Hydro-View IV User Guide

Hydro-View IV User Guide
Hydro-View IV User Guide
To re-order quote part number:
HD0531
Revision:
1.5.0
Revision date:
Aug 2015
Copyright
Neither the whole or any part of the information contained in nor the product described in this documentation may
be adapted or reproduced in any material form except with the prior written approval of Hydronix Limited,
hereinafter referred to as Hydronix.
© 2015
Hydronix Limited
7 Riverside Business Centre
Walnut Tree Close
Guildford
Surrey GU1 4UG
United Kingdom
All rights reserved
CUSTOMER RESPONSIBILITY
The customer in applying the product described in this documentation accepts that the product is a
programmable electronic system which is inherently complex and which may not be completely free of errors. In
doing so the 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 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
ACKNOWLEDGEMENTS
Hydronix, Hydro-Probe, Hydro-Mix, Hydro-Skid, Hydro-View and Hydro-Control are Registered Trade Marks of
Hydronix Limited
2
Hydro-View IV User Guide HD0531 Rev 1.5.0
Hydronix Offices
UK Head Office
Address:
7 Riverside Business Centre
Walnut Tree Close
Guildford
Surrey
GU1 4UG
Tel:
Fax:
+44 1483 468900
+44 1483 468919
Email:
[email protected]
[email protected]
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
+1 888 887 4822 (Toll Free)
+1 231 439 5001
Fax:
European Office
Covers Central Europe, Russia and South Africa
Tel:
Fax:
+49 2563 4858
+49 2563 5016
French Office
Tel:
+33 652 04 89 04
Hydro-View IV User Guide HD0531 Rev 1.5.0 3
4
Hydro-View IV User Guide HD0531 Rev 1.5.0
Revision history
Revision
No
Software
Version
Date
Description of Change
1.0.0
1.0.0
May 2012
First Release
1.1.0
1.1.0
June 2012
Diagnostics Section Updated
1.2.0
1.3.0
Jan 2013
Averaging Mode and Sensor Restore Updated.
Calibration section Updated
1.2.1
1.3.0
May 2013
Minor Formatting update
1.3.0
1.3.0
Aug 2013
Change to panel cut-out dimensions
1.4.0
1.3.0
Nov 2013
Minor Formatting Update
1.5.0
1.5.0
Aug 2015
Sensor cable installation advice updated
Hydro-View IV User Guide HD0531 Rev 1.5.0 5
6
Hydro-View IV User Guide HD0531 Rev 1.5.0
Table of Contents
Chapter 1 Introduction........................................................................................................................... 13
1 Introduction to the Hydro-View IV .............................................................................................. 13
2 About this manual....................................................................................................................... 14
3 Safety ......................................................................................................................................... 14
4 Application Examples ................................................................................................................. 16
Chapter 2 Mechanical Installation ......................................................................................................... 17
1 Weight and Dimensions ............................................................................................................. 17
2 Mounting and installation ........................................................................................................... 18
3 Operating Temperature .............................................................................................................. 19
4 Memory Card .............................................................................................................................. 19
Chapter 3 Electrical Installation............................................................................................................. 21
1 Connector pin assignments ........................................................................................................ 21
2 Power Supply ............................................................................................................................. 23
3 Communications ......................................................................................................................... 23
4 Cables ........................................................................................................................................ 24
5 USB Port .................................................................................................................................... 25
Chapter 4 Configuration ........................................................................................................................ 27
1 Logging in as Engineer .............................................................................................................. 27
2 Connecting Sensors ................................................................................................................... 27
3 Configuring Sensors ................................................................................................................... 27
4 Configuring the System Settings ................................................................................................ 27
5 Configuring the Overview Screen .............................................................................................. 28
6 Calibrating the sensors............................................................................................................... 28
7 Upgrading the Hydro-View Firmware ......................................................................................... 28
8 Backing up the System............................................................................................................... 28
Chapter 5 System Navigation ............................................................................................................... 29
1 Screen Navigation ...................................................................................................................... 29
2 The Overview Screen ................................................................................................................. 33
3 Display Setup Screen ................................................................................................................. 34
4 Main Menu Screen ..................................................................................................................... 35
5 User Accounts Screen................................................................................................................ 36
6 System Screens ......................................................................................................................... 37
7 Sensor Screens .......................................................................................................................... 39
8 Calibration Screens .................................................................................................................... 51
9 Logging Screens ........................................................................................................................ 56
Chapter 6 Material Calibration .............................................................................................................. 59
1 Introduction to Material Calibration ............................................................................................ 59
2 Moisture Calibration ................................................................................................................... 60
3 Brix Calibration ........................................................................................................................... 62
4 Hints: .......................................................................................................................................... 62
5 Equipment .................................................................................................................................. 62
6 Calibration Procedure................................................................................................................. 63
Appendix A Default PIN Codes ............................................................................................................. 69
Appendix B USB Memory Stick file format............................................................................................ 71
Appendix C Frequently Asked Questions ............................................................................................. 73
Hydro-View IV User Guide HD0531 Rev 1.5.0 7
Appendix D Diagnostics ........................................................................................................................ 75
Appendix E Glossary............................................................................................................................. 77
Appendix F Document Cross Reference .............................................................................................. 79
1 Document Cross Reference ....................................................................................................... 79
8
Hydro-View IV User Guide HD0531 Rev 1.5.0
Table of Figures
Figure 1: The Hydro-View IV ................................................................................................................. 13
Figure 2: Rear view of the Hydro-View IV ............................................................................................. 17
Figure 3: The Hydro-View mounting bracket ........................................................................................ 18
Figure 4: The panel cut-out for the Hydro-View IV ............................................................................... 18
Figure 5: Fitting the RS485 Adapter ..................................................................................................... 21
Figure 6: Hydro-View Wiring Diagram .................................................................................................. 22
Figure 7: Hydro-View Wiring Diagram (with Hydronix Enclosure) ........................................................ 22
Figure 8: Hydronix Enclosure internal wiring ........................................................................................ 23
Figure 9: Menu Structure ...................................................................................................................... 29
Figure 10: Selecting the language ........................................................................................................ 31
Figure 11: The Overview Screen .......................................................................................................... 33
Figure 12: The Display Setup Screen ................................................................................................... 34
Figure 13: The Main Menu Screen ....................................................................................................... 35
Figure 14: The User Accounts Screen .................................................................................................. 36
Figure 15: The First System Screen ..................................................................................................... 37
Figure 16: The Second System Screen ................................................................................................ 38
Figure 17: The Third System Screen .................................................................................................... 38
Figure 18: Sensor Identification Screen ................................................................................................ 39
Figure 19: Sensor Backup / Restore Screen ........................................................................................ 40
Figure 20: Analogue Outputs Screen .................................................................................................... 40
Figure 21: Digital Inputs / Outputs Screen ............................................................................................ 42
Figure 22: I/O Test Screen .................................................................................................................... 44
Figure 23: Averaging Screen ................................................................................................................ 45
Figure 24: Calibration Screen ............................................................................................................... 46
Figure 25: Signal Processing Screen .................................................................................................... 47
Figure 26: Temperature Compensation Screen.................................................................................... 48
Figure 27: Factory Settings Screen ...................................................................................................... 48
Figure 28: Temperature Screen ............................................................................................................ 49
Figure 29: IO Status Screen.................................................................................................................. 49
Figure 30: Resonator Screen ................................................................................................................ 50
Figure 31: Calibration List Screen ......................................................................................................... 51
Figure 32: Edit Calibration Screen ........................................................................................................ 52
Figure 33: Edit Calibration Points Screen ............................................................................................. 53
Figure 34: Edit Calibration Points Graph Screen .................................................................................. 54
Figure 35: Remote Averaging (Input set for Average / Hold) ................................................................ 55
Figure 36: Remote Averaging (Input not set for Average / Hold).......................................................... 55
Figure 37: Logging Screen .................................................................................................................... 56
Figure 38: Logging Wizard Page 1 ....................................................................................................... 56
Figure 39: Logging Wizard Page 2 ....................................................................................................... 57
Hydro-View IV User Guide HD0531 Rev 1.5.0 9
Figure 40: Logging Wizard Page 3 ....................................................................................................... 57
Figure 41: Calibration Graph ................................................................................................................. 61
Figure 42: Sensor selection screen ...................................................................................................... 63
Figure 43: Calibration screen ................................................................................................................ 63
Figure 44: Edit Calibration screen ......................................................................................................... 63
Figure 45: Averaging selection ............................................................................................................. 64
Figure 46: Manual start average screen ............................................................................................... 64
Figure 47: Averaging complete screen ................................................................................................. 65
Figure 48: Adding moisture value screen ............................................................................................. 65
Figure 49: Calibration graph.................................................................................................................. 66
Figure 50: Update calibration to sensor screen .................................................................................... 66
Figure 51: Updated calibration field ...................................................................................................... 67
Figure 52: Calculating true Moisture Content ....................................................................................... 67
Figure 53: USB memory Stick File Layout ............................................................................................ 71
10
Hydro-View IV User Guide HD0531 Rev 1.5.0
Box Contents
Standard Contents:
1 x
Hydro-View IV Unit
1 x
Mounting Bracket
1 x
RS-485 and Power Adaptor
1 x
Documentation CD
1 x
Quick Installation Guide
1 x
Quick Start Guide
Available accessories:
Part No.
Description
0116
24v DC Power Supply 30 Watt
0175
Panel Mount USB Socket
2010
Wall Mounted Enclosure
Hydro-View IV User Guide HD0531 Rev 1.5.0 11
12
Hydro-View IV User Guide HD0531 Rev 1.5.0
Chapter 1
Introduction
Figure 1: The Hydro-View IV
1 Introduction to the Hydro-View IV
The Hydro-View IV is a touch screen computer based upon the Microsoft Windows CE operating
system that has been designed to work with the Hydronix range of sensors to provide a live
display of on-line process measurements and enable quick and easy calibration and
configuration of the sensors. The Hydro-View can connect to up to 16 sensors at one time.
Its main display page supports 1, 2 or 4 screen areas, each of which is configurable to display a
trend graph or numeric display of measurements from any connected sensor.
The Hydro-View stores multiple material calibrations for each sensor, allowing rapid re-calibration
if the material being measured is changed. The intuitive multi-point calibration feature enables
the sensor to be easily and precisely calibrated.
As well as being connected to a Hydro-View, the sensors can also be integrated with a control
system via their analogue outputs. Digital inputs and outputs on the sensors allow for averaging
start and stop in a batch process.
In order to correctly understand the use of the Hydro-View IV unit it is important to understand
the capabilities of the sensor that is to be attached to the unit. Please read the relevant user
guide that is supplied with the sensor. Alternatively please download the user guide from the
Hydronix website: www.hydronix.com
Hydro-View IV User Guide HD0531 Rev 1.5.0 13
Introduction
Chapter 1
Hydro-View IV
RS485
4-20mA*
Average / hold input control
Analogue Inputs
A/I 1
4-20mA
A/I 2
A/I 3
Average / hold input control
A/I 4
4-20mA
Average / hold input control
4-20mA
Average / hold input control
* Can also be a 0-20mA / 0-10V DC
2 About this manual
This manual is both an installation guide and a user guide.
This manual contains sections on mechanical installation, electrical installation as well as
calibrating and configuring Hydronix sensors using the Hydro-View IV.
3 Safety
The Hydro-View IV has been designed to meet the requirements of IEC/EN 61010-1 : 2001 and
ANSI/UL 61010-1 Second Edition.
This equipment is designed to be safe when used for its intended purpose and under the
following conditions.
3.1
Intended Purpose
The Hydro-View IV is intended to be used as a display, calibration and configuration interface
for Hydronix sensors in an industrial environment where it should be installed by suitably
qualified and competent personnel.
3.2
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 device and be within easy reach of the operator.
Disconnect all signals from any voltage supply before the unit is opened for any adjustment,
maintenance or repair work.
14
Hydro-View IV User Guide HD0531 Rev 1.5.0
Chapter 1
Introduction
Ensure that only fuses of the correct type and rating are fitted.
Ensure that the Hydro-View is mounted in an environment that will not cause electrical
interference.
3.3
Explanation of Symbols and Markings
It is important to understand the meaning of the various symbols and markings on the HydroView equipment as follows:
Caution – risk of electric shock.
Caution – refer to accompanying documents.
3.4
Clearance Requirements
It is important to ensure that the Hydro-View has adequate clearance for ventilation and
access. The USB socket should be easily accessible.
