Emerson 2468CD- Manuals
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User Manual Emerson 2468CD
Summary
About this manual This manual describes the Hydrastep 2468CB and 2468CD Electronic Gauging Systems along with the recommended options. Except where stated otherwise, the information contained in this manual can be assumed to apply to either system. This manual is divided into three parts; the first ...
SYMBOLS USED IN THIS MANUAL AND ON THE UNIT Symbol Meaning Direct Current Alternating Current Earth (ground) terminal Protective conductor terminal Caution (refer to accompanying documents)
24685034 Pt.1 - 1 Part 1 Hydrastep 2468CB & 2468CD Electronic Gauging System
24685034 Pt.1 - 5 Part 1 Contents Chapter 1 Introduction to the Hydrastep 2468 Electronic Gauging System Chapter 2 2468CB & 2468CD Dual Power Supply Version Chapter 3a 2468 - Relay Output Board Option Chapter 3b Delay Relay Output Board Option Chapter 3c 2468 Opto-isolated Output Board Option Ch...
Hydrastep 2468CB and 2468CD Manual Introduction to the Hydrastep 2468 Electronic Gauging System 24685034 1-1 1 Introduction to the Hydrastep 2468 Electronic Gauging System Contents Page No. 1.1 WATER LEVEL MEASUREMENT .......................................................... 3 1.2 HYDRASTEP 2468 EL...
Hydrastep 2468CB and 2468CD Manual Introduction to the Hydrastep 2468 Electronic Gauging System 24685034 1-3 1.1 WATER LEVEL MEASUREMENT The Hydrastep 2468 Electronic Gauging System is designed as an electronic alternative to water level gauges on boilers, giving a more reliable and safer water leve...
Hydrastep 2468CB and 2468CD Manual Introduction to the Hydrastep 2468 Electronic Gauging System 24685034 1-5 1.2 HYDRASTEP 2468 ELECTRONIC GAUGING SYSTEM The Hydrastep 2468 is a sophisticated and flexible electronic gauging system. It is supplied in two main versions: A Single Power Supply System ...
Hydrastep 2468CB and 2468CD Manual Introduction to the Hydrastep 2468 Electronic Gauging System 24685034 1-7 1.4 HYDRASTEP 2468 UPGRADE PATHS AND AVAILABLE OPTIONS Table 1.1 describes the available versions of the Hydrastep 2468 Electronic Gauging System and their possible options. Existing System A...
Hydrastep 2468CB and 2468CD Manual 2468CB & 2468CD Dual Power Supply Version 24685034 2-1 2 2468CB & 2468CD Dual Power Supply Version Contents Page No. 2.1 INTRODUCTION ....................................................................................... 2-3 2.2 ELECTRODE CABLING SYSTEM .....
2468CB & 2468CD Dual Power Supply Version Hydrastep 2468CB and 2468CD Manual 2-2 24685034 2.5.2 DISPLAY BOARD 24680515 ............................................................... 2-20 2.5.2.1 Link LK1 Setting .................................................................... 2-20 2.5.2.2 C...
Hydrastep 2468CB and 2468CD Manual 2468CB & 2468CD Dual Power Supply Version 24685034 2-5 2.3.1 INPUT BOARD (PCB 24680501 AND PCB 24680516) The input board processes the electrode inputs to provide water level data for display purposes and a current output representing the water level. Fault det...
2468CB & 2468CD Dual Power Supply Version Hydrastep 2468CB and 2468CD Manual 2-8 24685034 2.4 INSTALLATION This section deals with the mechanical installation of the electronic enclosure and the electrical connections required for the basic system. Any installation dealing with the options avail...
2468CB & 2468CD Dual Power Supply Version Hydrastep 2468CB and 2468CD Manual 2-10 24685034 2.4.2 ELECTRICAL INSTALLATION This section deals with the interconnection between the electrodes and the electronic enclosure, the connection of the ac mains power supply to the electronic enclosure and th...
Hydrastep 2468CB and 2468CD Manual 2468CB & 2468CD Dual Power Supply Version 24685034 2-11 2.4.2.2 Connecting Cables to Water Column Electrodes (16 Electrode System - See Page 2-WD.7) The following assumes that the electrodes have been fitted to the water column. 1. Gain access to the electrodes...
2468CB & 2468CD Dual Power Supply Version Hydrastep 2468CB and 2468CD Manual 2-12 24685034 Figure 2.3: Enclosure cable layout for 16 electrode system 2.4.2.3 Connecting the Electrode Cable Assemblies to 2468 Enclosure WARNING Mains voltages are present in this instrument when power is connected....
Hydrastep 2468CB and 2468CD Manual 2468CB & 2468CD Dual Power Supply Version 24685034 2-17 This concludes the electrical installation requirements for the basic instrument configuration. Connections within the enclosure for the options available will be covered in the Installation sections of th...
Hydrastep 2468CB and 2468CD Manual 2468CB & 2468CD Dual Power Supply Version 24685034 2-23 2.6 FAULT ANALYSIS & CORRECTIVE ACTION Faults in the system will generally be indicated by the YELLOW LED on the front panel and by the fault output on the display board. The main faults, which are cat...
Hydrastep 2468CB and 2468CD Manual 2468CB & 2468CD Dual Power Supply Version 24685034 2-31 2.6.2 PARTS LIST - HYDRASTEP 2468 CB & CD VERSIONS Item Description Mobrey Part No. Item Description Mobrey Part No. Electronic Enclosure Input PCB assembly (2468CB) Fuse link 200mA (T) ceramic Fuse li...
