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Hydronix Hydro-Probe XT, User Manual

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Hydro-Probe XT User Guide HD0538 Rev: 1.6.0   53 

Chapter 7 

Sensor diagnostics 

The following tables list the most common faults found when using the sensor.  If you are unable to 

diagnose the problem from this information, please contact Hydronix technical support. 

1  Sensor Diagnostics 

1.1 

Symptom: No output from sensor 

Possible 

explanation

 

Check 

Required result 

Action required on 

failure 

Output is working 

but not correctly 

Perform simple test 

with hand on sensor 

Milliamp reading 

within the normal 

range (0-20mA, 4-

20mA) 

Power down and re-

power sensor 

No power to sensor  DC power at 

junction box 

+15Vdc to +30Vdc 

Locate fault in 

power supply/wiring 

Sensor has 

temporarily locked 

up 

Power down and re-

power sensor 

Sensor functions 

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 

Check sensor 

connector pins 

Sensor MIL-Spec 

connector pins are 

damaged 

Disconnect the 

sensor cable and 

check if any pins 

are damaged 

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. Correct the 

configuration 

Digital RS485 

connection is not 

working.  Sensor 

should be returned 

to Hydronix for 

repair. 
 

 

Summary of Contents for Hydro-Probe XT

Page 1: ...Hydro Probe XT User Guide To re order quote part number HD0538 Revision 1 6 0 Revision date January 2020 ...

Page 2: ...e 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 descr...

Page 3: ...om 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 Office Te...

Page 4: ...4 Hydro Probe XT User Guide HD0538 Rev 1 6 0 ...

Page 5: ... 1 0 June 2013 Formatting Updates 1 2 0 August 2013 Corrosion protection section added to Chapter 2 1 3 0 February 2014 Figure 29 30 updated 1 4 0 April 2014 Figure 15 description updated 1 4 1 May 2014 Minor Formatting update 1 5 0 July 2016 Updated Sensor Cable part Numbers and Hydro Com information 1 6 0 January 2020 Address Change ...

Page 6: ...6 Hydro Probe XT User Guide HD0538 Rev 1 6 0 ...

Page 7: ...output connection 30 6 Connecting to a PC 31 Chapter 4 Configuration 35 1 Configuring the Sensor 35 2 Analogue output setup 35 3 Digital inputs output setup 37 4 Filtering 38 5 Alternative Measurement Techniques 39 Chapter 5 Sensor Integration and Calibration 43 1 Sensor Integration 43 2 Sensor Calibration 43 Chapter 6 Optimising Sensor and Process Performance 51 1 General to all Applications 51 2...

Page 8: ...8 Hydro Probe XT User Guide HD0538 Rev 1 6 0 ...

Page 9: ... 24 Figure 17 Hydro Probe installed in an Extension Mounting Sleeve 25 Figure 18 Hydro Probe installed with a drip loop 25 Figure 19 Deflector plate 25 Figure 20 0975A Sensor cable connections 28 Figure 21 RS485 multi drop connection 29 Figure 22 Correct RS485 cable networks 29 Figure 23 Incorrect RS485 cabling 29 Figure 24 Internal external excitation of digital input 1 2 30 Figure 25 Activation ...

Page 10: ...10 Hydro Probe XT User Guide HD0538 Rev 1 6 0 ...

Page 11: ...ension mounting sleeve 0975A 4m sensor cable 0975A 10m 10m sensor cable 0975A 25m 25m sensor cable 0116 Power supply 30 Watt for up to 4 sensors 0067 Terminal box IP66 10 terminals 0049A RS232 485 converter DIN rail mounting 0049B RS232 485 converter 9 pin D type to terminal block SIMxx USB Sensor Interface Module including cables and power supply Hydro Com configuration and diagnostics software i...

Page 12: ...onditions However as with other sensitive electronic devices care should be taken not to subject the sensor to unnecessary impact damage particular the ceramic faceplate which whilst being extremely resistant to abrasion is brittle and may be damaged if hit directly CAUTION NEVER HIT THE CERAMIC Care should be taken to ensure that the Hydro Probe XT has been correctly installed and in such a manne...