The minimum clearance for the top and sides of the enclosure is 50mm. It may be necessary
to allow more space at the side to allow access to the USB socket.
3.5
IP Rating
When correctly integrated into a suitable enclosure, the front panel and touch screen are
designed to be rated to Ingression Protection (IP) rating IP66. This has the American
equivalent NEMA 4.
This IP/NEMA rating is only applicable if the unit is installed in accordance with the
mechanical mounting procedures detailed in Chapter 2 of this Document.
3.6
Environmental Conditions
The range of environmental conditions for which the equipment has been designed are:
3.7
•
Indoor Use Only
•
Altitude up to 2000m
•
Temperature 0°C to 50°C (32°F to 122°F)
•
Maximum relative humidity 80% for temperatures up to 31 °C decreasing linearly to
50% relative humidity at 50 °C
•
Pollution Degree 3 (Electrical Equipment in industrial or farming areas, untreated
rooms and Boiler rooms)
Lightning Strikes
Consideration should be given to protecting the installation from damage caused by lightning
and similar electrical disturbances.
Many installations will be in situations that are particularly 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).
Hydro-View IV User Guide HD0531 Rev 1.5.0 15
Introduction
Chapter 1
Precautions should be taken to avoid damage by lightning in areas where there is a known
risk.
It is recommended to install suitable lightning barriers to all conductors in the sensor
extension cable. Ideally, these would be fitted at both ends of this cable to protect the sensor,
the Hydro-View and any other equipment connected to it.
It is recommended to install the equipment using screened cables to the specification defined
in Chapter 3 Section 4.
3.8
Cleaning
The front panel of the Hydro-View should be cleaned with a soft cloth. Abrasive materials and
liquids must not be used.
Note: Do not direct a water jet at the unit.
4 Application Examples
The Hydro-View may be used to configure and monitor Hydronix sensors in a variety of
applications. It is possible to connect the Hydro-View to any of the current range of Hydronix
digital sensors. The specific choice of sensor will depend upon the requirements of the
application. Individual sensor user guides explain the full functionality of each sensor as well as
installation and calibration advice that will be relevant when using the Hydro-View.
Common applications are as follows:
4.1
Batch Averaging
A sensor is used to measure and record an average moisture % of a batch of material
released from a bin (silo) over a short period of time. The Hydro-View may be used to
configure the averaging parameters of the sensor including enabling the sensor to start and
stop averaging during the discharge period. The start and stop signal is given directly to the
sensor via a limit switch position on a gate or from a third party control system.
4.2
Mixing Applications
The Hydro-View may be used in conjunction with a Hydro-Mix or Hydro-Probe Orbiter sensor
to monitor a mixing process. The sensor is positioned within the mixer and the Hydro-View
may be used to display a graph of moisture over time. This is useful to identify the degree of
homogeneity in the material. Amongst other configurable parameters in the sensor the
Hydro-View may be used to configure high and low moisture level alarms.
4.3
Continuous Monitoring of Material
The Hydro-View may be used to configure and monitor a sensor in a continuous process with
the output from the sensor used by third party automation to control the process. Examples
are sensors positioned in screw conveyors or on belt conveyors. As with other applications
the Hydro-View may be used to configure filtering and smoothing parameters within the
sensor to achieve the best possible signal. The Hydro-View may be used to configure high
and low moisture level alarms. Refer to the sensor user guide.
For further information on any of the above please refer to the relevant sensor user guide.
16
Hydro-View IV User Guide HD0531 Rev 1.5.0
Chapter 2
Mechanical Installation
Figure 2: Rear view of the Hydro-View IV
1 Weight and Dimensions
Fascia:
145mm (W) x 104mm (H); (5.7” (W) x 4.1” (H))
Panel Cut Out:
128mm (W) x 94mm (H); (5.1” (W) x 3.7” (H))
Max Panel Thickness:
3mm
Depth:
41mm (1.6”)
Depth behind fascia:
35mm (1.4”)
Weight:
270g
NOTE:
Input / Output connections are made to the base so access needs to be allowed for the cables
and connectors.
A USB connection is available on the right hand side of the unit (viewed from the rear). Sufficient
space should be left to allow insertion of a USB memory stick, if required. A Panel Mount USB
Socket is available as an accessory.
A minimum of 50mm of space should be allowed around the unit for cooling air circulation.
Hydro-View IV User Guide HD0531 Rev 1.5.0 17
Mechanical Installation
Chapter 2
2 Mounting and installation
2.1
Panel Mounting
The unit can be mounted in a control panel (maximum thickness 3mm) using the mounting
bracket supplied. To fit the mounting bracket, locate the bracket holes over the four screws
on the rear of the Hydro-View and drop into place. Tighten the eight screws evenly against the
panel.
Figure 3: The Hydro-View mounting bracket
To install the Hydro-View
•
Cut out an aperture in the panel of the correct size. See Figure 4 for a template.
•
Remove the mounting bracket from the rear of the unit by lifting it upwards and then
unhooking it.
•
Insert the Hydro-View through the prepared hole.
•
Re-fit the mounting bracket to the unit and tighten the screws evenly to pull the fascia
towards the control panel.
Panel or Enclosure
Cut out for
Hydro-View IV
1
94 + 0 mm
1
128 + 0 mm
R 3mm
Figure 4: The panel cut-out for the Hydro-View IV
18
Hydro-View IV User Guide HD0531 Rev 1.5.0
Chapter 2
2.2
Mechanical Installation
Mounting with Hydronix Enclosure
If a suitable control panel or cabinet is not available, the Hydro-View may be mounted in the
Hydro-View Wall Mounted Enclosure (part number 2010). The Hydro-View is fitted inside the
enclosure as described in section 2.1. The cables supplied in the enclosure are connected to
the Hydro-View and tightened in place with their locking screws.
3 Operating Temperature
The unit has been designed to work in ambient air temperatures inside the cabinet of 0 – 50 °C
(32 – 122 °F).
Where ambient temperatures vary from this a temperature regulation system may need to be
installed.
4 Memory Card
A Mini SD card is installed in the right hand side of the unit. This should not be removed or
interfered with, as this could prevent the correct operation of the Hydro-View and will invalidate
the warranty.
Hydro-View IV User Guide HD0531 Rev 1.5.0 19
Mechanical Installation
20
Hydro-View IV User Guide HD0531 Rev 1.5.0
Chapter 2
Chapter 3
Electrical Installation
This chapter explains the configuration of the connectors on the Hydro-View unit and how the wiring
should be designed and installed. These connections will vary depending on the configuration and
integration requirements of the system design.
The supplied RS485 Adapter should be plugged into the 9-way D plug on the bottom of the unit, and
secured in place with the fixing screws.
Power Connector
RS485 Adaptor
Figure 5: Fitting the RS485 Adapter
1 Connector pin assignments
1.1
Power Connector
Pins
Name
Description
+
+24V DC
Positive Supply connection
-
0V
0V Supply connection
1.2
RS485 Adapter
Pins
Name
Description
A
RS485 A
RS485 A data line
B
RS485 B
RS485 B data line
Hydro-View IV User Guide HD0531 Rev 1.5.0 21
Electrical Installation
1.3
Chapter 3
Wiring Diagram
Hydro-View IV
(rear view)
+
-
A
B
Hydronix Sensor
RS485
G
(letters refer to
F
0V
B
pins on
MIL-SPEC
connector)
A
24V
Figure 6: Hydro-View Wiring Diagram
1.4
Wiring Diagram with Hydronix Enclosure
4-way
Terminal
Block
inside Hydronix Enclosure
+
-
A
B
Hydronix Sensor
RS485
G
(letters refer to
F
0V
B
pins on
MIL-SPEC
connector)
A
24V
Figure 7: Hydro-View Wiring Diagram (with Hydronix Enclosure)
Using a suitable cable gland, connect a cable into the Hydro-View enclosure and wire to the
four way terminal block in the bottom right hand corner as shown in Figure 7. The wires from
the top of the terminal block are then wired into the Hydro-View as shown in Figure 8.
Additionally, plug the USB cable into the USB port on the Hydro-View.
22
Hydro-View IV User Guide HD0531 Rev 1.5.0
Chapter 3
Electrical Installation
Hydro-View IV
(rear view)
+
-
A
B
Red / black twisted
pair from terminal
block
White
/
black
twisted pair from
terminal block
Figure 8: Hydronix Enclosure internal wiring
2 Power Supply
The unit uses 24v DC, with a nominal power rating of 7W excluding the sensors.
Minimum supply:
24v DC, 0.2A (5W)
Recommended supply:
Hydronix part number 0116
Important:
If power is being supplied to more than one sensor from the HydroView IV, a more appropriate, higher powered supply must be
specified.
3 Communications
3.1
RS485
The RS485 connection is used for communicating with Hydronix moisture sensors. It is
possible to update the material calibration, change operating parameters and carry out sensor
diagnostics from the Hydro-View.
3.2
RS485 Wiring Recommendations
The performance and reliability of a RS485 network can depend significantly on the quality
and design of the wiring used. See section 4.1 below for recommended wire specifications.
Hydro-View IV User Guide HD0531 Rev 1.5.0 23
Electrical Installation
Chapter 3
Ideally, sensors on a RS485 network should be connected in a daisy chain arrangement, as
shown here:
In practice, this arrangement is hard to achieve, so sensors may be wired using very short
stubs:
Although it may appear simpler,
wiring in a star configuration with
each sensor wired back to the
Hydro-View should be avoided.
4 Cables
4.1
Sensor cable
The sensor must be connected using an extension cable made up from a suitable length of
2
two pairs twisted (4 cores total) screened (shielded) cable with 22 AWG, 0.35mm 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 cables, must be screened and the screen must be
connected to earth at the sensor end only.
The cable from the sensor to the control unit must be distanced from any heavy equipment
and associated power cables, particularly the power cable mixers or bin gates. Failure to
separate the cables can lead to signal interference.
24
Hydro-View IV User Guide HD0531 Rev 1.5.0
Chapter 3
4.2
Electrical Installation
Analogue cables
The analogue cables should be of good quality screened cable. They should be distanced
from heavy equipment and power cables to avoid signal interference.
5 USB Port
The Hydro-View has one USB port built into the unit to enable backup, restore and upgrade of
the system and sensor logging functions. This accepts a standard USB memory stick of up to
4GBytes.
A panel mounting USB socket with an extension cable is available from Hydronix (Part Number
0175) to provide easier access to the USB socket. 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.
Hydro-View IV User Guide HD0531 Rev 1.5.0 25
Electrical Installation
26
Hydro-View IV User Guide HD0531 Rev 1.5.0
Chapter 3
Chapter 4
Configuration
1 Logging in as Engineer
Commissioning of a system is an advanced function and should be carried out by an engineer
with suitable knowledge of the site and application. In order to access all of the necessary
functions in the Hydro-View, the engineer should be logged into the Hydro-View with engineer
level permissions – see Chapter 5 Section 5. The engineer should also be familiar with the
functionality of the sensor that is to be connected to the Hydro-View IV.
2 Connecting Sensors
Up to 16 Hydronix sensors may be connected to the Hydro-View unit. Each needs to have a
unique address between 1 and 16.
All new sensors shipped by Hydronix are set to address 16. For this reason it is recommended to
connect sensors one at a time to the Hydro-View. When each sensor is connected its address
should be changed, as described in Chapter 5 Section 7.1. It is also recommended to change the
name of the sensor to represent its location or function within the system, as this simplifies fault
finding and makes the Hydro-View much simpler to use.
Sensors may be added to the system (or removed) at any time. The Hydro-View automatically
checks for additional sensors that have appeared, but note that it may take up to a minute for the
Hydro-View to find the new sensor.
3 Configuring Sensors
Each sensor should be configured appropriately for the class of application – see Chapter 4 for
possible applications and suitable settings for the sensors in each case. Chapter 5 Section 7
details all of the sensor setting options.
4 Configuring the System Settings
Once the sensors are installed and correctly configured, the Hydro-View can be set up to display
information relevant to the application.
The first System screen (Chapter 5 Section 6.1) allows the selection of the user interface
language, and the number of display areas on the Overview Screen. The time and date can also
be set on this screen.
The second System screen (Chapter 5 Section 6.2) allows a choice of a light, dark or standard
colour scheme. This may helpful in particularly dark or bright conditions or where the user has a
particular preference.
The third System screen (Chapter 5 Section 6.3) allows a backup and restore function. If the
Hydro-View is replacing an old unit, a backup from the old unit may be made and restored to the
new unit. This will copy all of the settings. Similarly if a number of Hydro-View units are being
installed in similar applications on one site, then using the backup / restore function may save
some time in setting up subsequent units.
Once the Hydro-View is configured, it is recommended that the access PIN codes are changed
to prevent inadvertent access and editing of the system. See Chapter 5 Section 5.
If the new PIN numbers are accidentally forgotten, Hydronix technical support can provide a 1day valid code to allow access to the system. When using this code, the PIN numbers should be
changed to a memorable number.
For security reasons, it is not advisable to use PIN codes used elsewhere (e.g. your bank PIN
number) as these are stored in the system database and may be accessible by Hydronix
technical support staff.
Hydro-View IV User Guide HD0531 Rev 1.5.0 27
Configuration
Chapter 4
5 Configuring the Overview Screen
The Overview screen (see Chapter 5 Section 6.1) can be configured to show 1, 2 or 4 display
areas – see Chapter 5 Section 3. Each of these display areas is configurable. It is possible to
select which sensor, which reading and whether this is shown numerically or graphically. A
graphical display can be configured to display different time periods and different vertical ranges.
See Chapter 5 Section 3.
Any combination is possible, so with four display areas selected it is possible to show four
readings from one sensor, one reading from four sensors, different readings from all four
sensors, or the same reading from the same sensor both numerically and graphically. The
selection of this setup is entirely down to site requirements and user preferences.
6 Calibrating the sensors
If the Hydro-View is to show true moisture (rather than the Unscaled reading) or the control
system an input from the sensor that corresponds to a moisture % then the sensors must be
calibrated to the material being measured. As each sensor may be installed in a different
manner, it is advised that each is individually calibrated even if they are measuring in similar
materials. For this reason, the Hydro-View does not allow Calibrations to be copied from one
sensor to another.
Detailed information regarding calibration and the calibration procedure is given in Chapter 6.
7 Upgrading the Hydro-View Firmware
From time to time Hydronix will issue updates to the Hydro-View Firmware. These may add new
features and functions to the product and are also designed to improve performance.
To upgrade the firmware, proceed as follows:
1.
2.
3.
4.
5.
Download the latest version of the Firmware HS0097 from www.hydronix.com.
This will be a .zip file, which should be extracted onto the root of a USB Memory stick.
Doing this should create a folder called HydroView_IV\Upgrade which contains a number
of files.
Turn off power to the Hydro-View and plug the memory stick into the USB socket on the
side of the Hydro-View, or into the USB Extension socket if this has been installed.
Turn power on again, and the Hydro-View will detect the Upgrade files and automatically
upgrade itself to the new version.
When the upgrade is complete and the Overview screen is shown, the USB Memory stick
may be removed.
Removal of the USB Memory stick before the upgrade is complete may
damage your Hydro-View and prevent it from starting up.
Removal of power to the Hydro-View before the upgrade is complete may
damage your Hydro-View and prevent it from starting up.
8 Backing up the System
Once the Hydro-View is fully configured and the sensors calibrated, it is advisable to carry out a
system backup (Chapter 5 Section 6.3) to keep a record of the configuration. This may be useful
should the unit fail and need to be replaced in the future. Note that only one backup may be
stored on a single USB memory stick, so a backup should be copied to a PC as soon as possible
to prevent it being over-written by another backup in the future. The name of the file should not
be changed if it is later to be used to restore a system. Using a suitable folder structure on the
PC will enable backups from a number of Hydro-View units to be stored
28
Hydro-View IV User Guide HD0531 Rev 1.5.0
Chapter 5
System Navigation
1 Screen Navigation
The Hydro-View is a touch screen device. Navigation of the system is achieved by touching on
the screen itself to activate relevant features. This must be done with a finger – tools such as
pens and screwdrivers will not work and may damage the surface of the screen.
Menu Tree
IO Status
Temperature
Backup /
Restore
System
Colour
Scheme
Factory
Settings
Temp.
Compensation
Digital Input /
Output
Analogue
Outputs
Backup /
Restore
Sensor
Identification
Select Sensor
Signal
Processing
IO Tests
Logging
Wizard 3
Logging
Wizard 2
Logging
Wizard 1
User Accounts
Main Menu
Edit Calibration
Calibrations
Logging
Remote
Averaging
Select Sensor
Display Setup
Edit Points
Edit Points
Graph
Averaging
Resonator
Calibration
Figure 9 below shows the entire menu structure of the Hydro-View IV. Certain screens are
only accessible to certain user levels.
Overview
1.1
Figure 9: Menu Structure
Hydro-View IV User Guide HD0531 Rev 1.5.0 29
System Navigation
1.2
Chapter 5
Applying Power
The Hydro-View starts up as soon as power is applied to it. The green light in the bottom right
hand corner of the bezel will illuminate and the screen starts with a Hydronix start-up screen
and progress indicator.
The unit is ready to use when the Overview Screen (Figure 11) is displayed.
1.3
Using the touch screen
Any areas on the screen that are white may be selected by touching them. Numeric values
are entered using the keypad that pops up with the entered text being shown in the box at the
top. Selections from multiple options appear in a list when a selection box is touched, with the
current value highlighted in white at the top and if this is selected then the selection box will
be cancelled.
1.4
Selecting your language
By default, the Hydro-View starts up in English. The language can be changed as shown
below, and once this has been chosen, the Hydro-View will always start in the new language.
30
Hydro-View IV User Guide HD0531 Rev 1.5.0
Chapter 5
System Navigation
Figure 10: Selecting the language
Hydro-View IV User Guide HD0531 Rev 1.5.0 31
System Navigation
Chapter 5
Access Levels and Permissions
1.5
The Hydro-View IV provides three User Access levels, each with different permissions. This
allows the system to be ‘locked down’ for the majority of users, allowing only approved users
to access the more in-depth system functionality.
If one of the functions described here is not available to you, this is most likely because you
are not logged in with sufficient permissions. The default PIN numbers for each user are given
in Appendix A and it is recommended that these are changed to prevent inadvertent access to
the system.
The table below shows the Access Levels and what is available to each user:

