HB Products HBX Manual del operador
HBX-all types installaon and calibraon manual 03 date: 26-06-2020 WWW.HBPRODUCTS.DK
Installation and conguration guide
HBX Vapor Quality sensor
Sensors for optimizing Evaporator Control, both for DX (direct expansion) and
overfeed - systems
For compressor protection and leakage detection (ammonia carbamate)
Introduction:
The three dierent versions are available, with the same function. Pipe size and piping layout, bend or
straight, is dierent and suited for dierent applications. The strainer house version has one xed ow di-
rection, whereas the two stainless versions accept ow in both directions.
HBX Vapor Quality Sensors measures the Vapor Quality of the refrigerant vapor leaving an evaporator and
use this signal for controlling the expansion valve. Thanks to the capacitive measurement principle it is able
to measure the liquid content of the uid leaving the evaporator without pressure drop.
For “DX” systems the vapor quality sensor can replace the conventional superheat control and is able to re-
duce the superheat to zero. The sensor can control the valve directly or it can provide the high vapor quality
measurement for an external control system. The vapor quality sensor reacts instantaneously if the dryness
of the gas is changed in the evaporator outlet. Experience has shown that the entire system is in better bal-
ance with minimum variation in pressure.
In overfeed and ooded systems the sensor is able to measure the low vapor quality in the evaporator outlet
and control the circulation ratio (CR) by controlling the liquid valve or the pump capacity, either directly or
as an input for a PLC.
The sensor is manufactured in stainless steel or carbon steel and can be used for all commonly used refrig-
erants CO2, Hydrocarbons, ammonia, HFO’s and HFC’s with dierent settings. The HBX sensor is available in
several versions, with and without temperature sensor and cable for direct connection to an expansion valve.
Three types of expansion valves are supported: stepper motor, PWM pulse modulating ex. AKV valves and
modulating 4-20mA controlled expansion valve.
A special ATEX/IECEx (EEx ib IIC) version is available for use in special hazardous areas and with ammable
refrigerants. This product is only suited for external control and is not able to control an expansion valve di-
rectly.
Angle rod version
In-line version
Angle strainer versions
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HBX-all types installaon and calibraon manual 03 date: 26-06-2020 WWW.HBPRODUCTS.DK
Table of Contents
Introducon............................................................................................... 1
Safety Instrucon ...................................................................................... 2
Applicaon and mounng strainer house version .................................... 3
Applicaon and mounng straight pipe version ....................................... 4
Applicaon and mounng angle rod version ............................................ 5
Installaon of temperature sensor............................................................ 6
Removal of electrical unit.......................................................................... 7
Sensor conguraon ................................................................................. 7
How to use the sensor............................................................................... 8
How to setup the sensor as input for a PLC .............................................. 9
Advanced sengs for sensor as input for PLC input............................... 10
Using the sensor for ooded operaon together with a PLC ................. 11
Operang a batch freezing process......................................................... 11
Using the alarm funcon for leakage control and comp. protecon ...... 11
Calibraon of sensor ............................................................................... 12
How does the expansion valve control loop work for DX operaon…..…14
How to setup the sensor as direct controller—basic sengs................. 16
How to setup the sensor as direct controller—Advanced sengs ......... 17
Controlling a ooded or semi ooded evaporator ................................. 18
Connecng diagram stepper motor ........................................................ 19
Connecng diagram motor valve ............................................................ 20
Connecng diagram pulse modulang.................................................... 21
Connecng diagram PLC and ATEX/Ex/IECEx ......................................... 22
Remote seng ........................................................................................ 23
LED indicaons on sensor head............................................................... 24
Use of the sensor with other refrigerants ............................................... 24
Safety Instructions
CAUTION! Read this setup guide before installing and using the HBX Sensor.
Installation of HBX sensor must be carried out by a trained professional with in-depth knowledge of both refrigera-
tion and electronics. Improper installation and use of the HBX Sensor may result in damage to material and/or peo-
ple. The installation and use of the HBX Sensor must be done according to local regulation.