Hydrastep 2468CB and 2468CD Manual Wiring Diagrams for Dual Power Supply Version 24685034 2-WD.1 2 Wiring Diagrams for Dual Power Supply Version Contents Page No. Figure 2.1 - Electrode cable connections to 8 port column ....................................... 2-WD.3 Figure 2.2 - Electrode cable con...
Hydrastep 2468CB and 2468CD Manual Relay Output Board Option 24685034 3a-1 3a 2468 - Relay Output Board Option Contents Page No. 3A.1 GENERAL DESCRIPTION 3 3A.2 INSTALLATION 3 3A.2.1 STORAGE & PRE-INSTALLATION INSPECTION ................................... 3 3a.2.1.1 Storage Area ..................
Hydrastep 2468CB and 2468CD Manual Relay Output Board Option 24685034 3a-3 3A.1 GENERAL DESCRIPTION The Relay Output Board (PCB 24680504) has four relays and is mounted on top of the input board using 3 nylon spacers. Electrical connection between the two boards is via plug and socket (SK1 on the in...
Relay Output Board Option Hydrastep 2468CB and 2468CD Manual 3a-4 24685034 3a.2.2.1 Fitting the Nylon Spacers to the Relay Output Board The spacers fit into the holes within the white-bordered areas on the output board (see Figure 3a.1 on page 3a-6). 1. Fit the nylon spacers into their prepared hole...
Relay Output Board Option Hydrastep 2468CB and 2468CD Manual 3a-6 24685034 3A.3 RELAY BOARD CONFIGURATION The 24680504 Relay Output Board has three configuration switches: SW6: Selects Electrode or Alarm state for RL1. SW1 - SW4: Selects individual electrode for relays RL1 to RL4. SW5: Selects...
Hydrastep 2468CB and 2468CD Manual Relay Output Board Option 24685034 3a-7 3A.3.1 RELAY OUTPUT BOARD 3a.3.1.1 Configuring the Relay Output Board WARNING Mains voltages are present in this instrument when power is connected. De-energise before opening front cover. 1. Isolate the 2468 electronics encl...
Relay Output Board Option Hydrastep 2468CB and 2468CD Manual 3a-10 24685034 3a.3.2.3 ‘One out of Two’ Relay Alarm System Either of the relays involved can cause an alarm when their assigned electrode registers an alarm condition. The alarm condition is selected by switch SW5 to provide relay energis...
Hydrastep 2468CB and 2468CD Manual Relay Output Board Option 24685034 3a-11 3a.3.2.4 ‘Two out of Two’ Relay Alarm System This system requires both relays to operate to cause an alarm when their assigned electrodes register an alarm condition. Case A - Relays normally energised, de-energise both to t...
Relay Output Board Option Hydrastep 2468CB and 2468CD Manual 3a-12 24685034 3a.3.2.5 ‘Two out of Four’ Relay Alarm System In the following diagrams (5A & 5B) indicate the electrode channel selected for each relay. A fully functioning system (NO FAULTS) will perform a low level trip at elect...
Relay Output Board Option Hydrastep 2468CB and 2468CD Manual 3a-14 24685034 3a.3.2.6 ‘Two out of Three’ Relay Alarm System In the following diagrams (7A & 7B) indicate the electrode channel selected for each relay. A fully functioning system (NO FAULTS) will cause a low level trip at electro...
Hydrastep 2468CB and 2468CD Manual Relay Output Board Option 24685034 3a-15 3A.4 COMPONENT REPLACEMENT The relay board contains no replaceable circuit components, failure of the board requires replacement of the entire board. The only component that can be replaced is the nylon spacer. 3A.4.1 REPLAC...
Relay Output Board Option Hydrastep 2468CB and 2468CD Manual 3a-16 24685034 3A.5 SPECIFICATION Outputs: 4 x Alarm/Trip Relays Relay Contact Rating: ac dc Maximum voltage: 250V 125V Maximum current: 8A 8A Maximum switching power: 1500VA 240W ( 30V) 65W ( 60V) 25W ( 125V) For type nA safety: 100...
Hydrastep 2468CB and 2468CD Manual Delay Relay Output Board Option 24685034 3b-1 3b Delay Relay Output Board Option Contents Page No. 3B.1 GENERAL DESCRIPTION ........................................................................................ 3 3B.2 INSTALLATION ...................................
Delay Relay Output Board Option Hydrastep 2468CB and 2468CD Manual 3b-4 24685034 3B.2.2 MECHANICAL INSTALLATION The output board is mounted directly on top of the input board. The input board is supplied with three nylon spacers fitted. The output board is then aligned on its Berg socket/plug interc...
Delay Relay Output Board Option Hydrastep 2468CB and 2468CD Manual 3b-6 24685034 3B.3 DELAY RELAY BOARD CONFIGURATION The 24680509 Delay Relay Output Board has three configuration switches and twenty split pad links for delay time selection. The switches are: SW6: Selects Electrode or Alarm state ...
Delay Relay Output Board Option Hydrastep 2468CB and 2468CD Manual 3b-12 24685034 3b.3.2.3 ‘One out of Two’ Relay Alarm System Either of the relays involved can cause an alarm when their assigned electrode registers an alarm condition. The alarm condition is selected by switch SW5 to provide relay e...
Hydrastep 2468CB & 2468CD Manual Opto-isolated Output Board Option 24685034 3c-1 3c 2468 Opto-isolated Output Board Option Contents Page No. 3C.1 GENERAL DESCRIPTION ........................................................................................ 3 3C.2 INSTALLATION ........................
