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Hydronix Hydro-Mix, Configuration And Calibration Manual

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Configuration 

Chapter 2 

Configuration and Calibration Guide HD0679 Rev 1.2.0 27 

Unscaled 

Calculation

Moisture 

Coefficients

Moisture 

Calculation

Output Mode

(Current Loop or RS485 request)

Actual Output

Mode F

Mode E

Mode V

A, B, C, D (Mode F)

A, B, C, D (Mode E)

A, B, C, D (Mode V)

Mode F

Mode E

Mode V

Mode F

Mode E

Mode V

Current Loop or 

RS485

None 

Specified

Selected by 

Unscaled 1 Type 

(F, E, V) 

 

Figure 12: None specified Output Selection 

As older host applications are unable to write the A, B, C and D coefficients for each of the 
modes, a final extension is made that supports a set of Legacy Mode coefficients which are 
supported by existing host systems. This is shown in the final version of the diagram: 

Unscaled 

Calculation

Moisture 

Coefficients

Moisture 

Calculation

Output Mode

(Current Loop or RS485 request)

Actual Output

Mode F

Mode E

Mode V

A, B, C, D (Mode F)

A, B, C, D (Mode E)

A, B, C, D (Mode V)

Mode F

Mode E

Mode V

Mode F

Mode E

Mode V

Current Loop or 

RS485

None 

Specified

Selected by Unscaled 

1 Type (F, E, V) 

Selected by 

Unscaled 1 

Type  (F, E, V)

A, B, C, D (Legacy)

 

Figure 13: Legacy Output Selection 

 

If a current loop output is set without a Mode specifier or an RS485 protocol request is made 
without

 a Mode specifier

 (for a Moisture value) t

hen the following process is followed: 

•

 

If the Legacy Coefficients are non-zero then these are used to calculate the Moisture 
value. (Red arrows in the diagram) 

•

 

If the Legacy Coefficients are all zero, then the Unscaled 1 Type is used to select the 
relevant coefficients and Moisture (Green arrows). This enables a sensor to be fully 
calibrated on a current host system in all modes and operated on a legacy host 
system.  

9.4 

Unscaled 2 

In Legacy sensor products a second Unscaled calculation was implemented to allow the 
comparison of two modes at the same time. This allowed Unscaled readings for a second 
mode to be output, but not Moisture readings. Unscaled 2 has been implemented in the latest 
sensors for backwards compatibility, but as these sensors calculate all of the modes all of the 
time it should not be used for new host system implementation. 

In the latest sensors, multiple RS485 protocol requests can be made to compare modes, or 
the two analogue current loop outputs can be configured for different modes. 

 

 

Summary of Contents for Hydro-Mix

Page 1: ...Hydronix Moisture Sensor Configuration and Calibration Guide To re order quote part number Revision Revision date HD0679 1 2 0 October 2015 ...

Page 2: ... customer therefore undertakes responsibility to ensure that the product is properly installed commissioned operated and maintained by competent and suitably trained persons and in accordance with any instructions or safety precautions made available or good engineering practice and to thoroughly verify the use of the product in the particular application ERRORS IN DOCUMENTATION The product descri...

Page 3: ...onix 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 Off...

Page 4: ...4 Configuration and Calibration Guide HD0679 Rev 1 2 0 ...

Page 5: ...Guide HD0679 Rev 1 2 0 5 Revision history Revision No Date Description of Change 1 0 0 Feb 2015 First Release 1 1 0 July 2015 Multi Mode Calibration Section Added 1 2 0 October 2015 Process for calibrating a sensor in a mixer added ...

Page 6: ...6 Configuration and Calibration Guide HD0679 Rev 1 2 0 ...

Page 7: ...putting the Sensor Data 26 Chapter 3 Sensor Integration and Material Calibration 29 1 Sensor Integration 29 2 Introduction to Material Calibration 29 3 SSD Coefficient and SSD Moisture Content 31 4 Storing Calibration Data 31 5 Calibration Procedure for Flowing Material Linear 32 6 Good Bad Calibration 34 7 Quadratic Calibration 35 8 Calibrating a sensor in a mixer 36 9 Brix Calibration 38 Chapter...

Page 8: ...8 Configuration and Calibration Guide HD0679 Rev 1 2 0 ...

Page 9: ...gnal 2 23 Figure 10 Relationship of Unscaled Values to Moisture 25 Figure 11 Data arrangement in the sensor 26 Figure 12 None specified Output Selection 27 Figure 13 Legacy Output Selection 27 Figure 14 Calibrations for 3 Different Materials 29 Figure 15 Typical Calibration Results 30 Figure 16 Calibration inside the Sensor 31 Figure 17 Calibration inside the Control System 32 Figure 18 Example of...