Altering type-approved equipment voids the type approval. The product's input and output, as well as its accesso-
ries, may only be connected as described in this guide. HB Products assumes no liability for damages resulting from
failing to follow the instructions in this setup guide.
Intended use. The purpose of the HBX sensor is refrigerant measurement and control.
If the HBX is to be used in a different way, prior, written consent must be obtained from HB Products.
Repair: Any repair must be carried out by a trained professional.
Disposal instructions: The HBX is designed for long life operation. If or when it becomes necessary to dispose of
the sensor it must be done according to local regulation.
CAUTION! This symbol refers to a possible limitation of functionality or risk in usage.
NOTE! Contains important additional information about the product and provides further advice.
CAUTION! Factory sengs do not guarantee safe operaon since the conguraon
parameters depend on the system design
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HBX-all types installaon and calibraon manual 03 date: 26-06-2020 WWW.HBPRODUCTS.DK
Up
Flow direcon
Flow direcon
H
H
H
Risk of trapped refrigerant
around the sensor disturbs the
measurement when lid points
downwards
Application and mounting instruction
Sensor mounted in a strainer house (HBX-xxx-ST)
The HBX-sensor is mounted after the evaporator and is able to measure the Vapor Quality (dryness) from 0.2 to 1. The
output can be used as input to a PLC or it can control the expansion valve directly or both. The sensor is mounted in a
strainer house where the strainer is replaced by the sensor. Compared to the original strainer the ow direction is
opposite and the mounting is upside down.
The sensor have to be mounted in downward sloping pipes to ensure drainage of refrigerant, and oil. The lid needs to
be upwards as other mountings will be sensitive to oil contamination and trapped refrigerant during startup.
When the sensor is welded into the plant the lid and sensor have to be removed. After the welding the piping have
to be checked for welding debris and deformations which might disturb the measurement. The distance between
the sensor element and the wall has to be uniform.
The lid with sensor is reassembled and the bolts are tightened according to the table.
HRemove lid with sensor
before welding
Max torque for bolts
H
Flow direcon
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HBX-all types installaon and calibraon manual 03 date: 26-06-2020 WWW.HBPRODUCTS.DK
Application and mounting instruction
Sensor mounted in a straight pipe HBX in-line
The HBX-sensor is mounted after the evaporator and is able to measure the Vapor Quality (dryness) from 0.2 to 1. The
output can be used as input to a PLC or it can control the expansion valve directly or both. This sensor version is
mounted in a straight pipe and it accepts ow in both directions.
The sensor can be mounted in dierent positions as long as you make sure there is no trapped refrigerant inside the
sensor during startup. Mounting the sensor with the electronic unit pointing downwards is not ideal as the connectors
might disturb the liquid ow in the bottom of the pipe and make the measurement unprecise.
The electrical unit can be mounted on either of the two connecting points
When the sensor is welded into the plant the electronic unit
has to be removed in order to protect it from the heat. The
studs have to be cooled during welding as they include O-rings
which does not tolerate temperature beyond 100°C (212°F). A
wet cloth is normally sucient to cool the studs.
Remove electronic unit be-
fore welding or soldering and
cool the studs ex. with a wet
cloth.