Hydrastep 2468CB & 2468CD Manual Opto-isolated Output Board Option 24685034 3c-3 3C.1 GENERAL DESCRIPTION The Opto-isolated Output Board (PCB 24680505) has four opto-isolated outputs and is mounted on top of the input board using 3 nylon spacers. Electrical connection between the two boards is v...
Opto-isolated Output Board Option Hydrastep 2468CB & 2468CD Manual 3c-6 24685034 3C.3 OPTO-ISOLATED OUTPUT BOARD CONFIGURATION The 24680505 Opto-isolated Output Board has three configuration switches: SW6: Selects Electrode or Alarm state for Opto-output 1. SW1 - SW4: Selects individual elec...
Hydrastep 2468CB & 2468CD Manual Opto-isolated Output Board Option 24685034 3c-7 3C.3.1 CONFIGURING THE OPTO-ISOLATED OUTPUT BOARD WARNING Mains voltages are present in this instrument when power is connected. De-energise before opening front cover. Gain access to the printed circuit board assem...
Hydrastep 2468CB & 2468CD Manual Remote Display Options 24683B, C & D 24685034 4-3 4.1 REMOTE DISPLAY OPTIONS The 24683B, C, and D Remote Display Units give a repeat display of the water level state and fault alarm state of the Hydrastep 2468 Electronic Gauging System. Each type of remote di...
Hydrastep 2468CB & 2468CD Manual Remote Display Options 24683B, C & D 24685034 4-5 4.2.2 RECONFIGURING THE 24683D REMOTE DISPLAY The procedure for reconfiguring the 24683D for operation with 18 to 32 electrodes is: 1. Undo the four screws securing the transparent cover and remove the cover. ...
Remote Display Options 24683B, C & D Hydrastep 2468CB & 2468CD Manual 4-6 24685034 4.3 MECHANICAL INSTALLATION Of the three types of remote display units, types 24683B and 24683C are intended for panel mounting and type 24683D is intended for wall mounting. The installation procedures for pa...
Hydrastep 2468CB & 2468CD Manual Remote Display Options 24683B, C & D 24685034 4-7 4.4 ELECTRICAL INSTALLATION Up to six remote displays may be driven by the Hydrastep 2468 unit. One remote display can be powered from the main unit, but all the others must have a local supply. A remote displ...
Remote Display Options 24683B, C & D Hydrastep 2468CB & 2468CD Manual 4-8 24685034 4.4.1 STAR AND DAISY CHAIN CONNECTIONS Multiple remote display units can be connected to the main 2468 unit in two ways: ‘star’ or ‘daisy chain’. (See Figure 4.3) You can use either or both of these, in whiche...
Hydrastep 2468CB & 2468CD Manual Remote Display Options 24683B, C & D 24685034 4-9 4.4.2 EXAMPLE OF A ‘STAR CONNECTED’ SYSTEM Figure 4.4 shows two remote displays connected in a ‘star’. Where more than one remote display is in use, local supplies with isolated outputs must be used to power t...
Hydrastep 2468CB & 2468CD Manual Remote Display Options 24683B, C & D 24685034 4-11 4.4.4 CONNECTING CABLES TO THE REMOTE DISPLAY The following procedure can be used for each remote display that is to be connected: 1. Gain access to the remote display terminal block. On the 24683B and 24683C...
Remote Display Options 24683B, C & D Hydrastep 2468CB & 2468CD Manual 4-12 24685034 4.4.5 CONNECTING THE DISPLAY CABLES TO HYDRASTEP 2468 WARNING : Mains voltages are present in the 2468 Hydrastep unit when power is connected. De-energise before opening the front cover. The connection proced...
Hydrastep 2468CB & 2468CD Manual Remote Display Options 24683B, C & D 24685034 4-13 4.5 SYSTEM OPERATION When the system is brought on line check for complete agreement between the remote display and the Hydrastep level indicator display. 4.6 FAULT ANALYSIS AND CORRECTIVE ACTION Indication F...
Remote Display Options 24683B, C & D Hydrastep 2468CB & 2468CD Manual 4-16 24685034 4.7 COMPONENT REPLACEMENT Hydrastep remote display units contain no user-replaceable electronic components. Board failure requires the faulty PCB to be removed and returned for service and a serviceable PCB t...
Hydrastep 2468CB & 2468CD Manual Remote Display Options 24683B, C & D 24685034 4-17 4.8 SPECIFICATION REMOTE DISPLAY UNITS INDICATION Red/green 6mm×3mm LEDs CASE STYLE 24683B and 24683C: Panel mounting; 24683D: Rugged enclosure, to IP65/NEMA 4X DIMENSIONS 24683B: 144mm×72mm×200mm deep (5.67”...
Hydrastep Pressure Parts Operating Manual Part No: 24675030 Status: B Issue: A Authors: J. Smith / M. Le-Fevre / RCD Date: March 2006
24675030 Pt.2 - 3 About this manual This manual describes various procedures involved in the installation of the Hydrastep water columns, their attachments and the electrodes used in determining the level of water in the column. Part 2 - Pressure Parts Chapter 1 is a general introduction to the Hydr...
24675030 Pt.2 - 5 R E M I N D E R ELECTRODE INSTALLATION THREADED ELECTRODE(S), PART Nos. 459600602 & 459600802 MAKE SURE THAT THE COMPRESSION GASKET IS REGISTERED IN THE PROBE RECESS PRIOR TO TIGHTENING THE ELECTRODE. THIS CENTRES THE GASKET TO THE PROBE. CORRECT INCORRECT ELECTRODE COLUMN BODY...
