix The mixing times can only be determined empirically as there are many factors that affect how l...

Page 37: ...ry and then the Trim function is used to open the valves to add more water until a point where the mix consistency is correct The recipe is then updated automatically with the trim water that was added and can be run again This process is detailed below After the correct water quantity has been determined the recipe can be calibrated using the mix log as detailed in Chapter 8 2 2 Setting the recip...

Page 38: ...he batch control system Wait for the cycle to finish Press 2 4 Trim the water manually to reach the desired consistency Task Action Check the consistency of the mix If possible observe the mix in the mixer through the inspection hatch to see if more water is needed On the Overview Screen press the Trim button to select the trim function options Press Either To add a set quantity of water enter the...

Page 39: ...in the last mix is highlighted by default You can use the Filtered By option at the top to change the filtering options for the list To change the mix log display between moisture and unscaled press the Display Unscaled button Displaying the Deviation values in unscaled Dry DeviationUS and Wet DeviationUS shows the stability of the signal during the Averaging Time at the end of the mixing phases F...

Page 40: ...Running the First Mix Chapter 7 40 Hydro Control VI Operators Guide HD0456 Rev 1 7 1 ...

Page 41: ...geneity required can be defined by the user and this will affect the mix time Moisture Time Recipe Averaging Time Deviation Figure 17 How the deviation is calculated The Mix Log shows the homogeneity of the mix by displaying a deviation which is calculated as the difference between the maximum and minimum values seen during the averaging time as shown in Figure 17 This calculation is performed at ...

Page 42: ...r calculation is performed at the end of the Dry Mix and the Main Water Addition is performed in one shot the degree of homogeneity at the end of the Wet Mix can be varied by adjusting the Wet Mix Time It is important to note that if the Wet Mix Time is shortened then the alarm tolerances may need to be increased to stop the controller from alarming at the end of the mix due to the mix not being c...

Page 43: ... as in most circumstances only the moisture of the finished mix is of concern 2 4 CALC Mode Pre wet Water In some cases it is possible that after addition of certain admixtures usually SCC admixtures that the wet mix reading is out of the measurement range of the sensor In situations where materials such as metal fibres are added during the dry mix the sensor may no longer be able to give reliable...

Page 44: ...s Press the Menu button Press Press the Mix Log button Press Select the mix in the Mix Log that corresponds to the selected good batch Check the stability of the mix by setting the mix log to Display Unscaled and looking at the Dry and Wet Mix Deviation These should be less than 3 and preferably less than 0 5 For sensors with multiple measurement modes check the deviation for each available mode S...

Page 45: ...by the hydration process The concrete should be spread thinly before performing the bake out Enter the Moisture Target value Press OK If the mix consistency would have been improved by adding or subtracting a certain quantity of water then this value can be added at this point and the OK button pressed Enter the Water Trim value Press OK If no dry weight has been entered into the recipe then the c...

Page 46: ...A B C xx litres x litres y unscaled units Figure 19 The CALC Mode Calculation As the diagrams in Figure 19 show if it takes x litres to get from moisture point A to moisture point B then as the sensor unscaled value is linear with moisture a calibration line can be obtained that can then be used to calculate the amount of water needed to get from any new moisture point to the target value B In the...

Page 47: ...to make sure that the averaging time is set correctly A longer averaging time will give a better average reading but will also extend the mix time In normal circumstances a typical averaging time would not be greater than 10 seconds After a calibration has been set the system should be monitored for at least two more mixes to check that the system is correctly compensating for changes in the dry m...

Page 48: ...l result in the calculation incorrectly determining the moisture change for the calibration Even when using a mixer moisture control system it is important to correct for the weight of the moisture in the raw material being used to ensure that the mix design is consistent Any moisture in the raw materials will affect the weight of raw material dosed and will affect the aggregate cement ratio It is...