Page 10: ...10 Configuration and Calibration Guide HD0679 Rev 1 2 0 ...

Page 11: ...ing Hydronix sensors only Hydro Probe Model number HP04 onwards Hydro Probe XT Model number XT02 onwards Hydro Probe Orbiter Model number ORB3 onwards Hydro Probe SE Model number SE03 onwards Hydro Mix Model number HM08 onwards User guides for other model numbers are available from www hydronix com Hydro Probe XT Hydro Mix Hydro Probe Orbiter Hydro Probe SE ...

Page 12: ...ively to signal an operator that a storage bin needs to be refilled Hydronix sensors are specially designed using suitable materials to provide many years of reliable service even in the most arduous conditions However as with other sensitive electronic devices care should be taken not to subject the sensor to unnecessary impact damage Particular care should be paid to the ceramic faceplate which ...

Page 13: ... All references to Hydro Com in this user guide refer to software version 2 0 0 and higher The sensor can be configured using older versions of Hydro Com however some features will not be available See the relevant Hydro Com user guide for more details There are two basic configurations for connecting the sensor to a batch control system Analogue output A DC output is configurable to 4 20 mA 0 20 ...

Page 14: ...Chapter 1 Introduction 14 Configuration and Calibration Guide HD0679 Rev 1 2 0 ...

Page 15: ...parameters However not all the functions are used in every sensor application Averaging parameters for example are typically used for batch processes 2 Analogue Output Setup The working range of the two current loop outputs can be configured for the equipment it is connected to for example a PLC may require 4 20 mA or 0 10V DC etc The outputs can also be configured to represent different readings ...

Page 16: ... Unscaled 2 The Filtered Unscaled uses the second measurement mode configured in the sensor Note This mode is not available in all sensors Please see the technical specification in the relevant installation guide for more details 2 2 5 Average Unscaled This is the Raw Unscaled variable processed for batch averaging using the averaging parameters To obtain an average reading the digital input must ...

Page 17: ...100 C 2 3 Low and High These two values set the moisture range when the output variable is set to Filtered Moisture or Average Moisture The default values are 0 and 20 where 0 20mA 0mA represents 0 and 20mA represents 20 4 20mA 4mA represents 0 and 20mA represents 20 These limits are set for the working range of the moisture and must be matched to the mA to moisture conversion in the batch control...

Page 18: ...icate a vessel empty state Data out of range The output will be active if the moisture reading is above or below the moisture include limits or the Unscaled is above or below the Unscaled include limits Sensor OK This output will be active if The frequency reading is between the defined air and water calibration points 3 The amplitude reading is between the defined air and water calibration points...

Page 19: ...data is processed for batch averaging when using the digital input or remote averaging They are not normally used for continuous processes 4 1 High Limit and Low Limit The High Limit and Low Limit may be set for both the moisture and the Unscaled value The two parameters operate independently If the sensor reading falls outside of these limits during sensor averaging the data will be excluded from...

Page 20: ...r set using the Filtering Time function smoothes the whole frequency range Each filter is described in detail below 5 1 Slew Rate Filters The Slew Rate Filters are useful for clipping large peaks or troughs in the sensor reading caused by mechanical interference in a process The filters set rate limits for large positive and negative changes in the raw signal It is possible to set limits for posit...

Page 21: ... trace of a flowing material The signal is erratic due to the action of the material flowing past the sensor Raw Unscaled Unscaled Time S Figure 4 Raw Unscaled Moisture Trace in Flowing Material The positive peaks and negative troughs can be clipped using the Slew Rate Filters reducing unwanted noise After the signal has been through the Slew Rate Filters and if selected the DSP filter the signal ...

Page 22: ...ints A and B signify that all of the ingredients within the mixer are homogenously mixed together A B Filtered Unscaled Water Addition Mixer loaded with material Dry mixing time Wet mixing time Mixer discharge Time Figure 6 Typical Moisture Curve The degree of stability at points A and B can have a significant effect on accuracy and repeatability Most automatic water controllers measure the dry mo...

Page 23: ...ng the RAW Unscaled Signal 1 Figure 9 shows the effect of the following settings Slew Rate Light Slew Rate Light Filtering Time 7 5 seconds Applying Filter Slew rate Light Slew Rate Light Filtering Time 7 5 Seconds Unscaled Raw and Filtered Time s Figure 9 Filtering the RAW Signal 2 In Figure 9 it is clear that the signal at the dry phase of the mix cycle is more stable which is more advantageous ...