Available

Read Only

Not Available
Function
Operator
Supervisor
Engineer






Main Menu Screen



User Accounts Screen



System Screens



Sensor Screens



Calibration Screens



Logging Screens



Overview Screen
Display Setup Screen
32
Hydro-View IV User Guide HD0531 Rev 1.5.0
Chapter 5
System Navigation
2 The Overview Screen
The Overview Screen is the main screen used for displaying sensor information.
1
2
3
Figure 11: The Overview Screen
The Overview Screen may be configured to display 1, 2 or 4 ‘areas’ each of which may be
configured separately. The default display is one area, as shown in Figure 11. Each area may
be configured to display any reading from any sensor in the form of a trend graph or numeric
display. The layout for each area is arranged in a standard format:
1.
2.
3.
The name of the sensor being displayed in that screen area.
The name of the sensor reading being displayed.
The current value of the reading.
Touching anywhere on the Overview Screen will move to the Display Setup Screen. Touching
a particular area (e.g.: Top left) will access the setup for that area of the Overview Screen.
The number of areas shown on the Overview Screen is configured in the System Screen
(Figure 15).
Hydro-View IV User Guide HD0531 Rev 1.5.0 33
System Navigation
Chapter 5
3 Display Setup Screen
Operator

Supervisor

Engineer

The Display Setup Screen configures the selected area of the Overview Screen. Touch one of
the screen areas on the Overview Screen, and the Display Setup Screen appears to configure
that area.
Figure 12: The Display Setup Screen
Sensor Name shows which sensor is currently displayed. Touch to select a different sensor if
connected.
Sensor Cal. shows the calibration currently in the selected sensor, if this is recognised by the
Hydro-View. Touch to change the calibration to another valid calibration for this sensor.
Display Variable shows which parameter from the sensor is displayed. Touch to change.
Show Graph - check this box to show a graph on the Overview Screen. If this is not checked,
then the display will be numeric.
Graph Length - If a graph is selected, this value shows the time period displayed (X axis).
Graph Height - If a graph is selected, this determines the maximum sensor parameter value
shown on the graph (Y axis).
Overview - Returns to the Overview Screen.
Menu - Accesses the Main Menu.
34
Hydro-View IV User Guide HD0531 Rev 1.5.0
Chapter 5
System Navigation
4 Main Menu Screen
Operator

Supervisor

Engineer

The Main Menu Screen accesses all other parts of the system. Different options will be
enabled depending on the access level currently logged in. If no sensors have been found,
then Sensor, Calibration and Logging will be disabled, regardless of the access level.
Figure 13: The Main Menu Screen
Overview - Returns to the Overview Screen (Section 2)
System - Accesses the System Setup Screens (Section 6)
Sensor - Accesses the Sensor Setup Screens (Section 7)
Calibration - Accesses the Material Calibration Screens (Section 8)
User Accounts - Accesses the User Accounts Screen (Section 5)
Logging - Accesses the Sensor Logging Screen (Section 9)
Hydro-View IV User Guide HD0531 Rev 1.5.0 35
System Navigation
Chapter 5
5 User Accounts Screen
Operator