With the sensor downwards the
internal connections will disturb
the liquid ow in the bottom of
the pipe. The measurements
might be unprecise
Apply
cooling
When mounted horizontally
make sure refrigerant and
oil is drained for instance by
inclining the sensor 1
This mounting
will suer from
trapped refrig-
erant in the
sensor tube
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HBX-all types installaon and calibraon manual 03 date: 26-06-2020 WWW.HBPRODUCTS.DK
HBX
Flow direcon
Angle minimum 30 downwards
Evaporator
Application and mounting instruction
Angle rod version
The sensor accepts ow in both directions, but has to be mounted in downward sloping pipes to ensure drainage of
refrigerant, and oil. The sensor can be mounted in dierent positions. But some will be sensitive to oil contamination
and trapped refrigerant during startup. Make sure that the sensor rod inside the long pipe is free from trapped refrig-
erant and oil at any time. The sensor pipes have a larger dimension than stated in the specication, but is delivered
with reductions to t the specied pipe diameter. This is done to avoid pressure loss coming from a massive inner rod
lling some of the pipe and reducing the cross section
Workarounds for low mounted evaporator outlets
It is important to secure drainage of liquid refrigerant and oil as this could
aect the sensor and especially oil is dicult to remove with a low velocity
gas. Especially in small systems without oil separator, it is important to keep
the sensor free from oil to avoid it disturbing the measurement.
Both pipes should be angled minimum downwards 1 degree or designed with a
P-trap/drop-leg to secure drainage.
This mounting will suer
from trapped refrigerant in
the metal block, where the
sensor is mounted
This mounting will suer from
trapped refrigerant in the
sensor tube
This mounting will suer from
trapped refrigerant in the sensor
tube
H
Flow direcon
Flow direcon
Slope downwards
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HBX-all types installaon and calibraon manual 03 date: 26-06-2020 WWW.HBPRODUCTS.DK
Installing the Sensor
The sensor is installed in the outlet of the evaporator, as part of the sucon line. Soldering connecon, ngs and pipes are
made of stainless steel. The sensor part itself must be removed by unscrewing it from the steel block/base part before sol-
dering.
Unscrew the complete sensor part before solder-
ing.
Use two wrenches when dismantling and installing
the HBX-Sensor. One to turn the sensor and one on
to stabilize the steel block to avoid stress to the
soldering's.
Use thread sealant.
We recommend using liquid thread sealant when
installing the sensor
Insulate the entire
mechanical sensor
part with insulation
foam.
Temperature sensor installaon
Refrigeraon systems working with NH3 can operate well without a temperature sensor, but most other refrigerant benet
from temperature measurement. The temperature measurement is used for oseng the Zero point and makes the meas-
urement more accurate.
The sensor normally has a cable with a temperature sensor which has to be mounted to the pipework using cable es or to
the lid of the larger strainer models. The mounng on the outside of the pipe provides sucient accuracy. The temperature
sensor compensates for the change in the dielectrical constant with the temperature and make the measurement more ac-
curate when starng the system.
The temperature sensor should
be mounted to a pipe in posi-
tion 3 or 9 o’clock with cable
ties as shown.
For strainer houses the clip can
be used for attaching it to the
lid
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HBX-all types installaon and calibraon manual 03 date: 26-06-2020 WWW.HBPRODUCTS.DK
Sensor conguraon
All HBX sensors can be calibrated using a PC and a, M12 -USB cable. The soware can be downloaded freely on the HB
Products web page. The conguraon data can be stored in the sensor and will be there unl erased without power con-
necon—just like you store data on a memory sck. When you change a value /seng there will be put a check mark next
to it and that indicates you have changed something and need to store the data in the sensor.
When the sensor is mounted in a refrigeraon plant where it is dicult to reach or it is very cold you should consider us-
ing an M12 extension cable in your installaon. This allows for conguraon of your sensor where you have your M12/
M12 connecon.
PLC
Cable from HB sensor
USB
M12 female
M12 male
USB conguraon cable used for con-
necng all sensors with M12 con-
nector to a PC with the HB tool
order code HBxC-USB
Removal of the electrical unit
End view without electronic unit
The threaded union between the electronic and
mechanical part allows for fast removal and
remounng of the electronic element without
interfering with the pressurised system. No
tools are needed for the operaon.