24675030 Pt.2 - 7 N O T I C E THE HYDRASTEP VESSEL AND PROBE SYSTEM PROVIDES A SELF-FLUSHING FEATURE THAT PREVENTS THE ACCUMULATION OF DEBRIS IN THE VESSEL. THIS ELIMINATES THE NEED FOR PERIODIC BLOWING DOWN OF THE VESSEL. DO NOT BLOW DOWN THE HYDRASTEP VESSEL IF A BLOCKAGE IS SUSPECTED. REFER TO TH...
24675030 Pt.2 - 9 Part 2 - Hydrastep Pressure Parts Chapter 1 General Introduction Chapter 2 Installation Procedures Chapter 3 Fault Repair and Commissioning Chapter 4 Unit Description Chapter 5 Unit Specifications - Hydrastep
Hydrastep Pressure Parts General Introduction 24675030 1-1 1 General Introduction 1.1 PRINCIPLE OF OPERATION ................................................................... 1-3 1.2 WATER LEVEL INDICATION ................................................................... 1-3 Illustrations Figure...
Hydrastep Pressure Parts General Introduction 24675030 1-3 1.1 PRINCIPLE OF OPERATION The Hydrastep systems have been designed as electronic alternatives to conventional visual water gauges on boilers, giving more reliable and safer water level indication. The system is based on the significant diff...
Hydrastep Pressure Parts Installation Procedures 24675030 2- 1 2 Installation Procedures Contents Page No. 2.1 SCOPE OF PROCEDURES ...................................................................... 2-3 2.2 STORAGE .....................................................................................
Installation Procedures Hydrastep Pressure Parts 24675030 2-3 2.1 SCOPE OF PROCEDURES The procedures apply to the Hydrastep Boiler Drum Water Level Equipment supplied by Mobrey, who are responsible, under their supply contract, for delivery of all items of the above equipment listed in the delivery ...
Installation Procedures Hydrastep Pressure Parts 2-4 24675030 The water column is delivered along with the correct number of electrodes of the relevant pressure type (high or low) and complete with gaskets or ferrules and fixing nuts, where applicable. The electrodes should only be fitted to the col...
Installation Procedures Hydrastep Pressure Parts 2-6 24675030 The water connection to the water column must be fully insulated by lagging. The steam connection must also be lagged, but a minimum length of 0.5 metre of the steam leg must be left unlagged where the steam leg joins the water column (se...
Hydrastep Pressure Parts Fault Repair and Commissioning 24675030 3-1 3 Fault Repair and Commissioning Contents Page No. 3.1 BACKGROUND 3-3 3.1.1 SAFETY PRECAUTIONS .......................................................................... 3-3 3.1.2 WATER COLUMN ISOLATION ...............................
Fault Repair and Commissioning Hydrastep Pressure Parts 3-4 24675030 3.1.2 WATER COLUMN ISOLATION After obtaining authority to isolate the column: a) Close off the steam and water isolating valves. b) Where the column is connected to a closed drain, open the drain valve and, when the pressure equali...
Hydrastep Pressure Parts Fault Repair and Commissioning 24675030 3-5 Where scoring or erosion of the electrode port seat has occurred in the water column, the seat can be re-cut to acceptable standards using a service tool as listed below. Service Tool 246791AA – for use with electrodes 246781A* a...
Fault Repair and Commissioning Hydrastep Pressure Parts 3-6 24675030 f) Refit the electrical lead(s) and guard. Recommission as detailed later in this Chapter. 3.1.5 PROCEDURE FOR CHANGING HIGH PRESSURE ELECTRODES Carry out the isolation procedure as detailed in sub-section 3.1.2. Ensure that the tr...
Hydrastep Pressure Parts Fault Repair and Commissioning 24675030 3-7 3.2.2 WATER COLUMN TRANSIENT RESPONSE Starting with the water level at or below mid-gauge, note the lowest ‘steam’ indicating channel at this stage and fully close the water isolating valve nearest the water column quickly. Time th...
Hydrastep Pressure Parts Unit Description 24675030 4-1 4 Unit Description Contents Page No. 4.1 LOW PRESSURE ELECTRODES ............................................................ 4-3 4.2 HIGH PRESSURE ELECTRODES ........................................................... 4-4 4.3 WATER COLUMN (L.P....
Unit Description Hydrastep Pressure Parts 4-4 24675030 4.2 HIGH PRESSURE ELECTRODES High pressure electrodes can be used for pressures in the range 50bar (725psi) to 300bar (4350psi) see Chapter 5 for Specifications. These electrodes are used with the high pressure water column shown in Figure 1.3...
Hydrastep Pressure Parts Unit Specifications - Hydrastep 24675030 5-1 5 Unit Specifications - Hydrastep 5.1 ELECTRODES Type 459600602 Complete with sealing gasket: Metaflex. Screw in type M18 x 1.5 Insulator: Zirconia ceramic Rating 120 bar (1740 psi) at 370 C (698 F) pH range 7-11 Hydrostatical...
Unit Specifications - Hydrastep Hydrastep Pressure Parts Manual 5-2 24675030 5.2 WATER COLUMNS Type Low Pressure: Rating 120bar (1740psi) at 343 C (650 F) Type High Pressure: Rating 210bar (3045psi) at 370 C (698 F) (Series III) Type High Pressure: Rating 300bar (4350psi) at 560 C (1040 ...
Pt.3 - 1 Part 3 Hydrastep 2468CA, CB, CC & CD Electronic Gauging System
Hydrastep 2468 - Technical Manual Appendix A: CSA Approval A-1 A CSA Certified A.1 GENERAL All drawings in this manual are given here for planning purposes only. Before commencing with implementation, reference should always be made to the current issue of the appropriate drawings. Contact the facto...