Supervisor

Engineer

The User Accounts Screen allows users to ‘log in’ to the Hydro-View with different
permissions levels. After completing operations as Supervisor or Engineer it is advisable to
log out to prevent inadvertent access and changes to the system setup. It is necessary to log
out as one user before logging in as a different user. By default the permissions are set to
Plant Operator.
Default PIN numbers are given in Appendix A. For added security, it is advisable to change
these as soon as the system is commissioned. In the event that a PIN is changed and is
subsequently forgotten, contact Hydronix Support for further assistance.
Figure 14: The User Accounts Screen
Current User shows which User is currently logged in.
Log In - Log into Hydro-View with Supervisor level permissions. Enter the 4-digit PIN when the
keypad appears. If successful, the Log Out and Edit PIN buttons become active. If the wrong PIN
is entered, the system remains logged out.
Log Out - Log out Supervisor.
Edit PIN - Edit Supervisor PIN number. Enter a new 4-digit PIN when keypad appears. When
prompted, confirm that the correct PIN has been entered.
Log In - Log into Hydro-View with Engineer level permissions. Enter the 4-digit PIN when the
keypad appears. If successful, the Log Out and Edit PIN buttons become active. If the wrong PIN
is entered, the system remains logged out.
Log Out - Log out Engineer.
Edit PIN - Edit Engineer PIN number. Enter a new 4-digit PIN when keypad appears. When
prompted, confirm that the correct PIN has been entered.
Menu returns to Main Menu
36
Hydro-View IV User Guide HD0531 Rev 1.5.0
Chapter 5
System Navigation
6 System Screens
There are three System Setup screens which allow the user to configure the user interface of
the Hydro-View. Each screen requires different access permission levels.
6.1
System Screen 1 of 3
Operator

Supervisor

Engineer

Figure 15: The First System Screen
Version - The current firmware version of the Hydro-View IV.
Serial Number - The Serial number of the Hydro-View IV.
Language - The current User Interface language. Touch to change.
Overview Display - The number of display areas on the Overview Screen. Touch to change.
IP Address - The IP Address of the Hydro-View if an Ethernet network cable is connected.
Date and Time - Current date and time. Touch to set this correctly.
Next - Accesses the Second System Screen.
Menu - Returns to Main Menu
Hydro-View IV User Guide HD0531 Rev 1.5.0 37
System Navigation
6.2
Chapter 5
System Screen 2 of 3
Operator

Supervisor

Engineer

Figure 16: The Second System Screen
Light - Select Light, Standard or Dark colour scheme.
Next - Accesses the Third System Screen.
Menu - Returns to Main Menu
6.3
System Screen 3 of 3
Operator

Supervisor

Engineer

Figure 17: The Third System Screen
Backup - Backups up or “Saves” the System Settings and Calibrations to a USB memory
stick. Only one System Backup can be stored on a memory stick, so this overwrites any
previous backups.
Restore - Restores the System Settings and Calibrations from a USB memory stick. This can
be used to recover a Hydro-View that has had its settings changed, or to copy the settings
from one unit to another. All settings are overwritten in the unit, and cannot be recovered after
a Restore operation.
Next - Accesses the First System Screen.
Menu - Returns to Main Menu
38
Hydro-View IV User Guide HD0531 Rev 1.5.0
Chapter 5
System Navigation
7 Sensor Screens
Operator