Page 24: ... measurements Mode V and Mode E are often employed with lower density materials such as grain or other organic materials They are also associated with any material that has a variable bulk density that correlates to moisture content Mode V and Mode E may also be beneficial for high intensity mixing applications of high density material and for other mixing applications with distinct changes in den...

Page 25: ...om each of the different measurement modes in the same process Data can easily be recorded using a PC and the Hydronix Hydro Com software these results may then be plotted to ascertain the most suitable measurement mode For further analysis including sensor filtering analysis Hydronix can also offer advice as well as software to enable the experienced user to achieve the best possible settings for...

Page 26: ... be requested Using the extended protocol the host might request Average Unscaled Mode V or Filtered Unscaled Mode E for example A full protocol specification is available by request from Hydronix for users wishing to implement the Hydro Link protocol in a control system 9 3 Backwards Compatibility with Older Host Systems For new host system implementations the scheme described above Figure provid...

Page 27: ... 1 Type F E V A B C D Legacy Figure 13 Legacy Output Selection If a current loop output is set without a Mode specifier or an RS485 protocol request is made without a Mode specifier for a Moisture value then the following process is followed If the Legacy Coefficients are non zero then these are used to calculate the Moisture value Red arrows in the diagram If the Legacy Coefficients are all zero ...

Page 28: ...Chapter 2 Configuration 28 Configuration and Calibration Guide HD0679 Rev 1 2 0 ...

Page 29: ...relates to the measurement in air and 100 relates to water This is used to give a raw output value from a Hydronix sensor which ranges from 0 to 100 and is called the Unscaled value 2 2 Why Calibrate Hydronix Microwave Moisture Sensors measure the electrical properties of a material Each material has its own unique electrical characteristics and as a result a calibration process must be performed ...

Page 30: ...egarding specific applications please consult the Hydronix support team support hydronix com 2 4 The Calibration Types Hydronix Microwave Moisture Sensors can be calibrated using several different methods Linear A material calibration for moisture is normally linear and calibrating to this is described on page 32 The following equation is used Moisture B x Unscaled Reading C SSD Quadratic There is...

Page 31: ...as concrete production only this surface water is used in the process which is why it is this value that is generally referred to in concrete mix designs Oven dried moisture Total water adsorption value SSD offset in the sensor surface moisture free moisture 4 Storing Calibration Data There are two ways of storing the calibration data either in the control system or in the sensor Both methods are ...

Page 32: ...ined immediately without connecting the sensor to a PC to update the material calibration Calibrations can be switched between sensors easily 5 Calibration Procedure for Flowing Material Linear To determine the calibration line at least two points are required Each point is derived by flowing material over the sensor and finding the sensor s Unscaled reading At the same time a sample of the materi...

Page 33: ...scaled value is recorded as the material is passing the sensor At the same time a sample of the material needs to be collected Samples should be taken as close to the sensor as possible this will ensure that the sample collected is a true representation of the material the sensor was measuring 2 To perform the calibration the Average Unscaled value can be obtained by either triggering the Average ...

Page 34: ...cument number HD0682 Note 1 Standards for testing aggregates recommend that for representative sampling at least 20kg of bulk material is required 0 4mm material Note 2 Standards for testing aggregates recommend that for representative sampling the difference in moisture should be no greater than 0 1 5 4 Calculating the Moisture Content 320 3g 1288 7g 1236 3g A B C Moisture Content B C C A x 100 E...

Page 35: ...is not used to ensure representative moisture reading for the entire batch Figure 19 Examples of Poor Material Calibration Points 7 Quadratic Calibration Hydronix Microwave Moisture sensors are able to utilise a quadratic calibration function for use in the rare occasions where a material is non linear For quadratic calibrations where the calibration points do not form a straight line the A coeffi...

Page 36: ...mixer When a sensor has been installed in a mixer with multiple materials and it is required to output moisture it is not always possible to perform a standard calibration process This is especially true in concrete production Taking samples of the finished wet concrete and performing a bake out to determine the moisture is not reliable due to the chemical reactions and safety issues The following...

Page 37: ...𝟑 5 To create a calibration point the dry material must be loaded into the mixer and mixed thoroughly until the sensor signal is stable this indicates that the mix is homogenous Once the signal is stable record the sensors Unscaled value In this example the value was 35 Unscaled 6 To create a second calibration point add a set amount of water to the mixer in this example 35 litres is added Thoroug...

Page 38: ...s mainly used in the food industry The Brix calculation is different from the linear calculation used for moisture To create a calibration line the following equation is used us D e B A Brix us C where us is the Unscaled value from the sensor This equation gives an exponential curve When using the sensors to measure Brix the sensor must still be calibrated to the process being monitored The proces...