Page 49: ...or example half batches Disadvantages The AUTO Mode is more dependent on mixer efficiency than the CALC Mode as the sensor must be able to monitor the water that has been dosed This is not always the case in some mixers and therefore it can take a long time for total water addition as water must be added more slowly to allow the sensor to detect the added water and for the Hydro Control VI to reac...

Page 50: ... of batches whilst increasing the Proportional Gain value to a point where it just overshoots the target value then reduce the gain value so that it stops overshooting the target and this gives the optimal value for the Proportional Gain parameter If during the water addition phase the moisture value approaches the target but is not able to reach it then this may be due to insufficient water being...

Page 51: ...Gain Integral Gain will act to increase the water flow depending on the length of time that has passed This can be used to correct the addition when the moisture tails off after the initial water addition Moisture Time Target Too Low Too High Correct Figure 26 The effect of changing the Derivative Gain The Derivative Gain only needs to be changed if there is overshoot on the target that settles as...

Page 52: ...e The Admix Enable parameter in the Recipe is used to control the point at which the admixture is dosed during the main water addition phase In CALC Mode this is a percentage of total calculated water and in AUTO Mode it is a percentage of the final moisture target In cases where an admixture is being used and where an actual moisture for both the Dry Mix and the Wet Mix is required for quality re...

Page 53: ...mode cycle 4 2 Setting up the 2 Step Water Addition This procedure requires that you have already set up the basic recipe as per Chapter 7 Task Action Press the Menu button Press Press the Recipe Overview button Press Select the recipe to set up and then press the Edit Recipe button Press On Page 1 in the Water Addition section select the box 2 Step Addition On Page 2 go to the Admix Settings and ...

Page 54: ...rack feature The Auto track feature is enabled at the point Dry Mix Time Auto track Time It will then continue to mix until the Auto track parameters are met or to the end of Dry Mix Time The Auto track monitors the sensor values If the value falls outside of the Auto track Mix Deviation parameter the Auto track timer is reset as shown in the inset diagram in Figure 29 If during the mixing phase t...

Page 55: ... on water demand increase per C Temperature Correction Settings in the recipe can be used to do this The Hydro Control will adjust the moisture target to compensate It should be noted that this method will increase variance in the water cement ratio and thus widen strength variation tests The temperature compensation works simply by taking the difference between the current temperature and the Tem...

Page 56: ...Using Moisture Control Chapter 8 56 Hydro Control VI Operators Guide HD0456 Rev 1 7 1 ...

Page 57: ...al that a problem exists to the batch control system This output could also be used to trigger an audible or visual warning The alarm is also recorded in the Mix Log Figure 30 Page 2 of the System Parameters screen Alarms can be enabled disabled and configured from page 2 of the System Parameters as shown in Figure 30 When troubleshooting alarms the wiring connections and any related OPTO Input an...

Page 58: ...ter increments when the water valves are opened Leaking Water Valve Alarm This alarm is triggered if the water meter pulses when both of the water valves have been closed for more than 5 seconds during the dry and wet mix phases Check The valves to see if they are leaking The water meter is working correctly Waiting For Tank Fill Alarm Only available if Expansion Board is fitted This alarm is trig...

Page 59: ... These alarms are triggered at the end of the Wet Mix Phase if the average moisture recorded during the Recipe Averaging Time is below or above the target by more than the Minus Tolerance or Plus Tolerance parameters specified in the recipe The mix can then be rejected or accepted by the operator and this is recorded in the mix log If the mix is rejected then the operator also has an option to act...

Page 60: ...ered can be reduced by decreasing the Auto track Mix Time or increasing the allowed Mix Deviation either in the recipe or the system parameters The recipe mix time parameters are set to be long enough for the mix to stabilise Sensor Fault Alarm This alarm is triggered when the Hydro Control detects a problem with the RS485 communications with the sensor Check Ensure that communications cables are ...

Page 61: ...es 2 Accessing the Mix Log The mix log is accessed on the Hydro Control itself from the Overview Screen by pressing the Menu button and then the Mix Log button Figure 32 The Mix Log The Mix Log screen contains the batch details of all the mixes that have been run Additional data can be accessed by scrolling the screen using the left and right arrow keys Filter options may also be used to filter th...