Supervisor

Engineer

A sequence of 10 screens allows the configuration and diagnosis of any attached sensor. When
the Sensor button on the Main Menu is touched, a list of the connected sensors appears. Select
the sensor to configure to access the Sensor Setup screens.
Any changes made to the sensor settings are automatically written to the sensor. These are
committed to the sensors flash memory when the Sensor Screens are exited, so that they are
retained if the sensor is turned off.
7.1
Sensor Identification Screen
Figure 18: Sensor Identification Screen
Sensor Name – The Name of the sensor. It is helpful to name the sensor to describe its
function or location within the system. Touch the box for an Alpha-Numeric keyboard to enter
a new name.
Address - The address of the sensor on the RS485 network. Touch to change.
Checksum - The checksum of the firmware currently in the sensor. This is used for support
purposes only.
ID - The unique hardware identity of the sensor.
Firmware - The version of firmware currently in the sensor.
Next - Accesses the Second System Screen.
Menu - Returns to the Main Menu.
Hydro-View IV User Guide HD0531 Rev 1.5.0 39
System Navigation
7.2
Chapter 5
Sensor Backup / Restore Screen
This screen is used to back up or restore all sensor settings.
Figure 19: Sensor Backup / Restore Screen
Backup - Backup all of the sensors settings to a USB memory stick. Enter a file name when
prompted. This file is stored on the USB stick in a folder \HydroView_IV\BackUpFiles\ in a
format compatible with Hydro-Com, the Hydronix PC based sensor configuration and
calibration software.
Restore - The sensors settings may be restored from a Hydro-Com compatible backup file.
This file must be on a USB memory stick in the folder \HydroView_IV\BackUpFiles\. The file
should then be selected from a list of possible files. Restoring a sensor will overwrite all of its
settings.
Upgrade - Upgrade the Sensor firmware. The upgrade is carried out from a Hydro-Com
compatible upgrade file (downloadable from www.hydronix.com). This file must be unzipped
and placed on a USB memory stick in a folder \HydroView_IV\FirmwareFiles\. The file can
then be selected from a list.
Next - Accesses the Sensor Analogue Outputs Screen.
Menu - Returns to the Main Menu
7.3
Analogue Outputs Screen
The working range of the current loop outputs can be configured to suit the equipment to
which it is connected. The analogue output is normally configured to be proportional to the
percentage moisture reading. However it is possible to make the analogue output represent
other types of output variables which are selectable from the O/P Variable 1 and O/P Variable
2 options.
Figure 20: Analogue Outputs Screen
40
Hydro-View IV User Guide HD0531 Rev 1.5.0
Chapter 5
System Navigation
Output Type: (touch to select)
0-20mA
This is the factory default. The addition of an external 500R
precision resistor converts to 0 – 10 V
4-20mA
This is a standard 4 – 20 mA output
Compatibility
This mode produces an analogue current with an inverted
exponential characteristic that is compatible with earlier
analogue versions of the Hydronix moisture sensors (HydroProbe and Hydro-Mix IV). A 500 R precision resistor is
required to convert to voltage. This configuration must ONLY
be used with a Hydro-Control IV or a Hydro-View II.
Output 1 Variable: (touch to select)
Select which measurement is to be output on Current Loop 1.
Raw Moisture
This is scaled from the 'Raw Unscaled' variable using the A,
B, C and SSD coefficients. It is not recommended to use
Raw measurements as they may disrupt system control due
to excessive noise.
Filtered Moisture
This is scaled from the 'Filtered Unscaled' variable using the
A, B, C and SSD coefficients. Recommended output for
Continuous Control applications when an absolute moisture
reading is required.
Average Moisture
This is scaled from the 'Average Unscaled' variable using
the A, B, C and SSD coefficients. Recommended output for
Batch Averaging applications when absolute moisture is
required.
Raw Unscaled
This is a reading between 0 (Air) and 100 (Water) from
which absolute moisture may be calculated. It is not
recommended to use Raw measurements as they may
disrupt system control due to excessive noise.
Filtered Unscaled
This is the 'Raw Unscaled' variable which has been
processed using the filtering parameters in the Signal
Processing screen. Recommended output for Continuous
Control applications when an absolute moisture reading is
not required.
Average Unscaled
This is the 'Raw Unscaled' reading processed for batch
averaging using the parameters in the Averaging screen.
Recommended output for Batch Averaging applications
when absolute moisture is not required.
Remote Value
Allows a value for the analogue output to be sent of the
RS485 communications port, for example for repeating an
internal process variable in a control system.
Hydro-View IV User Guide HD0531 Rev 1.5.0 41
System Navigation
Chapter 5
Temperature
Outputs the temperature of the Material being measured as
reported by the sensor with a fixed scaling of 0 – 100oC.
Raw Unscaled 2
This is a second Raw Unscaled reading supported by some
sensors. Raw Unscaled 2 may be calculated using a
different Measurement Mode from Raw Unscaled 1. It is not
recommended to use Raw measurements as they may
disrupt system control due to excessive noise.
Filtered Unscaled 2
This is the 'Raw Unscaled 2' variable which has been
processed using the filtering parameters in the Signal
Processing screen.
Brix
(Applies to Hydro-Probe SE sensors only). This is scaled
from the 'Filtered Unscaled' variable using the A, B, C and D
Brix coefficients for measurements in sugar based materials.
Output 2 Variable - (touch to select) For sensors with two current loop outputs, select which
measurement is to be output on Current Loop 2. Options are the same as for Current Loop 1.
High % - The high scale for Moisture output. This is the percentage Moisture represented by
20mA output current.
Low % - The low scale for Moisture output. This is the percentage Moisture represented by
0mA (or 4mA) output current.
Next - Accesses the System Screen.
Menu - Returns to the Main Menu
7.4
Digital Inputs / Outputs Screen
The sensors have one digital input and one digital input / output. These may be configured for
a number of different uses.
Figure 21: Digital Inputs / Outputs Screen
42
Hydro-View IV User Guide HD0531 Rev 1.5.0
Chapter 5
System Navigation
I/P 1 Use - The current use of Input 1. Touch to change:
Unused
The digital input is ignored.
Average / Hold
Input is used to control the start and stop period for batch
averaging. When the input signal is activated (+24 VDC),
the ‘Raw’ values (unscaled and moisture) start to average
(after a delay period set by the 'Average/Hold Delay'
parameter). When the input is then deactivated (0V),
averaging is stopped and the average value is held constant
so that it can be read by the batch controller PLC. When the
input signal is activated once again the average value is
reset and averaging commences. This is the recommended
setting to use in a Batch Averaging application.
Moisture / Temp
This allows the user to switch the analogue output between
the normal moisture variable and temperature. This is useful
when the temperature is required whilst still using only one
analogue output. With the input low the analogue output will
indicate the appropriate moisture variable (unscaled or
moisture %). When the input is activated the analogue
output will indicate the temperature (in degrees centigrade).
Note that for the Hydro-Probe Orbiter, Hydro-Mix VII and
Hydro-Probe SE this will be the material temperature. For
the Hydro-Probe II and Hydro-Mix V and VI sensors this
temperature will be the resonator temperature.
I/P 2 Use - The current use of Input / Output 2. Touch to change:
Unused
The digital input is ignored.
Moisture / Temp
This allows the user to switch the analogue output between the
normal moisture variable and temperature. This is useful when the
temperature is required whilst still using only one analogue output.
With the input low the analogue output will indicate the appropriate
moisture variable (unscaled or moisture%). When the input is
activated the analogue output will indicate the temperature (in
degrees centigrade). Note that for the Hydro-Probe Orbiter, HydroMix VII and Hydro-Probe SE this will be the material temperature.
For the Hydro-Probe II and Hydro-Mix V and VI sensors this
temperature will be the resonator temperature.
Bin Empty
The sensor output is activated to indicate that the probe is in air,
and can be used to indicate a material bin / silo is empty. It is
activated when the signals (moisture% or unscaled) drop below the
low limit parameters in the averaging frame. This may be used in a
Continuous Control application. To only use the moisture % value
set the unscaled low limit to zero.
(output)
Data Invalid
(output)
The output is activated to indicate that the sensor reading
(moisture% and/or unscaled) is outside the valid range set by 'Low
Limit' and 'High Limit' parameters in the averaging frame. This
would typically be used on a conveyor application to signal material
too wet or too dry.
Hydro-View IV User Guide HD0531 Rev 1.5.0 43
System Navigation
Chapter 5
Probe OK
(output)
Arm Type - The current type of arm fitted if the sensor is a Hydro-Probe Orbiter. Touch to
change.
Test I/O - Accesses the I/O Test Screen.
Next - Accesses the Sensor Averaging Screen.
Menu - Returns to the Main Menu
7.5
I/O Test Screen
The I/O Test screen provides a method of testing the I/O, to ensure that the sensor is
correctly connected to the control system. Be aware that if the control system is running,
manually adjusting the I/O may have unexpected consequences.
Figure 22: I/O Test Screen
1: - Slider for testing Analogue Output 1. Current mA value is displayed in the box.
2: - Slider for testing Analogue Output 2 (not available on all sensor models). Current mA
value is displayed in the box.
Digital In 1 - Light indicates the status of Digital Input 1. Red for active (24V applied); White
for inactive.
Digital I/O 2 - Light indicates the status of Digital Input / Output 2 when this is configured to
be used as an input. When this is configured to be used as an output only, an ON / OFF
button allows the output to be set.
4mA - Pre-defined current output setting for Output 1. Toggles in the sequence:
•
0mA, 4mA, 12mA, 20mA
4mA - Pre-defined current output setting for Output 2 if fitted. Toggles in the sequence:
•
0mA, 4mA, 12mA, 20mA
OK - Completes the test and closes this screen.
44
Hydro-View IV User Guide HD0531 Rev 1.5.0
Chapter 5
7.6
System Navigation
Sensor Averaging Screen
The Sensor Averaging Screen is used to configure sensor alarms and averaging parameters.
Figure 23: Averaging Screen
Average / Hold Delay - Shows the current Average / Hold Delay. Touch to change.
When using the sensor to measure the moisture content of a material that is discharged from
a bin or silo, there is frequently a short delay between the control signal issued to begin the
batch and the material beginning to flow over the sensor. Moisture readings during this time
should be excluded from the batch average value as they are likely to be an unrepresentative
static measurement. The ‘Average/Hold’ delay value sets the duration of this initial exclusion
period. For most applications 0.5 seconds will be adequate but it may be desirable to
increase this value.
Options are: 0, 0.5, 1.0, 1.5, 2.0, 5.0 seconds
Moisture High - Shows the current Moisture High value. Touch to change.
The upper limit of Moisture values that will be included in the average calculation. If this value
is exceeded, the Data Invalid output is set (if selected).
Moisture Low - Shows the current Moisture Low value. Touch to change.
The lower limit of Moisture values that will be included in the average calculation. If the
moisture falls below this value, the Data Invalid output will be set (if selected) and the Bin
Empty output will be set (if selected).
Unscaled High - Shows the current Unscaled High value. Touch to change.
The upper limit of the Unscaled reading that will be included in the average calculation. If this
value is exceeded, the Data Invalid output is set (if selected). Leave set to 100 if just an alarm
based on the moisture % value is required.
Unscaled Low - Shows the current Unscaled Low value. Touch to change.
The lower limit of the Unscaled reading that will be included in the average calculation. If
Unscaled falls below this value, the Data Invalid output will be set (if selected) and the Bin
Empty output will be set (if selected).
Leave set to 0 if just an alarm based on the moisture % value is required.
Averaging Mode- Selects the sensor output mode used for averaging during calibration.
Selectable between Raw and Filtered. Note that this option is only available when a Hydronix
sensor with firmware version HS0089 v1.09 or higher is connected. Raw should be selected
for most applications. Filtered is suitable for mixer applications where the signal is very noisy,
Contact Hydronix for advice in this instance.
Next - Accesses the Sensor Calibration screen.
Menu - Returns to the Main Menu.
Hydro-View IV User Guide HD0531 Rev 1.5.0 45
System Navigation
7.7
Chapter 5
Sensor Calibration Screen
Figure 24: Calibration Screen
A, B, C, D - The current A, B, C and D coefficients used in the Material calibration. These may
be edited on this screen, but it is advisable to use the built in Calibration functions to ensure
an accurate material calibration is achieved. For a Moisture sensor, the Material calibration
formula is:
2
Moisture = A x Unscaled + B x Unscaled + C - D
The D coefficient is the Water Absorption Value (WAV) or Surface Saturated Dry (SSD)
property of the material, available from the material supplier.
For a sensor capable of being calibrated to a measurement of Brix instead of moisture, the
Brix calibration formula is:
C x Unscaled
Brix = A – B x e
2
+ D x Unscaled
Calibration - Accesses the Calibration Screen – the recommended method of adjusting the
Calibration coefficients.
Next - Accesses the Signal Processing Screen.
Menu - Returns to the Main Menu.
46
Hydro-View IV User Guide HD0531 Rev 1.5.0
Chapter 5
7.8
System Navigation
Signal Processing Screen
The sensors include a number of filtering options to remove noise from the signal. Each has a
particular function as described below. The filters should be used in a combination to remove
as much noise from the signal as possible, without reducing the response to changes in
moisture content. For complex applications data may be logged and an external programme
used to optimise these parameters.
Figure 25: Signal Processing Screen
Filtering Time - This shows the current smoothing time applied to the signal. Touch to
change. This is useful when there is a lot of noise or variation in the signal. Standard times
are 0, 1, 2.5, 5, 7.5 and 10 seconds.
Slew Rate + - This shows the current Positive Slew Rate filter setting. Touch to change. This
filter sets the rate limit for large positive changes in the ‘raw’ signal. This is helpful in
applications where inherent irregularities in the signal would tend to make it unstable, for
example a mixer floor sensor where blades are regularly passing the sensor face. The options
are: None, Light, Medium and Heavy.
Slew Rate - : - This shows the current Negative Slew Rate filter setting. Touch to change.
This filter sets the rate limit for large negative changes in the ‘raw’ signal. This is helpful in
applications where inherent irregularities in the signal would tend to make it unstable, for
example a mixer floor sensor where blades are regularly passing the sensor face. The options
are: None, Light, Medium and Heavy.
DSP Filter - For sensors which support this option, this shows the current setting of the Digital
Signal Processing Filter. Touch to change. After the slew rate filters the signal is passed
through a digital filter which uses a special algorithm to filter out the noise. There are six
settings for the digital filter: Unused, Very Light, Light, Medium, Heavy and Very Heavy.
Unscaled 1 - For sensors which support this option, this shows the current measurement
mode used to calculate the Unscaled 1 reading. Touch to change. In most cases, Standard
Mode works extremely well. For further details of the Measurement Modes, refer to the
Sensor User Guide.
Unscaled 2 - For sensors which support this option, this shows the current measurement
mode used to calculate the Unscaled 2 reading. Touch to change. In most cases, Standard
Mode works extremely well. For further details of the Measurement Modes, refer to the
Sensor User Guide.
Next - Accesses the Temperature Compensation screen.
Menu - Returns to the Main Menu.
Hydro-View IV User Guide HD0531 Rev 1.5.0 47
System Navigation
7.9
Chapter 5
Temperature Compensation Screen
These settings should not be changed unless advised to do so by a Hydronix
trained engineer.
Figure 26: Temperature Compensation Screen
Hydronix sensors include temperature compensation algorithms to provide a consistent
reading over a wide temperature range. These coefficients are used to carry out the
calculations and are set in the factory, individually to each sensor. These should not normally
be changed.
Next - Accesses the Factory Settings Screen.
Menu - Returns to the Main Menu.
7.10 Factory Settings Screen
The sensor user manual should be read and understood before attempting to
change these parameters.
Figure 27: Factory Settings Screen
Water/Air - These show the Air and Water points used to calculate the Unscaled readings.
These are set in the factory and should not be manually entered.
Auto Cal – Applicable only to the Hydro-Probe Orbiter and the Hydro-Mix VII sensors.
Touching the Auto Cal button starts the Auto Cal sequence. See the sensor user manual for
further information.
48
Hydro-View IV User Guide HD0531 Rev 1.5.0
Chapter 5
System Navigation
Water - Starts a Water calibration measurement. Ensure that the sensors measurement face
is immersed in water (ideally with 0.5% salt by weight) and is free from other obstructions.
Touch the Water button. The sensor then takes a number of readings to establish an accurate
reference point in water.
Air - Starts an Air calibration measurement. Ensure that the sensors measurement face is in
air, is clean, dry and free from other obstructions. Touch the Air button. The sensor then takes
a number of readings to establish an accurate reference point in air.
Reset – This will reset the sensor to the factory settings that are stored in the sensors
memory. This will only work with sensor firmware HS0089 v1.09 and above. This option will
not be available if the sensor does not have the correct firmware installed.
Next - Accesses the Temperature Screen.
Menu - Returns to the Main Menu.
7.11 Temperature Screen
Figure 28: Temperature Screen
Electronics / Resonator / Material - These show the current temperatures being measured
by the sensor. Depending on the sensor type not all measurement may be available. These
may be higher than the current air temperature due to internal heating of the electronics.
Max / Min - These show the maximum and minimum temperatures experienced by the
internal electronics.
Next - Accesses the IO Status Screen.
Menu - Returns to the Main Menu.
7.12 IO Status Screen
Figure 29: IO Status Screen
Data Invalid - Shows red if the current Moisture or Unscaled readings are outside of the
Average include ranges set on the Averaging screen.
Hydro-View IV User Guide HD0531 Rev 1.5.0 49
System Navigation
Chapter 5
Digital In 1 - Shows red if the Digital Input 1 is active.
Digital I/O 2 - Shows red if the Digital Input 2 is active.
o
Too Cold - Shows red if the sensor is currently below 0 C, which could indicate that moisture
readings are not reliable.
Too Hot - Shows red if the sensor is too hot, which could be causing damage to the internal
electronics.
Comms Reliability - Indicates the reliability of the communications with the sensor since the
Hydro-View was turned on. A value above 95% is expected, and values significantly below
90% should be investigated as this may indicate a problem with the plant wiring which could
cause errors or missed readings.
Next - Accesses the Resonator Screen.
Menu - Returns to the Main Menu.
7.13 Resonator Screen
This screen contains advanced sensor diagnostic information that may be of use to Hydronix support
personnel.
Figure 30: Resonator Screen
Graph - This shows the live resonator response from the sensor.
Compensated Frequency - This shows the live temperature compensated frequency
measured by the sensor.
Compensated Amplitude - This shows the live temperature compensated amplitude
measured by the sensor.
Next - Accesses the Sensor Identification screen (first in the sequence).
Menu - Returns to the Main Menu.
50
Hydro-View IV User Guide HD0531 Rev 1.5.0
Chapter 5
System Navigation
8 Calibration Screens
Operator