Page 39: ...the sensor with the calibration 9 1 Good Bad Brix Calibration A good Brix calibration is achieved by analysing the material over the working range A good spread of points is necessary to provide higher accuracy Figure 22 shows a good calibration with all points close to the best fit curve Improved Calibration Current Calibration Brix Unscaled Figure 22 Example of a Good Brix Calibration Figure 23 ...

Page 40: ...Chapter 3 Sensor Integration and Material Calibration 40 Configuration and Calibration Guide HD0679 Rev 1 2 0 ...

Page 41: ...tabilise for 15 minutes after applying power before use Positioning The sensor should be in contact with a representative sample of the material Flow The sensor should be in contact with a consistent flow of material Material If the material type or source changes this may affect the moisture reading Material particle size If the particle size of the material being measured changes this may affect...

Page 42: ...Chapter 4 Best Practices 42 Configuration and Calibration Guide HD0679 Rev 1 2 0 ...

Page 43: ... correctly Check power No sensor output at control system Measure sensor output current at control system Milliamp reading within the normal range 0 20mA 4 20mA Varies with moisture content Check cabling back to junction box No sensor output at junction box Measure sensor output current at terminals in junction box Milliamp reading within the normal range 0 20mA 4 20mA Varies with moisture content...

Page 44: ...C and measure the analogue output from the sensor using an ammeter Milliamp reading within the normal range 0 20mA 4 20mA Replace analogue input card 1 3 Symptom Computer Does Not Communicate with the Sensor Possible explanation Check Required result Action required on failure No power to sensor DC power at junction box 15Vdc to 30Vdc Locate fault in power supply wiring RS485 incorrectly wired int...

Page 45: ...en drying Must be within working range of sensor Adjust sensor range and or calibration Interference from mobile phones Use of mobile phones close to sensor No RF sources operating near to sensor Prevent use within 5m of sensor Average Hold switch has not operated Apply signal to digital input Average moisture reading should change Verify with Hydro Com diagnostics No power to sensor DC power at j...

Page 46: ...sure calibration values are appropriate to working range Calibration values spread throughout range avoiding extrapolation Perform further calibration measurements Ice forming in material Material temperature No ice in material Sensor will not measure in ice Average Hold signal is not in use Control system is calculating batch average readings Average moisture readings must be used in batch weighi...

Page 47: ...and Calibration Guide HD0679 Rev 1 2 0 47 1 6 Sensor Output Characteristics Filtered Unscaled Output values shown are approximate RS485 4 20mA 0 20 mA 0 10 V Sensor exposed to air 0 4 mA 0 mA 0V Hand on sensor 75 85 16 17 6 mA 15 17 mA 7 5 8 5 V ...

Page 48: ...Chapter 5 Sensor Diagnostics 48 Configuration and Calibration Guide HD0679 Rev 1 2 0 ...

Page 49: ...hecking this calibration point If it lies near to or on the line then the calibration is still good Q What should I do if there is little variation of moisture in my material on the day I calibrate A For sand only HP04 only If you have dried different samples and there is little variation in moisture 1 2 then settle for one good calibration point by averaging the Unscaled readings and oven dried m...

Page 50: ...nsors have two lines on the rear plate label that indicate the angle that the sensor should be installed in relation to the material flow Correct alignment is where either line is in line with the material flow indicating that the ceramic is at the correct angle Q Does the angle of the sensor affect the reading A It is possible that changing the angle of the sensor can affect the readings This is ...

Page 51: ...ro Com User Guide HD0675 Hydro Probe and Hydro Probe XT Installation Guide HD0676 Hydro Mix Installation Guide HD0677 Hydro Probe Orbiter Installation Guide HD0678 Hydronix Moisture Sensor Electrical Installation Guide EN0077 Moisture Control Methods for Batching EN0078 Integrating Hydro Mix and Hydro Probe Sensors in a Grain Duct EN0079 HP04 Sensor Factory Default Parameters EN0080 XT02 Sensor Fa...

Page 52: ...Appendix A Document Cross Reference 52 Configuration and Calibration Guide HD0679 Rev 1 2 0 ...

Page 53: ...side Sensor 32 Procedure 32 Configuration 13 Data Invalid 19 Digital Inputs Output 17 Filtered Signal 23 Filtering 20 Filtering Time 20 Filters Slew Rate 20 Free Moisture 31 High Limit See Alarms Hydro Com 15 49 Low Limit See Alarms Measurement Modes 24 Measurement Technique 13 Moisture Negative 50 Surface 31 Moisture content 34 Moisture Temperature 18 Output 15 Parameters Averaging 19 Raw Moistur...

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