Page 13: ...t is configurable to 4 20 mA 0 20 mA 0 10 V output can be achieved using the 500 Ohm resistor supplied with the sensor cable Digital control an RS485 serial interface permits direct exchange of data and control information between the sensor and the plant control computer USB and Ethernet adapter options are also available The sensor can be configured to output a linear value of between 0 100 unsc...

Page 14: ...Chapter 1 Introduction 14 Hydro Probe XT User Guide HD0538 Rev 1 6 0 ...

Page 15: ...om vibrators If fitting to a vibratory feeder the advice from the manufacturer of the feeder should be followed or alternatively contact the Hydronix support department The sensor must be angled with the ceramic faceplate initially set to 60 to the flow as shown below to ensure that none of the material sticks to the ceramic faceplate This is indicated on the label when the A or B line is perpendi...

Page 16: ...and centred within the neck If it is fitted on the same side as the ram it should be angled towards the centre Ensure that the ceramic is not mounted closer than 150mm to any metalwork Ensure the sensor does not obstruct the gate Ensure that the ceramic faceplate is in the main flow of material Observe a test batch to identify the best position To prevent obstruction of the material where space is...

Page 17: ... opposite side to any vibrators where fitted Ensure the sensor ceramic is not mounted closer than 150mm to any metal work Ensure the sensor does not obstruct the door opening Ensure the ceramic face plate is in the main flow of the material Figure 7 Mounting the Hydro Probe XT in the bin wall If the sensor does not reach the main flow of material then an extension mounting sleeve should be used as...

Page 18: ... With vibratory feeders the sensor is normally fitted by the manufacturer contact Hydronix for further information on positioning It is difficult to predict where the flow of material occurs but the location shown below is recommended Figure 9 Mounting the Hydro Probe XT in a vibratory feeder Hydro Probe XT ...

Page 19: ... level of material on the belt it may be beneficial to fit diverters onto the conveyor as shown below This can build up the material to a deeper level for good measurement To aid calibration a manual switch may be fitted alongside the belt to switch the average hold digital input This will enable the readings to be averaged over a period of time whilst collecting samples and so giving a representa...

Page 20: ...w The ceramic face should be completely covered by a minimum of 100mm depth of material at all times a measurement is required An accessible sampling point should be installed approximately 150mm downstream of the sensor To aid calibration a manual switch should be fitted close to the sampling point to switch the average hold input This will enable the readings to be averaged over a period of time...

Page 21: ... The probe should be inserted so that the centre of the ceramic is in the centre of the flow The ceramic faceplate should be completely covered by a minimum of 100mm depth of material during measurement An accessible sampling point should be installed approximately 150mm downstream of the sensor To aid calibration a manual switch should be fitted close to the sampling point to switch the average h...

Page 22: ...d Mounting Sleeve however Hydronix would recommend using the Flanged Mounting Sleeve see Figure 15 338mm 50mm 170mm 218mm 89 mm Figure 13 The standard mounting sleeve part no 0025 3 2 Extension mounting sleeve part no 0026 For installation in larger bins 106mm 440mm 305mm 583mm 50mm Bin Wall A B A Sensor is secured to the inner sleeve by 6 hex screws use Locktite or similar on screw threads B Oute...

Page 23: ...r installations where vertical mounting is required Use with the Hydronix Clamp Ring part number 0023 A 100mm diameter hole is required to insert the Flanged Mounting Sleeve 126 mm Weld Clamp Ring Part No 0023 Clamp Ring Flanged Mounting Sleeve 110mm 16mm Ø100mm Hole Ø89mm Figure 15 Flanged Mounting Sleeve Part number 0024A ...

Page 24: ...the material does not fall onto the connector If the sensor is installed too far into the flow of the material then the connector may come into contact with the flow Do not allow the cable and connector to be covered in the falling material Position the sensor so the connector is not in the material flow See Figure 16 The sensor must remain in the main flow of the material at all times to produce ...

Page 25: ... moisture is allowed to run along the sensor cable and collect at the connector This can be reduced by installing the cable with a drip loop This will cause the moisture to drip off of the cable before it reaches the connector See Figure 18 Hydro Probe Bin wall Drip Loop Mounting Sleeve Figure 18 Hydro Probe installed with a drip loop 4 4 Protection cover Install a cover over the top of the sensor...