Manual Emerson 2468CD
Summary
About this manual This manual describes the Hydrastep 2468CB and 2468CD Electronic Gauging Systems along with the recommended options. Except where stated otherwise, the information contained in this manual can be assumed to apply to either system. This manual is divided into three parts; the first ...
SYMBOLS USED IN THIS MANUAL AND ON THE UNIT Symbol Meaning Direct Current Alternating Current Earth (ground) terminal Protective conductor terminal Caution (refer to accompanying documents)
24685034 Pt.1 - 1 Part 1 Hydrastep 2468CB & 2468CD Electronic Gauging System
24685034 Pt.1 - 5 Part 1 Contents Chapter 1 Introduction to the Hydrastep 2468 Electronic Gauging System Chapter 2 2468CB & 2468CD Dual Power Supply Version Chapter 3a 2468 - Relay Output Board Option Chapter 3b Delay Relay Output Board Option Chapter 3c 2468 Opto-isolated Output Board Option Ch...
Hydrastep 2468CB and 2468CD Manual Introduction to the Hydrastep 2468 Electronic Gauging System 24685034 1-1 1 Introduction to the Hydrastep 2468 Electronic Gauging System Contents Page No. 1.1 WATER LEVEL MEASUREMENT .......................................................... 3 1.2 HYDRASTEP 2468 EL...
Hydrastep 2468CB and 2468CD Manual Introduction to the Hydrastep 2468 Electronic Gauging System 24685034 1-3 1.1 WATER LEVEL MEASUREMENT The Hydrastep 2468 Electronic Gauging System is designed as an electronic alternative to water level gauges on boilers, giving a more reliable and safer water leve...
Hydrastep 2468CB and 2468CD Manual Introduction to the Hydrastep 2468 Electronic Gauging System 24685034 1-5 1.2 HYDRASTEP 2468 ELECTRONIC GAUGING SYSTEM The Hydrastep 2468 is a sophisticated and flexible electronic gauging system. It is supplied in two main versions: A Single Power Supply System ...
Hydrastep 2468CB and 2468CD Manual Introduction to the Hydrastep 2468 Electronic Gauging System 24685034 1-7 1.4 HYDRASTEP 2468 UPGRADE PATHS AND AVAILABLE OPTIONS Table 1.1 describes the available versions of the Hydrastep 2468 Electronic Gauging System and their possible options. Existing System A...
Hydrastep 2468CB and 2468CD Manual 2468CB & 2468CD Dual Power Supply Version 24685034 2-1 2 2468CB & 2468CD Dual Power Supply Version Contents Page No. 2.1 INTRODUCTION ....................................................................................... 2-3 2.2 ELECTRODE CABLING SYSTEM .....
2468CB & 2468CD Dual Power Supply Version Hydrastep 2468CB and 2468CD Manual 2-2 24685034 2.5.2 DISPLAY BOARD 24680515 ............................................................... 2-20 2.5.2.1 Link LK1 Setting .................................................................... 2-20 2.5.2.2 C...
Hydrastep 2468CB and 2468CD Manual 2468CB & 2468CD Dual Power Supply Version 24685034 2-5 2.3.1 INPUT BOARD (PCB 24680501 AND PCB 24680516) The input board processes the electrode inputs to provide water level data for display purposes and a current output representing the water level. Fault det...
2468CB & 2468CD Dual Power Supply Version Hydrastep 2468CB and 2468CD Manual 2-8 24685034 2.4 INSTALLATION This section deals with the mechanical installation of the electronic enclosure and the electrical connections required for the basic system. Any installation dealing with the options avail...
2468CB & 2468CD Dual Power Supply Version Hydrastep 2468CB and 2468CD Manual 2-10 24685034 2.4.2 ELECTRICAL INSTALLATION This section deals with the interconnection between the electrodes and the electronic enclosure, the connection of the ac mains power supply to the electronic enclosure and th...
Hydrastep 2468CB and 2468CD Manual 2468CB & 2468CD Dual Power Supply Version 24685034 2-11 2.4.2.2 Connecting Cables to Water Column Electrodes (16 Electrode System - See Page 2-WD.7) The following assumes that the electrodes have been fitted to the water column. 1. Gain access to the electrodes...
2468CB & 2468CD Dual Power Supply Version Hydrastep 2468CB and 2468CD Manual 2-12 24685034 Figure 2.3: Enclosure cable layout for 16 electrode system 2.4.2.3 Connecting the Electrode Cable Assemblies to 2468 Enclosure WARNING Mains voltages are present in this instrument when power is connected....
Hydrastep 2468CB and 2468CD Manual 2468CB & 2468CD Dual Power Supply Version 24685034 2-17 This concludes the electrical installation requirements for the basic instrument configuration. Connections within the enclosure for the options available will be covered in the Installation sections of th...
Hydrastep 2468CB and 2468CD Manual 2468CB & 2468CD Dual Power Supply Version 24685034 2-23 2.6 FAULT ANALYSIS & CORRECTIVE ACTION Faults in the system will generally be indicated by the YELLOW LED on the front panel and by the fault output on the display board. The main faults, which are cat...
Hydrastep 2468CB and 2468CD Manual 2468CB & 2468CD Dual Power Supply Version 24685034 2-31 2.6.2 PARTS LIST - HYDRASTEP 2468 CB & CD VERSIONS Item Description Mobrey Part No. Item Description Mobrey Part No. Electronic Enclosure Input PCB assembly (2468CB) Fuse link 200mA (T) ceramic Fuse li...