Supervisor

Engineer

Full details of the Material Calibration process are given in Chapter 6. This section explains the
navigation through the screens. When the Calibration button on the Main Menu is touched, a list
of the connected sensors appears. Select the sensor to calibrate to access the Calibration
screens.
8.1
Calibration List Screen
Figure 31: Calibration List Screen
Sensor Cal - Shows the name of the calibration currently in the selected sensor, if this is
stored in the Hydro-View and is recognised.
A list of all of the available Calibrations are displayed for the selected sensor. The list
automatically scrolls if there are more Calibrations than fit on the screen.
Scroll Up and Down buttons navigate the list of sensors. A Calibration can also be selected by
touching its name in the list.
New Cal. - Creates a new Calibration for the selected sensor. A maximum of 10 Calibrations
is allowed per sensor. If there are already 10 Calibrations, delete an existing one before
creating a new one. Touching this button creates a new Calibration and opens the Edit
screen.
Delete Cal. - Deletes the selected Calibration from the Hydro-View. This does not affect the
Calibration coefficients inside the sensor.
Edit Cal. - Shows the Edit Calibration Screen for the selected Calibration.
Save to File - Saves all of the Calibrations in the Hydro-View to a text file on a USB Memory
stick.
Write to Sensor - Writes the coefficients for the currently selected Calibration to the sensor.
Menu - Returns to the Main Menu.
Hydro-View IV User Guide HD0531 Rev 1.5.0 51
System Navigation
8.2
Chapter 5
Edit Calibration Screen
Figure 32: Edit Calibration Screen
Name - Shows the name given to this Calibration. Touch to edit.
Calibration Type - Shows the type of best fit line that is used for this Calibration.
Calibration Type
Application
Linear
Best option for the majority of materials,
including sands and aggregates.
Quadratic
May be more suitable for certain organic
materials.
Brix
Only available for sensors which measure
Brix and should be used to calibrate a Brix
measurement of dissolved solids in a sugar
solution.
Tolerance- Shows the Tolerance associated with this Calibration. Data points that are greater
than the tolerance from the best fit line are highlighted in red on the graph screen to assist in
identifying good and bad points. Touch to change.
Calibration Rules - Shows the Calibration Rules selected for the Calibration. Selecting the
correct rules for the application material can assist with creating an accurate Calibration,
particularly if only a limited number of sample points are available. Touch to select from None
or Aggregates. More information about calibration rules can be found in Chapter 6 Section
2.4.
A,B,C Coefficients - Shows the A, B and C coefficients calculated by the best fit algorithm for
the entered points. These values are changed by entering Unscaled and Moisture sample
points on the Edit Calibration Points screen.
For a Moisture sensor, the Material calibration formula is:
2
Moisture = A x Unscaled + B x Unscaled + C - D
For a Brix sensor, the Material calibration formula is:
C x Unscaled
Brix = A – B x e
52
Hydro-View IV User Guide HD0531 Rev 1.5.0
2
+ D x Unscaled
Chapter 5
System Navigation
The D coefficient is the SSD (Saturated Surface Dry) or Water Absorption Value (WAV)
property of the material, available from the material supplier, and should be entered here
before any sample points are entered if this is to be used in the Calibration. Touch to edit.
Edit Points - Accesses the Edit Calibration points Screen.
Cancel - Cancels the edit of the Calibration.
OK - Accepts the edit of the Calibration, and copies the changes to the Hydro-View database.
8.3
Edit Points Screen
Figure 33: Edit Calibration Points Screen
The main screen shows a list of the points currently used in the Calibration. Touch either the
Unscaled or Moisture box to edit the value. Touch the Include tick box to include / exclude the
point from the calculation of the coefficients. Excluded points are not shown on the graph. A
line highlighted in red indicates that data is missing, either because an Unscaled reading has
been taken from the sensor and is awaiting a laboratory moisture reading, or because it is the
blank line for a new point. Points with missing data are not included on the calculation of the
coefficients. A maximum of 20 points is allowed per calibration. A blank line is always present
at the bottom of the list for entering new points.
Scroll Up and Down buttons to navigate the list of points. The list automatically scrolls if there
are more points than fit on the screen.
Del. Point - Deletes the currently highlighted point from the Calibration.
Averaging - Accesses the Remote Averaging Screen to obtain a representative material
sample reading from the sensor. Particularly important in a Batch Averaging application.
Show Graph - Shows the list of points on a graph to assist with choosing the best points for a
good Calibration.
Cancel - Cancels the edit of the Calibration points.
OK - Accepts the edit of the Calibration points.
Hydro-View IV User Guide HD0531 Rev 1.5.0 53
System Navigation
Chapter 5
Edit Points Graph Screen
8.4
6
1
2
7
3
4
5
Figure 34: Edit Calibration Points Graph Screen
1.
2.
3.
4.
5.
6.
7.
The ‘best fit’ line calculated from the currently included data points is shown in black.
The Calibration limit lines are shown in red if Calibration Rules are enabled.
A point that is further from the ‘best fit’ line than the Tolerance allows is indicated in
red.
The point currently highlighted in the list is indicated by a circle.
The calibration line currently in the sensor is shown in grey.
Show List - Returns to the List view of the points.
Left and Right scroll buttons move the point selection up and down the graph. This
enables an out of tolerance point to be identified in the list view. When returning to the
List view, the selected point is highlighted in the list.
Remote Averaging Screen
8.5
The Remote Averaging function is a convenient way to obtain an averaged reading of a
material as it passes the sensor. This is particularly important in batch Averaging applications.
Remote Averaging works in two different ways, depending on the setting of the sensor’s
Digital Input.
8.5.1
Digital Input set for Average / Hold (typical Batch Average application)
With the Digital Input set for Average / Hold a warning is displayed that Averaging will be
automatic. Touching Yes will show the Averaging pop-up screen. This carries out the
Averaging function when the Average / Hold input is switched to active. When the input
returns to inactive a message is displayed giving the option to add a new point to the
Calibration. If a valid sample has been taken for a Laboratory measurement, then touch
Yes. A new point is added to the list and highlighted in red. Once a Laboratory test result
for the relevant batch is complete, the true moisture value can be entered into the
corresponding moisture value box.
54
Hydro-View IV User Guide HD0531 Rev 1.5.0
Chapter 5
System Navigation
Input
goes
active
Input
goes
inactive
Figure 35: Remote Averaging (Input set for Average / Hold)
The average unscaled reading is retained until the next averaging period begins. A new
Averaging process will start next time the input is switched to active..
When collecting samples it is important not to activate the Average/Hold input for longer
than the delay time when doing fine dosing or “jogging”.
8.5.2
Digital Input not set for Average / Hold
In this mode, the averaging is started and stopped manually. The timing of this must be
coordinated with the gathering of material samples for Laboratory tests.
Touch Start when the sample collection starts and touch Stop when collection ceases.
When averaging completes, a message is displayed giving the option of adding a new
point to the Calibration. If a valid sample has been taken for a Laboratory measurement,
then touch Yes. A new point is added to the list and highlighted in red. Once a Laboratory
test result for the relevant batch is complete, the true moisture value can be entered into
the corresponding moisture value box.
Figure 36: Remote Averaging (Input not set for Average / Hold)
Hydro-View IV User Guide HD0531 Rev 1.5.0 55
System Navigation
Chapter 5
9 Logging Screens
Operator