Page 26: ...e connector is still getting wet or covered by the material self amalgamating tape can be used to seal it and stop the water causing corrosion It is however preferential to keep the material away from the connector as this will be the best method of stopping the possibility of corrosion ...

Page 27: ...he control panel This can be used for diagnostic purposes and takes the minimum of effort and cost to connect at the time of installation Route the signal cable away from any power cables The sensor cable should only be grounded at the sensor end of the cable Ensure that the cable screen is not connected at the control panel Ensure that there is continuity of the screen through any junction boxes ...

Page 28: ... 2nd Analogue Positive Brown 6 E 2nd Analogue Return Black H Screen Screen K Brown E Black J Green G Black F White D Blue E Black C Yellow B Black A Red Positive Return 2nd Analogue Output 2nd Digital Input Output RS485B RS485A Positive Return 1st Analogue Output 1st Digital Input Output 0v VE Power Supply 15 30v DC Control Room Wiring 500 Ohm resistors for 0 10v signals Junction Box 0975A twisted...

Page 29: ... control device A Junction Box 0975A twisted pair Sensor Cable Do not connect screen at control cabinet H Screen B F G From other sensors Figure 21 RS485 multi drop connection When designing the cabling for the sensor network standard installation practices for RS485 networks is that the cable should run in a bus topology rather than as a star topology This means that the RS485 cable should run fr...

Page 30: ...presentative reading of the full sample during each batch An input is activated using 15 30v DC into the digital input connection The sensor power supply may be used as an excitation supply for this or alternatively an external source may be used as shown below Internal Excitation IP1 0975A twisted pair Sensor Cable C Yellow A Red External Excitation IP1 0975A twisted pair Sensor Cable C Yellow B ...

Page 31: ...85 A and B wires and can then be connected directly in to the PC serial communication port 1 2 3 4 5 RS232 RS485 K2 ADE Connect to PC serial port Hydronix Part No 0049B 6 DIP Switches control the configuration of the converter For both the 0049 and 0049B these should be set to Switch 1 ON Switch 2 OFF Switch 3 OFF Switch 4 ON Switch 5 OFF Switch 6 OFF RS485 A RS485 B Connect to Sensor Cable Figure...

Page 32: ...nterface Module Connect to PC USB Port Connect to 24v DC Power Supply Optional The Sensor Interface Modules is powered from the USB port The external 24v DC power supply can be used if sensor power is required See user guide HD0303 for further information RS485 sensor connection Sensor power optional Figure 28 RS232 485 converter connections Sensor Interface Module 6 4 Ethernet Adapter Kit part no...

Page 33: ...1 Hydronix Part No EPK01 10 100baseT CAT5e Cable to Sensor 0975A Description Colour Connector Pin RS485 A White F RS485 B Black G 0v DC Power Black B 24v DC Power Red A Ethernet Adapter Model EA01 24V Receive Transmit Ethernet Power Adapter Model EPA01 IN 24V OUT Junction box close to sensors Control Room Cabinet 10 100baseT CAT5e Ethernet to EPI01 10 100baseT CAT5e Ethernet to Network Switch EPI0...

Page 34: ... 2 3 4 0 10 20 30 40 50 60 70 80 Maximum Air Temperature C Number of Sensors Hydro Probe II 0 1 2 3 4 5 0 10 20 30 40 50 60 70 80 Maximum Air Temperature C Number of Sensors Figure 31 Maximum number of sensor connections dependent upon ambient temperature NOTE Operation above these limits may cause premature failure of the unit ...

Page 35: ...he addition of an external 500 Ohm precision resistor converts to 0 10V DC 4 20mA Compatibility For use with the Hydro View II unit 2 2 Output variable 1 and 2 These define which sensor readings the analogue output will represent and has 4 options NOTE This parameter is not used if the output type is set to Compatibility 2 2 1 Filtered Unscaled This represents a value which is proportional to mois...