Hydrastep 2468CB and 2468CD Manual Wiring Diagrams for Dual Power Supply Version 24685034 2-WD.1 2 Wiring Diagrams for Dual Power Supply Version Contents Page No. Figure 2.1 - Electrode cable connections to 8 port column ....................................... 2-WD.3 Figure 2.2 - Electrode cable con...
Hydrastep 2468CB and 2468CD Manual Relay Output Board Option 24685034 3a-1 3a 2468 - Relay Output Board Option Contents Page No. 3A.1 GENERAL DESCRIPTION 3 3A.2 INSTALLATION 3 3A.2.1 STORAGE & PRE-INSTALLATION INSPECTION ................................... 3 3a.2.1.1 Storage Area ..................
Hydrastep 2468CB and 2468CD Manual Relay Output Board Option 24685034 3a-3 3A.1 GENERAL DESCRIPTION The Relay Output Board (PCB 24680504) has four relays and is mounted on top of the input board using 3 nylon spacers. Electrical connection between the two boards is via plug and socket (SK1 on the in...
Relay Output Board Option Hydrastep 2468CB and 2468CD Manual 3a-4 24685034 3a.2.2.1 Fitting the Nylon Spacers to the Relay Output Board The spacers fit into the holes within the white-bordered areas on the output board (see Figure 3a.1 on page 3a-6). 1. Fit the nylon spacers into their prepared hole...
Relay Output Board Option Hydrastep 2468CB and 2468CD Manual 3a-6 24685034 3A.3 RELAY BOARD CONFIGURATION The 24680504 Relay Output Board has three configuration switches: SW6: Selects Electrode or Alarm state for RL1. SW1 - SW4: Selects individual electrode for relays RL1 to RL4. SW5: Selects...
Hydrastep 2468CB and 2468CD Manual Relay Output Board Option 24685034 3a-7 3A.3.1 RELAY OUTPUT BOARD 3a.3.1.1 Configuring the Relay Output Board WARNING Mains voltages are present in this instrument when power is connected. De-energise before opening front cover. 1. Isolate the 2468 electronics encl...
Relay Output Board Option Hydrastep 2468CB and 2468CD Manual 3a-10 24685034 3a.3.2.3 ‘One out of Two’ Relay Alarm System Either of the relays involved can cause an alarm when their assigned electrode registers an alarm condition. The alarm condition is selected by switch SW5 to provide relay energis...
Hydrastep 2468CB and 2468CD Manual Relay Output Board Option 24685034 3a-11 3a.3.2.4 ‘Two out of Two’ Relay Alarm System This system requires both relays to operate to cause an alarm when their assigned electrodes register an alarm condition. Case A - Relays normally energised, de-energise both to t...
Relay Output Board Option Hydrastep 2468CB and 2468CD Manual 3a-12 24685034 3a.3.2.5 ‘Two out of Four’ Relay Alarm System In the following diagrams (5A & 5B) indicate the electrode channel selected for each relay. A fully functioning system (NO FAULTS) will perform a low level trip at elect...
Relay Output Board Option Hydrastep 2468CB and 2468CD Manual 3a-14 24685034 3a.3.2.6 ‘Two out of Three’ Relay Alarm System In the following diagrams (7A & 7B) indicate the electrode channel selected for each relay. A fully functioning system (NO FAULTS) will cause a low level trip at electro...
Hydrastep 2468CB and 2468CD Manual Relay Output Board Option 24685034 3a-15 3A.4 COMPONENT REPLACEMENT The relay board contains no replaceable circuit components, failure of the board requires replacement of the entire board. The only component that can be replaced is the nylon spacer. 3A.4.1 REPLAC...
Relay Output Board Option Hydrastep 2468CB and 2468CD Manual 3a-16 24685034 3A.5 SPECIFICATION Outputs: 4 x Alarm/Trip Relays Relay Contact Rating: ac dc Maximum voltage: 250V 125V Maximum current: 8A 8A Maximum switching power: 1500VA 240W ( 30V) 65W ( 60V) 25W ( 125V) For type nA safety: 100...
Hydrastep 2468CB and 2468CD Manual Delay Relay Output Board Option 24685034 3b-1 3b Delay Relay Output Board Option Contents Page No. 3B.1 GENERAL DESCRIPTION ........................................................................................ 3 3B.2 INSTALLATION ...................................
Delay Relay Output Board Option Hydrastep 2468CB and 2468CD Manual 3b-4 24685034 3B.2.2 MECHANICAL INSTALLATION The output board is mounted directly on top of the input board. The input board is supplied with three nylon spacers fitted. The output board is then aligned on its Berg socket/plug interc...
Delay Relay Output Board Option Hydrastep 2468CB and 2468CD Manual 3b-6 24685034 3B.3 DELAY RELAY BOARD CONFIGURATION The 24680509 Delay Relay Output Board has three configuration switches and twenty split pad links for delay time selection. The switches are: SW6: Selects Electrode or Alarm state ...
Delay Relay Output Board Option Hydrastep 2468CB and 2468CD Manual 3b-12 24685034 3b.3.2.3 ‘One out of Two’ Relay Alarm System Either of the relays involved can cause an alarm when their assigned electrode registers an alarm condition. The alarm condition is selected by switch SW5 to provide relay e...
Hydrastep 2468CB & 2468CD Manual Opto-isolated Output Board Option 24685034 3c-1 3c 2468 Opto-isolated Output Board Option Contents Page No. 3C.1 GENERAL DESCRIPTION ........................................................................................ 3 3C.2 INSTALLATION ........................