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HBX-all types installaon and calibraon manual 03 date: 26-06-2020 WWW.HBPRODUCTS.DK
Setup — sensor or control
The sensor can operate in two very dierent modes
• As sensor input to a PLC, computer or other device that
uses the sensor signal
• A direct controller of an electrically controlled expansion
or liquid valve version with a cable output that can be set
up as a controller
Select Control/Sensor to select the mode
How to use the sensor
Two dierent versions
Two dierent versions exist
• A pure sensor version—without the controller capability
• A version which can both control an expansion valve with a simple input and act as a sensor together
with a PLC
The sensors that are able to control an expansion valve have a cable beside the temperature sensor cable,
which can be connected directly to the valve. The sensors which are specied only to provide a signal for a PLC
will only have the M12 connection. All sensors, except those for NH3 refrigeration, has a cable with a PT1000
temperature sensor, which measures the operating temperature and makes the needed compensations.
Alarm application
Some of the sensors can be used for providing an alarm when the liquid level is high or if ammonia carbamate
is detected. The sensor can still be used for measuring vapor quality and control a liquid valve either directly or
via a PLC
Stop-
start
Power
24VDC
PLC
Sensor only version
Controller and sensor
version
PLC
See page 9 and
forward
See page 14 and
forward
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HBX-all types installaon and calibraon manual 03 date: 26-06-2020 WWW.HBPRODUCTS.DK
Typical values for DX operation
When the sensor is not operating as a controller some of the parameters are irrelevant and the boxes are inactive
and shown in grey.
1. Set lter time to 2 seconds. The lter time is the period of time over which the X measurement is averaged.
The longer the range the smoother the measurement becomes, but the risk is that the system becomes too
slow.
2. Run in signal (digital input pin 5) is used as external start and stop when operating as a controller and
should be set to OFF
3. Zero cal. function: Choose ”ON” if you want to use the push bottom ”R” for zero calibration
4. The “Alarm setting in “X” “ and “Alarm delay in seconds” can be used, but normally the alarm is pro-
grammed in the PLC directly based on the mA signal.
5. The temperature compensation function is set to “Temp oset” unless you don’t want this functionality. This
only applies if the sensor has
a temperature sensor
6. “Select refrigerant type” is
for information only and
should not be used for chang-
ing refrigerant as it does not
change the important set-
tings, and the sensor will not
provide the correct measure-
ments. If your refrigerant is
not correct you need a com-
plete settings le - please con-
tact HB-products for this.
7. After changing settings push
the button ”Save to sen-
sor” (the message ”OK” on the
screen indicates that the set-
tings are saved)
8. Go to next page: Advanced
settings
How to setup the sensor as input for PLC
When using the sensor as input to a PLC the analog output
is used. The output can be scaled by adjusting a parame-
ter. Dry gas will always be 4 mA but the “X measuring
scale” found in the Calibration tab denes the 20 mA point
The ”X measuring scale” can be changed in the calibraon tab
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HBX-all types installaon and calibraon manual 03 date: 26-06-2020 WWW.HBPRODUCTS.DK
When the sensor is used as input for a PLC only the
relay function can be modien in the advance set-
tings' tab
1. Alarm output, NO (normally open) or NC
(normally closed) , default is ”NC” (Fail safe
function)
2. After Changing settings push the button ”Save
to sensor” (a message ”OK” on the screen
indicates that the settings are saved)
3. Save settings le is used to save all the set-
tings as a txt le
4. Load settings le is used to set up all parame-
ters from an existing txt le (copy data to a
new sensor)
Advanced settings for sensor as input for PLC
Tick o here for geng
access to selecon of
applicaon
Tick o
Set minimum
value here
Tick o here
and select
sensor type
Click here to
store the data
in the sensor
Under the calibration tab, the sensor can to be set to ooded operation called “HBX-CR” or DX but it does not really
matter when used for PLC input only.
How to change the “X measuring scale”
You start by ticking o the three small boxes to the right. At the same time you can change the operation range
from minimum in the box called “X measuring scale” to maximum called “Dry sensor” When you are done changing
the parameters, you store them in the sensor by clicking on “X scale calculation”
Tabla de contenidos
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