Page 36: ...held constant Figure 32 may be used to assist in selecting the correct analogue output variable for a given system Calibration inside sensor Averaging in the sensor using digital input Averaging in the sensor using digital input Average Unscaled Filtered Unscaled Average Moisture Filtered Moisture YES YES YES No No No See Note Note It would be advisable to average in the control system here Figure...

Page 37: ... is required whilst still using only one analogue output With the input active the analogue output will indicate the appropriate moisture variable Unscaled or moisture When the input is activated the analogue output will indicate the material temperature in degrees centigrade Temperature scaling on the analogue output is fixed zero scale 0 or 4mA corresponds to 0 C and full scale 20mA to 100 C The...

Page 38: ...is possible to set limits for positive and negative changes separately Options are None Light Medium and Heavy The heavier the setting the more the signal will be dampened and the slower the signal response 4 2 Digital Signal Processing The Digital Signal Processing Filters DSP remove excessive noise from the signal using an advanced algorithm The filter reduces high frequency noise The advantage ...

Page 39: ...and Standard Mode It is recommended that the modes are only changed after comparing the effectiveness of each mode in the specific application In situ trials may be conducted using the Hydronix Hydro Com software to record data and compare the effectiveness of each mode 5 1 When to use alternative measurement techniques The most appropriate mode will be determined by the requirements of the user t...

Page 40: ...ing measured All modes will give a stable linear output however line B will give better precision and accuracy Modes V and E will also be less susceptible to density fluctuations 1 5 5 4 3 2 40 35 30 25 20 15 10 0 A B 5 unscaled units 1 7 5 unscaled units 0 4 Sensor Unscaled Value Moisture Value Figure 33 Relationship of moisture to Unscaled values To determine which mode is the most appropriate i...

Page 41: ...o obtain an output signal that is calibrated to moisture an absolute moisture measurement it is recommended to calibrate using the different measurement modes and to compare results see Calibration page 43 For further information please contact the Hydronix support team at support hydronix com ...

Page 42: ...Chapter 4 Configuration 42 Hydro Probe XT User Guide HD0538 Rev 1 6 0 ...

Page 43: ... wish to develop their own interface 2 Sensor Calibration 2 1 Introduction to material calibration The raw output of a Hydronix sensor is an Unscaled value ranging from 0 to 100 units Each sensor is set so that a 0 Unscaled value relates to the measurement in air and 100 relates to water The relationship between the change in moisture to the change in Unscaled value will not be the same for two di...

Page 44: ...used in the calibration equation as shown below Moisture A x Unscaled value B Unscaled value C SSD Use of the quadratic coefficient A would only be necessary in complex applications and for most materials the calibration line will be linear in which case A is set to zero 2 2 SSD coefficient and SSD moisture content Saturated Surface Dry SSD is an offset adjustment typically used in aggregates and ...

Page 45: ...a dedicated material calibration page which allows a multiple point calibration to be generated for a material To calibrate outside of the sensor the control system will require its own calibration function and the moisture conversion can then be calculated using the linear Unscaled output from the sensor For guidance on setting the output see Figure 32 2 3 1 Calibration inside the Hydro Probe XT ...

Page 46: ...he need for an additional computer or RS485 adapter No need to learn how to use additional software If it is necessary to replace the sensor a replacement Hydronix sensor can be connected and valid results obtained immediately without connecting the sensor to a PC to update the material calibration Calibrations can be switched automatically when materials change Calibrations can be easily transfer...

Page 47: ...particular standard 2 4 1 Hints and safety Wear safety glasses and protective clothing to guard against ejection of material during the drying process Do not attempt to calibrate the sensor by packing material on the face The readings obtained will not be representative of those from a real application Always sample where the sensor is located Always take a reading of Unscaled at the same time as ...

Page 48: ...ure content using the moisture calculator Take care not to lose any of the samples during the drying process A good test to ensure the material is thoroughly dry is to stir it around to distribute the moisture and reheat 8 Return to the computer and record the Average Unscaled output which should show the Hold status Click Add Point to add the Average Unscaled value to the calibration table 9 Repe...