Page 62: ... phase Auto track Wet Mix Indicates if the auto track function was used during the wet mix phase Initial Mix Value US This is the moisture value taken during the Averaging Time or Auto track time at the end of the initial Mix Initial Mix Deviation US This is the deviation in the signal taken during the Averaging Time or Auto track time at the end of the initial Mix Pre wet Mix Value US This is the...

Page 63: ...on Error l gal sec lbs kg This is the difference between the actual quantity calculated for the batch and the amount actually added as recorded by the flow meter Total Water l gal sec lbs kg This is the total amount of water added to the mixer by the Hydro Control during the batch Water Cement Ratio This is the ratio of the water in the batch calculated from the average moisture value during the w...

Page 64: ...the second Moisture Offset value used to calculate the moisture for display This is used to rescale the graph after admixtures have been added to the mixer Calc Gain This is the Gain value used to calculate the quantity of water to add to the mixer when running calculation mode Calc Offset This is the Offset value used to calculate the quantity of water to add to the mixer when running calculation...

Page 65: ... accepted by the operator Mix Too Dry Accepted A Mix Too Dry alarm was triggered during the batch and the mix was accepted by the operator Water Limit Exceeded A Water Limit Exceeded alarm was triggered during the batch Max Dry Mix Time Exceeded A Max Dry Mix Time Reached alarm was triggered during the batch Max Wet Mix Time Exceeded A Max Wet Mix Time Reached alarm was triggered during the batch ...

Page 66: ... areas of homogeneity for example at the end of the dry and wet mixes where the mix times can be reduced without compromising the final mix Figure 33 The Mix Trace Screen Moisture The mix details at the bottom of the screen contain a list of points recorded during the batch and the amount of water added by the controller at that point in the batch It is possible to view any significant actions in ...

Page 67: ...ited and restored using the HC06 Database Editor software HS0100 The database editor is available free of charge from the Hydronix web site www Hydronix com For more details about the database editor see the HC06 Database Editor User Guide HD0583 4 1 Backup To backup the Hydro Control database System and Recipe Parameters and Mix Log 1 Insert a memory stick into one of the USB ports 2 Press the Me...

Page 68: ...be in the root directory of the Memory Stick 2 Press the Menu button 3 Press the System Parameters button 4 Press the Backup Restore button 5 Press the Restore button 6 Press the Yes button to over write the current database The Hydro Control will then restore the recipes settings and log file from the memory stick file and then reboot The Memory Stick can be removed at any point after the system ...

Page 69: ...ccess user accounts press the menu button followed by the user accounts button The user accounts screen is then displayed Figure 35 User accounts screen The up down arrows can be used to move up and down the user list Alternately a user can be selected simply by pressing the desired user on the list Pressing the modify or delete buttons will affect the highlighted user To create a user press the c...

Page 70: ...Setting Up User Accounts Chapter 11 70 Hydro Control VI Operators Guide HD0456 Rev 1 7 1 ...

Page 71: ...rator will see what changes are being made and what screens are accessed To connect to remote support press the menu button followed by The communications page will be displayed Press the Ethernet Comms page is now displayed Figure 37 Ethernet Comms Page Telephone the remote support telephone number displayed on the page When ready the support engineer will instruct the operator to press the conne...

Page 72: ...Remote Support Chapter 12 72 Hydro Control VI Operators Guide HD0456 Rev 1 7 1 ...

Page 73: ...s All the residual mix is discharged when emptying the mixer The mixing action close to the floor of the mixer is improved thereby improving the reading of the sensor Wear on the mixer floor plates will be reduced Reduced cycle times will result in savings in power consumption and reduce mixer wear 2 Ingredients If the aggregate masses are not corrected for high moisture contents then the aggregat...