Supervisor

Engineer

The logging function enables the recording of sensor readings over a period of time. This may be
useful for commissioning and optimising a system, including choosing the correct filter settings
for the sensor. Data is logged directly to a USB stick, which should remain connected to the
Hydro-View throughout the logging process. Once logging is started, the logging screen can be
exited and other functions carried out, with logging running continuously in the background.
Operations that require a large amount of communications with the sensor may cause gaps in
the logged data, so these should be avoided.
Figure 37: Logging Screen
Setup Logging - Starts the Logging Setup Wizard to configure logging.
Start - Starts recording data from the sensor, once the log is configured.
Stop - Stops recording data.
Menu - Returns to the Main Menu.
To being the logging process start by selecting “Setup Logging”.
Figure 38: Logging Wizard Page 1
Filename for storing logged data. Touch to edit.
OK - Accepts the filename and moves to the second screen.
Cancel - Cancels the Logging Setup process.
56
Hydro-View IV User Guide HD0531 Rev 1.5.0
Chapter 5
System Navigation
Figure 39: Logging Wizard Page 2
This screen shows a list of available sensors. Touch the check box for those to be logged.
Next - Moves to the third screen.
Figure 40: Logging Wizard Page 3
Interval - Shows the interval between samples. Touch to change.
Variable - Shows the reading from the sensor that will be logged. Touch to change.
Incl. Unscaled 2 - If checked, the Unscaled 2 will be added to the log (where supported).
Incl. Temperature - If checked, temperature readings will be added to the log
Only Log when Averaging - If checked, data will only be added to the log file when
Averaging is in progress. Requires Digital Input to be set as Average / Hold, otherwise nothing
will be logged. This feature is useful in Batch Averaging applications for recording the material
when it is flowing, without recording large amounts of data when it is not. A Batch Average
reading is added to the log file at the end of each batch. When logging using this option a new
batch will be recorded each time the average / hold input is activated. If this input is triggered
by a limit switch positioned on the bin (silo) gate a new batch will be recorded. If the gate is
opened between batches for weight correction purposes this will be recorded on multiple
batches is quick succession.
OK - Accepts the settings and returns to the Logging Screen.
Due to the available communications ‘bandwidth’, it may not be possible to log with all of the
options that have been selected. This occurs if too much data is requested from too many
sensors too frequently. In this case, a warning will appear and the wizard should be run again,
selecting either fewer sensors, less data or a longer interval between logs.
Hydro-View IV User Guide HD0531 Rev 1.5.0 57
System Navigation
58
Hydro-View IV User Guide HD0531 Rev 1.5.0
Chapter 5
Chapter 6
Material Calibration
1 Introduction to Material Calibration
For applications where a moisture value is required to be directly output from a sensor, the
sensor will require calibrating to the material that is to be measured.
The Hydro-View calibration screens are used to enter unscaled values and corresponding
moisture values derived from taking and drying samples. This process is intended for use with
sensors measuring in flowing materials, such as in bins or on conveyor belts. The calibration
procedure for mixer applications where water is added under controlled conditions for the
moisture to reach a specified value is performed by the mixer control system or the HydroControl VI.
Each material has its own unique electrical characteristic. The raw output of a Hydronix sensor
is an unscaled value ranging from 0 to 100. Each sensor is set so that a zero (0) unscaled value
relates to the measurement in air and 100 relates to water. The unscaled reading for example
from a sensor measuring fine sand at 10% moisture content will be different from the unscaled
reading (from the same sensor) when measuring coarse sand at 10% moisture content. For
highest accuracy it is necessary to ‘calibrate’ the sensors for different materials. A calibration
simply correlates the unscaled reading to ‘real’ moisture values which are to be determined in the
laboratory using a method called ‘bake-out’ or ‘desiccation’ test.
Moisture
20
vs
Unscaled
=
Calculated
moisture from
calibration
0%
0
Measured
point
calibration
100
The range of moisture for sand can vary from typically 0.5% (the Water Absorption Value (WAV)
or Surface Saturated Dry value (SSD) which is obtained from material suppliers) to
approximately 20% (saturated). Other materials can have an even greater range. Over this
moisture range for most materials, the reading from a Hydronix sensor is linear. For linear
relationships a calibration can be performed from only two points, but for improved accuracy a
larger number is preferred.
The equation of the best fit line through the calibration points is used to calculate ‘true’ moisture
from the unscaled reading. This equation is defined by a slope (B) and offset (C). These values
are therefore calibration coefficients and can be stored inside the sensor. The conversion to
moisture% is therefore:
Moisture% = B x (unscaled reading) + C – SSD
The SSD value is included in case it is required to output moisture values in excess of the
material’s absorbed moisture. In most cases this is set to zero.
For certain materials (principally organic materials), the calibration line may have a curved form
and for this an additional quadratic parameter (A) is used. The conversion to moisture% is
therefore:
2
Moisture% = A x (unscaled reading) + B x (unscaled reading) + C – SSD
Hydro-View IV User Guide HD0531 Rev 1.5.0 59
Material Calibration
Chapter 6
A good calibration is made by measuring material samples and taking readings over the full
working moisture range of the material. As many points as practical should be made as more
points provides higher accuracy. The graph below shows a good calibration with high linearity.
Good Moisture Calibration Data
Bake-Out Moisture %
12
10
8
6
4
2
0
0
20
40
60
80
100
120
Sensor Unscaled Output
Calibration inaccuracy is likely to result if:
•
Too small a sample of material is used for ‘baking-out’.
•
A very small number of samples are used (in particular 1 or 2 points).
•
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 ‘bake-out’
samples or poor sensor positioning with inadequate material flow over the sensor.)
•
If the averaging facility is not used to ensure representative moisture reading for the
entire batch.
Poor Moisture Calibration Data
12
10
10
Bake-Out Moisture %
Bake-Out Moisture %
Poor Moisture Calibration Data
12
8
6
4
2
0
8
6
4
2
0
0
20
40
60
80
Sensor Unscaled Output
100
0
20
40
60
80
100
Sensor Unscaled Output
The Hydro-View incorporates optional calibration rules to aid the user in obtaining reasonable
and accurate results despite any problems such as those mentioned above, (see Chapter 5
Section 8.2).
2 Moisture Calibration
In order to simplify the calibration procedure Hydro-View has the ability to check input calibration
values against a set of rules. These rules inform the user when input values may result in an
abnormal moisture calibration. They are most accurate for sands and small stone (less than
10mm). If used for other materials, they may try to force a less accurate calibration. If this is the
case the rules can be disabled.
The calibration function in Hydro-View allows the user to input material calibration data which is
then stored in the database and can be written as calibration coefficients into the sensor.
60
Hydro-View IV User Guide HD0531 Rev 1.5.0
Chapter 6
2.1
Material Calibration
Averaging
Averaging the output of a sensor over a period of time is essential for representative sampling
in most applications. In the case of a Hydro-Probe mounted in a material bin, once the gate
opens the material starts to flow until the gate closes. As the readings vary during this time
the only way in which to obtain a representative unscaled value is by continuously averaging
during the flow.
Digital input 1 can be used to determine when to average. For a bin installation the sensor
input could be generated from the bin-gate switch to give a +24VDC input when the gate is
open.
In this case the configuration of the sensor has to be set to ‘Average/Hold’ for this purpose.
2.2
Remote Averaging
If however, the installation is without an input that can switch to control the averaging function,
Hydro-View has the facility to manually select the start and stop period of averaging. This is
called ‘remote averaging’. Remote averaging is only possible if the first digital input is set to
‘Unused’. (See Chapter 5 Section 8.5)
2.3
Calibration Graph
Figure 41: Calibration Graph
The calibration data is displayed in a graphical form together with the current calibration line
from the sensor (in grey) and the Calibration Rule limits in red (if enabled). Any points further
from the calculated best fit line than the specified tolerance are shown in red. The point
currently selected in the list is highlighted by a circle.
2.4
Effect of the Calibration Rules
A mathematical best fit line is calculated from the calibration data points and it is this line,
described using the two variables B and C, which defines the calibration. The effect of the
rules is to improve this calibration line if the calibration data does not satisfy the criteria as
described below, in such cases the mathematical best fit line is modified.
Currently Hydronix provides calibration rules for standard sand only. This rule should be
enabled for sand so that data not fitting the criteria will be corrected for, providing a better
calibration. It should be noted that the calibration rules have been designed around a sensor
mounted at the suggested angle. See the individual sensor user manuals for more
information.
If however different materials are being measured or the installation is different from the
suggested method, then it may be necessary to disable the rules on the Edit Calibration
screen. (See Chapter 5 Section 8.2) This is application specific and should be determined by
the engineer commissioning the equipment.
Hydro-View IV User Guide HD0531 Rev 1.5.0 61
Material Calibration
Chapter 6
3 Brix Calibration
Some Hydronix sensors have the ability to measure the Brix content of a liquid. This is a
measure of the amount of dissolved sugar there is in a liquid and is used mainly in the food
industry.
Brix is measured in a way which is not proportional to the moisture in the material, which is what
the Hydronix sensors are designed to measure. To create a calibration line to calculate Brix from
the unscaled value a different equation is used. This equation is:
Brix = A − B ⋅ e( C ⋅unscaled ) + D ⋅ unscaled ²
This equation gives an exponential curve.
When using the sensors to measure Brix, the sensor must still be calibrated to the process being
monitored. If the sensor supports Brix measurement, an additional option is available under
Calibration Type.
4 Hints:
•
Wear safety glasses and protective clothing to guard against expulsion 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.
•
Whilst recording the sensor unscaled output, always sample where the sensor is located.
•
When calibrating coarse aggregates, do not use a calibration method that uses very
small samples, for example ‘Speedy’ or infra-red balance.
•
Never assume that material flowing out of two gates in the same bin is the same moisture
content and do not attempt to take samples from the flow in both gates to get an average
value – always use two sensors
•
Always use averaging
•
Ensure the sensor sees a representative sample of material
5 Equipment
62
•
Weighing scales - to weigh up to 2kg, accurate to 0.1g
•
Heat source – for drying samples, such as electric hot plate.
•
Container – with re-sealable lid for storing samples.
•
Polythene bags – for storing samples prior to drying
•
Scoop – for collecting samples
•
Safety equipment – including glasses, heat resistant gloves and protective clothing
Hydro-View IV User Guide HD0531 Rev 1.5.0
Chapter 6
Material Calibration
6 Calibration Procedure
6.1
Calibration Procedure
1.
From the main menu touch Calibration. Select the correct sensor when entering the
Calibration screen.
Available
sensors are
displayed
here
Figure 42: Sensor selection screen
2.
Create a new calibration (Figure 43). Select New Cal to open the Edit Calibration
screen.
Figure 43: Calibration screen
3.
In the Edit calibration screen (Figure 44) create a new calibration (see chapter 5
section 8.2 for full detail on how to set-up the calibration).
If the SSD value for the material is known (see section 7.7 ) it must be entered at
this stage before averaging.
Figure 44: Edit Calibration screen
Hydro-View IV User Guide HD0531 Rev 1.5.0 63
Material Calibration
4.
Chapter 6
Select Edit Points to open the Edit Calibration section (Figure 45). Select Averaging to
open the averaging control screen. Averaging will either be automatic (preferred) or
manual depending on the sensors configuration see Chapter 5 section 8.5 Remote
Averaging Screen for full set-up details.
Figure 45: Averaging selection
5.
For the next batch take a sample of the material. Using a scoop, collect a series of
small samples from the flow to yield around 5-10kg of material in the container. The
material MUST be collected at a position close to the sensor and therefore the sensor
reading relates to the particular batch of material passing the sensor. If the averaging
is in manual mode, then a second operator should start and stop the averaging from
the Hydro-View as material flows over the sensor (Figure 46). If in auto the averaging
will start when the digital input is activated and stop when the digital input is switch off.
Average
unscaled will
be displayed
here
Figure 46: Manual start average screen
6.
64
If you are satisfied that the sample collected is representative of the material flowing
over the sensor, return to the Hydro-View and accept the message to add a new point
to the Calibration. Return to the calibration screen by touching Exit.
Hydro-View IV User Guide HD0531 Rev 1.5.0
Chapter 6
Material Calibration
Figure 47: Averaging complete screen
7.
Mix the collection of material samples, remove approximately 1kg, dry it thoroughly
and calculate the moisture content using the moisture calculation procedure below
(section 6.2). 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 re-heat.
8.
Repeat step 7 for another 1Kg sample. If the moisture differs by more than 0.3%,
then one of the samples was not dried out completely and the test has to be restarted.
9.
Enter the average moisture of the two samples in the calibration points table, beside
the Unscaled reading calculated by the Hydro-View (Figure 48). This ‘Moisture’ and
‘Unscaled’ value make up one calibration point. Tick this point to include the values in
the calibration.
Enter calculated moisture %
Tick to include the
values in the
calibration
Figure 48: Adding moisture value screen
10. Repeat steps 5-9 for additional calibration points. Choose a different time of day or
different time of the year to ensure a wide range of moistures are sampled.
11. Select Show graph to examine the calibration graph (Figure 49).
Hydro-View IV User Guide HD0531 Rev 1.5.0 65
Material Calibration
Chapter 6
Figure 49: Calibration graph
A good calibration is one where the calibration points cover the complete
working moisture range of the material, and all points lie on or near to a straight
line. If any calibration points are suspected to be wrong then they can be
excluded from calibration by deselecting their corresponding tick box. It is
generally recommended that a spread of at least 3% will give best results
Any calibration point outside the tolerance set when the calibration was created
(Figure 44) will be shown in red. These points will need to be reviewed and deleted as
required. Use the arrow’s to select a point. The selected point will be highlighted in
blue in the edit calibration screen (Figure 50).
12. When the calibration is finished, update the new calibration coefficients to the sensor