Hydrastep 2468CB & 2468CD Manual Opto-isolated Output Board Option 24685034 3c-3 3C.1 GENERAL DESCRIPTION The Opto-isolated Output Board (PCB 24680505) has four opto-isolated outputs and is mounted on top of the input board using 3 nylon spacers. Electrical connection between the two boards is v...
Opto-isolated Output Board Option Hydrastep 2468CB & 2468CD Manual 3c-6 24685034 3C.3 OPTO-ISOLATED OUTPUT BOARD CONFIGURATION The 24680505 Opto-isolated Output Board has three configuration switches: SW6: Selects Electrode or Alarm state for Opto-output 1. SW1 - SW4: Selects individual elec...
Hydrastep 2468CB & 2468CD Manual Opto-isolated Output Board Option 24685034 3c-7 3C.3.1 CONFIGURING THE OPTO-ISOLATED OUTPUT BOARD WARNING Mains voltages are present in this instrument when power is connected. De-energise before opening front cover. Gain access to the printed circuit board assem...
Hydrastep 2468CB & 2468CD Manual Remote Display Options 24683B, C & D 24685034 4-3 4.1 REMOTE DISPLAY OPTIONS The 24683B, C, and D Remote Display Units give a repeat display of the water level state and fault alarm state of the Hydrastep 2468 Electronic Gauging System. Each type of remote di...
Hydrastep 2468CB & 2468CD Manual Remote Display Options 24683B, C & D 24685034 4-5 4.2.2 RECONFIGURING THE 24683D REMOTE DISPLAY The procedure for reconfiguring the 24683D for operation with 18 to 32 electrodes is: 1. Undo the four screws securing the transparent cover and remove the cover. ...
Remote Display Options 24683B, C & D Hydrastep 2468CB & 2468CD Manual 4-6 24685034 4.3 MECHANICAL INSTALLATION Of the three types of remote display units, types 24683B and 24683C are intended for panel mounting and type 24683D is intended for wall mounting. The installation procedures for pa...
Hydrastep 2468CB & 2468CD Manual Remote Display Options 24683B, C & D 24685034 4-7 4.4 ELECTRICAL INSTALLATION Up to six remote displays may be driven by the Hydrastep 2468 unit. One remote display can be powered from the main unit, but all the others must have a local supply. A remote displ...
Remote Display Options 24683B, C & D Hydrastep 2468CB & 2468CD Manual 4-8 24685034 4.4.1 STAR AND DAISY CHAIN CONNECTIONS Multiple remote display units can be connected to the main 2468 unit in two ways: ‘star’ or ‘daisy chain’. (See Figure 4.3) You can use either or both of these, in whiche...
Hydrastep 2468CB & 2468CD Manual Remote Display Options 24683B, C & D 24685034 4-9 4.4.2 EXAMPLE OF A ‘STAR CONNECTED’ SYSTEM Figure 4.4 shows two remote displays connected in a ‘star’. Where more than one remote display is in use, local supplies with isolated outputs must be used to power t...
Hydrastep 2468CB & 2468CD Manual Remote Display Options 24683B, C & D 24685034 4-11 4.4.4 CONNECTING CABLES TO THE REMOTE DISPLAY The following procedure can be used for each remote display that is to be connected: 1. Gain access to the remote display terminal block. On the 24683B and 24683C...
Remote Display Options 24683B, C & D Hydrastep 2468CB & 2468CD Manual 4-12 24685034 4.4.5 CONNECTING THE DISPLAY CABLES TO HYDRASTEP 2468 WARNING : Mains voltages are present in the 2468 Hydrastep unit when power is connected. De-energise before opening the front cover. The connection proced...
Hydrastep 2468CB & 2468CD Manual Remote Display Options 24683B, C & D 24685034 4-13 4.5 SYSTEM OPERATION When the system is brought on line check for complete agreement between the remote display and the Hydrastep level indicator display. 4.6 FAULT ANALYSIS AND CORRECTIVE ACTION Indication F...
Remote Display Options 24683B, C & D Hydrastep 2468CB & 2468CD Manual 4-16 24685034 4.7 COMPONENT REPLACEMENT Hydrastep remote display units contain no user-replaceable electronic components. Board failure requires the faulty PCB to be removed and returned for service and a serviceable PCB t...
Hydrastep 2468CB & 2468CD Manual Remote Display Options 24683B, C & D 24685034 4-17 4.8 SPECIFICATION REMOTE DISPLAY UNITS INDICATION Red/green 6mm×3mm LEDs CASE STYLE 24683B and 24683C: Panel mounting; 24683D: Rugged enclosure, to IP65/NEMA 4X DIMENSIONS 24683B: 144mm×72mm×200mm deep (5.67”...
Hydrastep Pressure Parts Operating Manual Part No: 24675030 Status: B Issue: A Authors: J. Smith / M. Le-Fevre / RCD Date: March 2006
24675030 Pt.2 - 3 About this manual This manual describes various procedures involved in the installation of the Hydrastep water columns, their attachments and the electrodes used in determining the level of water in the column. Part 2 - Pressure Parts Chapter 1 is a general introduction to the Hydr...
24675030 Pt.2 - 5 R E M I N D E R ELECTRODE INSTALLATION THREADED ELECTRODE(S), PART Nos. 459600602 & 459600802 MAKE SURE THAT THE COMPRESSION GASKET IS REGISTERED IN THE PROBE RECESS PRIOR TO TIGHTENING THE ELECTRODE. THIS CENTRES THE GASKET TO THE PROBE. CORRECT INCORRECT ELECTRODE COLUMN BODY...