Page 74: ...neous A different calibration may be required for large variations in batch volume e g half batches Calibrate when conditions and ingredients are typical e g not first thing in the morning when the aggregates are very wet or when the cement is hot When using a calibration based water addition method it is essential to obtain a correct dry reading Dry mix time must be long enough to obtain stabilit...

Page 75: ... that the OPTO will switch is 20mA Try adding a resistor in parallel with the coil to provide some extra switching current _ _ _ Q I think one of the I O modules is faulty how do I replace them A If you suspect a faulty OPTO module swap over an identical OPTO from a working input or output which you know works This will tell you if the original OPTO was faulty If you need a replacement then either...

Page 76: ..._ Q I have a recipe running that has been calibrated What happens if I change the gain and offset in the recipe manually A The moisture displayed is a number that is calculated from the sensors unscaled readings the recipe gain and recipe offset If the gain and offset are changed then this will affect the displayed moisture _ _ _ Q Can I still run in calculation mode without recalibrating if I cha...

Page 77: ...s for the unit to work with my batch controller A For the Hydro Control to work automatically with the batch control system the required input output signals are water meter input start input reset input fine valve output and mix complete output All other inputs outputs are optional _ _ _ Q The deviations for the dry and wet mix are stored in the mix log Are these deviations of unscaled values or ...

Page 78: ...sferred _ _ _ Q How do I calibrate my controller to display real moisture A To display real moisture when calibrating a recipe enter the true moisture for the final target The true moisture can either be determined from a sample of the concrete at the end of the mix or by calculating the amount of water in the mixer using the mix design parameters It is important to ensure that the correct dry wei...

Page 79: ...maged 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 sens...

Page 80: ...roller 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 the OPTO LED should light up Check wiring when 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 Remove...

Page 81: ...TO LED should light up Apply correct voltage 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 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 f...

Page 82: ... explanation Check Required result Action required on failure Caused by removing power to the Hydro Control before shutting down the system Press and hold the power button until the unit powers off and then press it again to restart Correct startup System Card will need replacing Contact Hydronix for further information ...

Page 83: ...is calibrated by running mixes in pre set mode and adding fixed quantities of water and changing this quantity depending on the resulting material When a good mix has been obtained the recipe can then be calibrated from the mix log Dry Mix Time The time taken for the Dry Mix which is the first mix that occurs after the pre wet water has been added If a two step addition is selected then the dry mi...

Page 84: ...ator which sits behind a ceramic faceplate Trim Water This is an amount of water that is added to the mixer after the calculated amount has been added This can be added manually by the operator or automatically from the recipe Unscaled This is the raw value of the sensor and is a value that changes linearly with the amount of moisture in the material being measure It is pre set in the factory for ...

Page 85: ...e You may find it beneficial to have a copy available when reading to this guide Document Number Title HD0455 Hydro Control VI Users 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 HD0583 Hydro Control VI Database Editor User Guid...

Page 86: ...Document Cross Reference Appendix C 86 Hydro Control VI Operators Guide HD0456 Rev 1 7 1 ...

Page 87: ...tion 46 Calibration 44 Calibration Failed 47 Configuration 42 Disadvantages 42 Dry Weight 48 Gain 31 Offset 31 Optimising 46 Calibration AUTO Mode 49 CALC Mode 44 Cement Addition 73 Cement In Input 22 Temperature 73 74 Timeout 22 Consistency 73 Deviation 41 Diagnostics Controller 79 Dribble Feed See Auto Mode Dry Mix Dry Mix 36 First Mix See Dry Mix Gain 31 Derivative 51 Integral 51 Proportional 5...

Page 88: ...aterial Addition 28 Mix Control 29 Mixing Times 28 Recipe Details 27 Temperature Correction Settings 33 Water Addition 27 Recipe Setup 36 Mix Times 36 Water quantity 37 Recipe Wizard 35 Remote Support 71 Restore 68 Running the first mix 36 Sensor Performance 73 Signal stability 74 Slump See Consistency Spray Bars 73 Temperature 73 Trim 38 Version Number 15 Water Dose 22 Water addition 74 Water Add...

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