by selecting OK on the two Edit Calibration screens to return to the calibration main
page (Figure 50).
Select the
required
calibration
Send calibration
to the sensor
Figure 50: Update calibration to sensor screen
13. Select the Calibration in the list and touch the ‘Write to Sensor’ button on the
Calibration screen. The Sensor Calibration field will then show that the sensor has
the new calibration installed (Figure 51). The moisture% output from the sensor
should represent true moisture of the material. This can be verified by taking further
samples and checking the laboratory moisture against the sensor output.
66
Hydro-View IV User Guide HD0531 Rev 1.5.0
Chapter 6
Material Calibration
Sensor calibration
updated
Figure 51: Updated calibration field
6.2
Moisture Calculation
The true moisture content is required for each calibration point. The method for taking
samples is described in Section 6.1 above, and the method for calculating moisture is
described below and summarised in Figure 52
Figure 52: Calculating true Moisture Content
A = Weight of the container
B = Weight of the container + wet material
C = Weight of the container + dry material
From this, the true moisture content is calculated:
Moisture = ( B – C ) / ( C – A )
Hydro-View IV User Guide HD0531 Rev 1.5.0 67
Material Calibration
68
Hydro-View IV User Guide HD0531 Rev 1.5.0
Chapter 6
Appendix A
Default PIN Codes
When the Hydro-View IV is first powered up, the following PIN codes are set as standard:
User Level
Default PIN Code
Supervisor
3737
Engineer
0336
It is recommended that these are changed once the system is commissioned to prevent
inadvertent access to the system and settings.
Hydro-View IV User Guide HD0531 Rev 1.5.0 69
Default PIN Codes
70
Hydro-View IV User Guide HD0531 Rev 1.5.0
Appendix A
Appendix B
USB Memory Stick file format
A number of operations in the Hydro-View utilise an external USB Memory stick that is plugged into
the unit. To simplify the use of the Hydro-View, a specific file layout is used on the USB Memory stick.
It most cases, it is not necessary for the user to know this in detail, but in order to find exported data
(Log files, Sensor Backups etc) and to place data required by the Hydro-View in the correct place,
refer to Figure 53.
The maximum size of Memory Stick supported by Hydro-View is 4GByte.
All the folders are within a top level folder called HydroView_IV which must be in the root of the drive.
The diagram below shows the structure of the file system on a typical memory Stick.
HydroView_IV folder.
Top level folder in root of disk.
All other folders are under here.
CalibrationFiles folder.
Calibration file exports
are
stored
here.
Automatically created
when required, if it
does not already exist.
BackupFiles folder.
Sensor backup files are
stored
to
here.
Automatically created
when required, if it
does not exist already.
FirmwareFiles folder.
Firmware
files
for
sensor upgrade are
placed in this folder.
Must be created by
User if needed. Files
placed elsewhere on
the disk will not be
found.
LogFiles folder.
Sensor log files are
stored
to
here.
Automatically created
when required, if it
does not exist already.
Upgrade folder.
Upgrades to HV04 firmware are
placed in this folder, in unzipped
format. At power up, this folder is
checked
and
firmware
is
upgraded if files exist. Must be
created by User if required.
Hydro-View
Backup
Database file.
Created when System is
backed up, and copied
back to unit when System
is restored.
Figure 53: USB memory Stick File Layout
Hydro-View IV User Guide HD0531 Rev 1.5.0 71
USB Memory Stick file format
72
Hydro-View IV User Guide HD0531 Rev 1.5.0
Appendix B
Appendix C
Q:
A:
Frequently Asked Questions
The Hydro-View continually displays “Searching for Sensor … xx”
This message indicates that there is a problem with the communication between the HydroView and the sensor. The first thing to check is cabling between the sensor and the HydroView. Try switching off power, this would reset the sensor and the Hydro-View. If the
problems still exist, see Appendix D for more details on communication diagnostics.
___
Q:
A:
How do I recalibrate the touch screen?
The touch screen on a Hydro-View is a capacitive device and cannot be recalibrated. If you
are looking at the display from above or below or one side, the screen calibration may appear
to be incorrect due to the thickness of the display glass. In this case, try to view the HydroView ‘face on’.
___
Q:
A:
___
Q:
A:
___
Q:
A:
___
Q:
A:
___
Q:
A:
___
Q:
A:
___
Q:
A:
Can I adjust the contrast on the display?
There is no way of adjusting the contrast of the display on a Hydro-View IV. If either the
backlight or the contrast if faulty, then the unit will need to be repaired by Hydronix.
We had a lightning strike and now the unit doesn’t work properly, can I do any onsite repairs?
It is not possible to do any repairs onsite, and any attempts of onsite repairs will invalidate any
warranty outstanding. In such cases the equipment should be sent back to Hydronix for
repair. See Chapter 1 Section 3.7 for details of reducing the risk due to lightning strikes.
The LCD screen has lines running through it. Can I replace the screen without sending the
unit back to Hydronix?
It is not possible to repair damaged screens onsite. The Hydro-View should be sent back to
Hydronix for repair by a qualified technician.
How do I know what firmware version I have?
The firmware version running on the Hydro-View can be checked in the System Setup screen
(see Chapter 5 Section 6.1)
How do I upgrade the Hydro-View firmware?
See Chapter 4 Section 7
I have changed the sensing arm on my Hydro-Probe Orbiter. Do I need to recalibrate
anything?
It will be necessary to calibrate the new sensing arm to the sensor electronics, so that the air
and water factory calibration settings are correct. This process is fully detailed in the HydroProbe Orbiter User Guide. The calibration can be performed using the Hydro-View IV from
the Sensor Configuration Factory Settings screen. (Chapter 5 Section 7.10).
How do I calibrate my Hydro-View to display real moisture?
To display real moisture, the sensor needs to be calibrated to the material being measured,
as described in Chapter 6. The Overview screen can then be configured to show Filtered
Moisture (see Chapter 5 Section 3).
Hydro-View IV User Guide HD0531 Rev 1.5.0 73
Frequently Asked Questions
74
Hydro-View IV User Guide HD0531 Rev 1.5.0
Appendix C
Appendix D
Diagnostics
The following tables list the most common faults found when using the Hydro-View. If you are unable
to diagnose the problem from this information, please contact your system installer or Hydronix
reseller.
Symptom: Displays shows ‘Searching For Sensor’ - no output from sensor
Possible explanation
Check
Required result
Action required on failure
No power to sensor.
Power
output
+24v DC
Locate
fault
supply/wiring
Sensor has temporarily
locked up
Power down and
re-power sensor
Sensor
functions
correctly
Check sensor connector pins
Sensor
connector
damaged
MIL-Spec
pins are
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.
Digital RS485 connection is
not working. Sensor should
be returned to Hydronix for
repair.
supply
in
power
Symptom: Incorrect sensor readings
Possible explanation
Check
Required result
Action required on failure
Sensor
unscaled
readings are incorrect
Select
Filtered
Unscaled
as
Display Variable on
Display
Setup
screen
Readings
should
be the following:
Contact your system installer
or Hydronix reseller for more
details.
Material Calibration
is incorrect.
Readings
should
be the following:
Select
Filtered
Unscaled
as
Display Variable on
Display
Setup
screen
Sensor exposed to
air = close to zero.
Hand on sensor =
75-85
Sensor
Moisture
readings are incorrect
Sensor exposed to
air = close to zero.
Hand on sensor =
75-85
Contact your system installer
or Hydronix reseller for more
details.
Hydro-View IV User Guide HD0531 Rev 1.5.0 75
Diagnostics
Appendix D
Possible explanation
Check
Required result
Incorrectly configured
Display
Area
on
Overview screen
Use the Display
Setup screen to
verify
that
the
correct sensor and
variable is selected
especially
if
–
sensors have not
been
clearly
renamed.
Display
Configuration
corrected
Action required on failure
is
Contact your system installer
or Hydronix reseller for more
details.
Symptom: Faulty display contrast
Possible explanation
Check
Required result
Action required on failure
Faulty internal power
supply to backlight.
-
Contact
your
system installer or
Hydronix
reseller
for repair details.
-
Backlight has failed
-
Contact
your
system installer or
Hydronix
reseller
for repair details.
-
Symptom: Green indicator illuminates but Hydro-View fails to start up
Possible explanation
Check
Required result
Action required on failure
MiniSD card has been
dislodged
Check that card is
fully inserted –
approx.
0.5mm
protruding
maximum. Release
card fully on spring
mechanism and reinsert.
Correct boot-up
Contact your system installer
or Hydronix reseller for repair
details.
Hydro-View power up
test has failed
Remove power and
re-apply
Correct boot-up
Contact your system installer
or Hydronix reseller for repair
details.
System SD card has
become corrupted
76
Hydro-View IV User Guide HD0531 Rev 1.5.0
Contact your system installer
or Hydronix reseller for repair
details.
Appendix E
Glossary
Analogue Output
The analogue outputs are continuously variable voltages or currents that can be configured to
output the sensor’s moisture or unscaled output to a control system using an analogue input
module.
Automatic Calibration (AutoCal)
To simplify repeating the factory calibration, some Hydronix sensors can be automatically
calibrated. This sets the air and water values for the arm. The sensor face must be clean, dry
and obstruction free to run the automatic calibration. Note that the result of this AutoCal is not as
precise as carrying out a full Air and Water calibration.
Averaging
In a batch averaging process, a sensor can be configured to average the reading of the material
seen during the entire batch, thereby providing a very accurate indication of the moisture.
Backup/Restore Settings
Al of the Hydro-View System Setting (including Calibrations) can be backed up to allow them to
be restored at a later time. The same applies to the sensor settings.
Calibration
Calibration is the process of relating the Unscaled reading taken by the sensor to a true moisture
content of a given material.
Material
The material is the physical product in which the sensor is measuring moisture. The material
must be flowing and must completely cover the sensor’s ceramic faceplate.
MiniSD card
A format of compact data storage using Flash memory. The Hydro-View IV has a single Mini SD
card that stores its operating software as well as its system database.
Moisture
The water held in the material. Moisture is defined in either dry weight or wet weight and is given
as a percentage.
Probe
See Sensor.
RS485
This is the serial communication protocol that the sensors use to communicate digitally with the
control system.
RS485 Address
As more than one sensor can be on a RS485 network together, the address determines which
sensor is which. The sensors leave the factory set to address 16 by default.
Hydro-View IV User Guide HD0531 Rev 1.5.0 77
Glossary
Appendix E
SD card
See Mini SD card
Sensor
The sensor is the physical device that is used to measure moisture in materials. The sensor
consists of a stainless steel case containing the electronic components connected to a resonator
which sits behind a ceramic faceplate.
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 each sensor and is
between 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-View IV.
78
Hydro-View IV User Guide HD0531 Rev 1.5.0
Appendix F
Document Cross Reference
1 Document Cross Reference
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
EN0040
Engineering Note – Wiring a Sensor to a PC
HD0127
Hydro-Probe II User Guide
Hydro-View IV User Guide HD0531 Rev 1.5.0 79
Document Cross Reference
80
Hydro-View IV User Guide HD0531 Rev 1.5.0
Appendix F
Index
Analogue output ............................................40
Average/Hold
Delay .........................................................45
Averaging ......................................................61
Remote ......................................................61
Back Up .........................................................40
Backup ..........................................................38
Bake-out test .................................................62
Batch Averaging ............................................16
Box Contents .................................................11
Brix
Calculate Brix ............................................62
Calibration .................................................62
Cables
Analogue ...................................................25
RS485........................................................24
Sensor .......................................................24
Calculator
Moisture .....................................................67
Calibration ...............................................60, 62
Inaccuracy of .............................................60
Material ......................................................59
New ...........................................................63
Procedure ..................................................62
Routine ......................................................62
Rules .........................................................61
Communications ...........................................23
RS485........................................................23
Continuous Monitoring ..................................16
Date and Time ...............................................37
Diagnostics
Controller ...................................................75
Frames
Analogue Output .......................................40
Installation .....................................................18
Material calibration ........................................59
Introduction ................................................59
Mechanical Installation
Mounting ................................................... 18
Mixing Applications ....................................... 16
Moisture Calculator ....................................... 67
Operating Temperature................................. 19
Power Supply ................................................ 23
Remote averaging......................................... 61
Restore ................................................... 38, 40
RS485 ........................................................... 23
RS-485
Wiring ........................................................ 23
Rules
Calibration ................................................. 61
Safety ............................................................ 14
Cleaning .................................................... 16
Clearance .................................................. 15
Environmental Conditions ......................... 15
IP Rating ................................................... 15
Lightning Strikes........................................ 15
Markings .................................................... 15
Precautions ............................................... 14
Symbols .................................................... 15
Samples
Drying ........................................................ 63
Taking ....................................................... 63
Sensor Alarms .............................................. 45
Sensor Cable ................................................ 24
Slew rate filters ............................................. 47
SSD ............................................................... 46
Surface Saturated Dry .................................. 46
Test
Bake-Out ................................................... 62
USB Ports ..................................................... 25
Water Absorption Value ................................ 46
WAV .............................................................. 46
Wiring
RS-485 ...................................................... 23
Hydro-View IV User Guide HD0531 Rev 1.5.0 81
Was this manual useful for you? yes no
Thank you for your participation!

* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project

Download PDF

advertisement