Page 49: ...value Using the dry weight method a 100 moisture value would indicate a 50 mass of dry material and a 50 mass of water Using this method it is therefore possible to have a moisture value of more than 100 All Hydronix calculations are based on a dry weight method unless otherwise specified 2 5 Good bad calibration A good calibration is made by measuring samples and taking readings over the full wor...

Page 50: ...calibration points are used in particular 1 or 2 points The sub sample tested is not representative of the bulk sample Samples are taken close to the same moisture content like the calibration graph shown below left A good range is necessary There is a large scatter in the readings as shown in the calibration graph below right This generally implies an unreliable or inconsistent approach to taking...

Page 51: ...ioning 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 the rheology of the material for the same moisture content I...

Page 52: ...Chapter 6 Optimising Sensor and Process Performance 52 Hydro Probe XT User Guide HD0538 Rev 1 6 0 ...

Page 53: ...ectly 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 Chec...

Page 54: ...tput from the PLC 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 incor...

Page 55: ... 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 junction b...

Page 56: ...ion 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 Do not rely on moisture readings Average Hold signal is not in use Control system is calculating batch average readings Average moisture readings must be used in batch weighing applicat...

Page 57: ...e HD0538 Rev 1 6 0 57 1 6 Sensor output characteristics Filtered Unscaled Output values shown are approximate RS485 4 20mA 0 20 mA 0 10 V Compatibility mode Sensor exposed to air 0 4 mA 0 mA 0V 10V Hand on sensor 75 85 15 17 mA 16 18 mA 7 5 8 5 V 3 6 2 8V ...

Page 58: ...Chapter 7 Sensor diagnostics 58 Hydro Probe XT User Guide HD0538 Rev 1 6 0 ...

Page 59: ... 35mm2 conductors Screen shield Braid with 65 minimum coverage plus aluminium polyester foil Recommended cable types Belden 8306 Alpha 6373 Maximum cable run 200m separate to any heavy equipment power cables 1 6 2 Digital serial communications Opto isolated RS485 2 wire port for serial communications including changing operating parameters and sensor diagnostics 1 7 Analogue outputs Two configurab...

Page 60: ...Chapter 8 Technical specification 60 Hydro Probe XT User Guide HD0538 Rev 1 6 0 ...

Page 61: ...and checking 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 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 moistures Hydro Com ...

Page 62: ...tinuously The Hydro Probe XT sensor has two lines marked A and B on the rear plate label Correct alignment is where either line A or line B is horizontal indicating that the ceramic is at the correct angle as suggested on Page 15 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 due to a change in compaction or ...

Page 63: ...d Output variable 2 Material Temp High 20 00 Low 00 00 Input Use 1 Avg Hold Input output Use 2 Unused Unscaled Type Mode V Unscaled 2 Type Mode E Smoothing time 1 0 Slew rate Light Slew rate Light Digital Signal Processing Unused Material calibration Moisture A 0 0000 B 0 2857 C 4 0000 SSD 0 00 Average hold delay 0 5 sec High limit m 30 00 Low limit m 0 00 High limit us 100 00 Low limit us 0 00 Fr...

Page 64: ...ev 1 6 0 1 2 Temperature Compensation The temperature compensation settings are individual to the unit and set in the factory during manufacturing These should not be changed In the event that these settings are required please contact Hydronix at support hydronix com ...

Page 65: ...This section lists all of the other documents that are referred to in this User Guide You may find it beneficial to have a copy available when reading to this guide Document Number Title HD0682 Hydro Com User Guide HD0303 USB Sensor Interface Module User Guide EN0071 Engineering Note Sensor Default Parameters ...

Page 66: ...Appendix B Document Cross Reference 66 Hydro Probe XT User Guide HD0538 Rev 1 6 0 ...

Page 67: ...2 Filtered Moisture 35 Filtered Unscaled 35 Filtering 38 Filtering Time 38 Filters Slew Rate 38 Flanged Mounting Sleeve 23 Free Moisture 44 High Limit See Alarms Hydro Com 27 35 61 Installation Advice 15 Electrical 27 Junction Box 29 Low Limit See Alarms Measurement Technique 12 Moisture Negative 62 Moisture Temperature 37 Mounting Conveyor Belt 19 General 16 In Bin Wall 17 In Neck of Bin 16 Optio...

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