AquaMix microwave moisture sensor for the mixer controls the water dosing to give consistent moisture or slump in the final product.
The AquaSense and AquaMix moisture sensors are available as stand-alone sensors or as “Complete Kits” which includes mounting flange, 10 ft (3m) cable and junction box.

These and other accessories are listed below.  Not all accessories are listed or illustrated;  contact us if you have a question.

Weldable AquaMix mount

AquaMix‘s weldable mount is welded to the body of the mixer after a hole is cut in the body and liner plate.  Its four jackscrews hold the clamping flange in place and position the sensor with its faceplate flush with the mixer’s interior surface.  As the liner plates wear, the moisture sensor has to be readjusted to again be flush with the surface, to avoid breakage of the faceplate.  This is achieved by adjustment of the nuts on the jackscrews.


AquaSense/AquaMix clamping flange

The flange clamps the sensor tightly to avoid slippage due to forces within the mixer.  The combination of moisture sensor and flange is then mounted on the four jackscrews of the weldable mount so as to position the faceplate flush with the interior surface of the mixer.  A special abrasion-resistant epoxy grout fills the gap between sensor and liner plate to provide a smooth transition from the liner plate to the sensor faceplate.

Junction box

The waterproof plastic junction box for both AquaSense and AquaMix contains a metal carrier that slides out to facilitate the cable connections.  On the terminal block are 24 volt power inputs, analog output, digital RS232 and RS485 bidirectional outputs as well as three alarm outputs.  Options include an output solid-state relay for high moisture alarm.  Relays are 110 VAC standard but can be replaced with any voltage if specified with order.


Connecting cable

The junction box is normally placed in any convenient position near the moisture sensor, within the reach of the 10 ft cable.  A 4-conductor shielded cable carries power and analog signal from here to the control system.  Other arrangements are available for digital transmission and for programming/calibration.  If it is more convenient to locate the junction box at a greater distance, 20 ft (6m) and 50 ft (15m) lengths are available.  The cable may also be connected directly to control equipment without use of the junction box.

View shows junction box, closed, with 10 ft (3m) cable.

Programming cable

The programming cable connects from the junction box to a PC or laptop computer.  Three pins engage the mating sockets in the terminal block and the other end terminates in an RS232 connector.  Since most computers no longer have this type of port, you will also require a RS232 to USB converter, available below or from any computer store.

With the programming cable connected to your computer, you can run the GUI software to monitor moisture and temperature, set up the parameters or calibrate the sensor.  One cable can be used for all sensors in the same plant.

24 volt DC power supply

Normally the moisture sensor is powered by the 24 volt DC power already available from the batch controller.  When a batch controller is not used or when no 24 volt power is available, this power supply can be used.  this regulated supply with detachable power cord powers up to 10 sensors, either AquaSense, AquaMix or a combination of sensors and other equuipment up to 1.5 A maximum.  It is fully UL and CE compliant for use inside a cabinet or stand-alone.  Supply voltage is 110 – 250 volts AC 50/60 Hz.

USB Converters

To convert the digital signal from the sensor to USB format for PC computers, a selection of converters is available.  Different models handle RS232, RS485 formats and signal isolation where power surges and lightning can destroy electronic equipment.  The RS232 connection allows a PC or laptop computer to set up and calibrate a single sensor.  RS485 allows two or more sensors to share the same line to the computer for setup, calibration and monitoring of the moisture and temperature readings.  AquaSense and AquaMix sensors can be connected to the same RS485 line.

Digital moisture display 1278

Although the AquaSense or AquaMix moisture sensor is normally connected to a control system, some custom measurement systems need a digital display.  The moisture display is powered directly from the 4-20 mA analog output from the sensor.  If multiple sensors are used, each sensor requires a separate display.

These displays are current powered.   each sensor can also be connected to the input of a PLC or computer by wiring these in series with the display.  The 4-20 mA current output preserves the full accuracy of the sensor, even with long cable runs.

The display is available as a waterproof wall-mounting box (at left) or as a panel-mounting bare board meter, model 1279 (at right).  Both are electrically identical.