24675030 Pt.2 - 7 N O T I C E THE HYDRASTEP VESSEL AND PROBE SYSTEM PROVIDES A SELF-FLUSHING FEATURE THAT PREVENTS THE ACCUMULATION OF DEBRIS IN THE VESSEL. THIS ELIMINATES THE NEED FOR PERIODIC BLOWING DOWN OF THE VESSEL. DO NOT BLOW DOWN THE HYDRASTEP VESSEL IF A BLOCKAGE IS SUSPECTED. REFER TO TH...
24675030 Pt.2 - 9 Part 2 - Hydrastep Pressure Parts Chapter 1 General Introduction Chapter 2 Installation Procedures Chapter 3 Fault Repair and Commissioning Chapter 4 Unit Description Chapter 5 Unit Specifications - Hydrastep
Hydrastep Pressure Parts General Introduction 24675030 1-1 1 General Introduction 1.1 PRINCIPLE OF OPERATION ................................................................... 1-3 1.2 WATER LEVEL INDICATION ................................................................... 1-3 Illustrations Figure...
Hydrastep Pressure Parts General Introduction 24675030 1-3 1.1 PRINCIPLE OF OPERATION The Hydrastep systems have been designed as electronic alternatives to conventional visual water gauges on boilers, giving more reliable and safer water level indication. The system is based on the significant diff...
Hydrastep Pressure Parts Installation Procedures 24675030 2- 1 2 Installation Procedures Contents Page No. 2.1 SCOPE OF PROCEDURES ...................................................................... 2-3 2.2 STORAGE .....................................................................................
Installation Procedures Hydrastep Pressure Parts 24675030 2-3 2.1 SCOPE OF PROCEDURES The procedures apply to the Hydrastep Boiler Drum Water Level Equipment supplied by Mobrey, who are responsible, under their supply contract, for delivery of all items of the above equipment listed in the delivery ...
Installation Procedures Hydrastep Pressure Parts 2-4 24675030 The water column is delivered along with the correct number of electrodes of the relevant pressure type (high or low) and complete with gaskets or ferrules and fixing nuts, where applicable. The electrodes should only be fitted to the col...
Installation Procedures Hydrastep Pressure Parts 2-6 24675030 The water connection to the water column must be fully insulated by lagging. The steam connection must also be lagged, but a minimum length of 0.5 metre of the steam leg must be left unlagged where the steam leg joins the water column (se...
Hydrastep Pressure Parts Fault Repair and Commissioning 24675030 3-1 3 Fault Repair and Commissioning Contents Page No. 3.1 BACKGROUND 3-3 3.1.1 SAFETY PRECAUTIONS .......................................................................... 3-3 3.1.2 WATER COLUMN ISOLATION ...............................
Fault Repair and Commissioning Hydrastep Pressure Parts 3-4 24675030 3.1.2 WATER COLUMN ISOLATION After obtaining authority to isolate the column: a) Close off the steam and water isolating valves. b) Where the column is connected to a closed drain, open the drain valve and, when the pressure equali...
Hydrastep Pressure Parts Fault Repair and Commissioning 24675030 3-5 Where scoring or erosion of the electrode port seat has occurred in the water column, the seat can be re-cut to acceptable standards using a service tool as listed below. Service Tool 246791AA – for use with electrodes 246781A* a...
Fault Repair and Commissioning Hydrastep Pressure Parts 3-6 24675030 f) Refit the electrical lead(s) and guard. Recommission as detailed later in this Chapter. 3.1.5 PROCEDURE FOR CHANGING HIGH PRESSURE ELECTRODES Carry out the isolation procedure as detailed in sub-section 3.1.2. Ensure that the tr...
Hydrastep Pressure Parts Fault Repair and Commissioning 24675030 3-7 3.2.2 WATER COLUMN TRANSIENT RESPONSE Starting with the water level at or below mid-gauge, note the lowest ‘steam’ indicating channel at this stage and fully close the water isolating valve nearest the water column quickly. Time th...
Hydrastep Pressure Parts Unit Description 24675030 4-1 4 Unit Description Contents Page No. 4.1 LOW PRESSURE ELECTRODES ............................................................ 4-3 4.2 HIGH PRESSURE ELECTRODES ........................................................... 4-4 4.3 WATER COLUMN (L.P....
Unit Description Hydrastep Pressure Parts 4-4 24675030 4.2 HIGH PRESSURE ELECTRODES High pressure electrodes can be used for pressures in the range 50bar (725psi) to 300bar (4350psi) see Chapter 5 for Specifications. These electrodes are used with the high pressure water column shown in Figure 1.3...
Hydrastep Pressure Parts Unit Specifications - Hydrastep 24675030 5-1 5 Unit Specifications - Hydrastep 5.1 ELECTRODES Type 459600602 Complete with sealing gasket: Metaflex. Screw in type M18 x 1.5 Insulator: Zirconia ceramic Rating 120 bar (1740 psi) at 370 C (698 F) pH range 7-11 Hydrostatical...
Unit Specifications - Hydrastep Hydrastep Pressure Parts Manual 5-2 24675030 5.2 WATER COLUMNS Type Low Pressure: Rating 120bar (1740psi) at 343 C (650 F) Type High Pressure: Rating 210bar (3045psi) at 370 C (698 F) (Series III) Type High Pressure: Rating 300bar (4350psi) at 560 C (1040 ...
Pt.3 - 1 Part 3 Hydrastep 2468CA, CB, CC & CD Electronic Gauging System
Hydrastep 2468 - Technical Manual Appendix A: CSA Approval A-1 A CSA Certified A.1 GENERAL All drawings in this manual are given here for planning purposes only. Before commencing with implementation, reference should always be made to the current issue of the appropriate drawings. Contact the facto...
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