Manuel d'utilisation / d'entretien du produit 2468CB du fabricant Emerson
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Hydrastep 2468CB and 2468CD Hydrastep 2468 Operating Manual 24685034, Rev. AE June 20 11 www.mobrey.com E lectronic Gauging System (Dual Power Supply Version).
CATEGORY SYMPTOM POSSIBLE CAUSES (See Note 1) SOLUTION (See Note 2) PSU (AC) PSU (DC) Hydrastep system does not power-up. Hydrastep system does not power-up. Wrong voltage setting. Incorrect supply. Blown fuse. Incorrect cable termination.
HYDRASTEP START-UP It is possible that some of these conditions wi ll be seen on a new Hydrastep installati on. ** This does not mean th at the equipment you ha ve purchased is faulty ** Due to the nature of the areas that Hydrastep is normall y in stalled, various conditions can occu r that make the instrument oper ate in an un usual manner.
About this manual This manual describes the Hydrastep 2468CB and 2468CD Electron ic Gaug ing Systems along with the recommended options. Except where stated otherwise, the information cont aine d in this manual can be assumed to apply to either system.
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 docum ents).
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24685034 Pt.1 - 1 Part 1 Hydrastep 2468CB & 2468CD Electronic Gauging System.
Pt.1 - 2 24685034.
24685034 Pt.1 - 3 DANGEROUS VOLTAGES ARE PRESENT IN THIS EQUIPMENT. ANY WARNING NOTICES OR PROCEDURES CO NTAINED IN THIS MANUAL OR ON THE EQUIPMENT SHOULD BE STRICTLY OBSERVED TO MAINTAIN SAFETY. THE USE OF THIS EQUI PMENT I N A MANNER NOT SPECIFIED IN THIS MANUAL MAY IMPAI R THE PROTECTION PROVIDED BY THIS EQUIPMENT.
Pt.1 - 4 24685034.
24685034 Pt.1 - 5 Part 1 Contents Chapter 1 Introduction to t he Hydrastep 2468 Electronic Gauging System Chapter 2 2468CB & 2468CD Dual Power Supply Version Chapter 3a 2468 - Relay Output Board O.
Pt.1 - 6 24685034.
Hydrastep 2468CB and 2468CD Manual Introduction to th e Hydrastep 2468 Electronic Gauging S ystem 24685034 1-1 1 Introduction to the Hydrastep 2468 Electronic Gauging System Contents Page No. 1.1 WATER LEVEL MEASUREMENT ...............................
Introduction to the Hydrastep 2468 Electronic Gauging S ystem Hydrastep 2468CB and 2468CD Manual 1-2 24685034 0040 Figure 1.1 - Front panel of the Hydrast ep 2468 gauging system.
Hydrastep 2468CB and 2468CD Manual Introduction to th e Hydrastep 2468 Electronic Gauging S ystem 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 level indication than conventional visual gauges.
Introduction to the Hydrastep 2468 Electronic Gauging S ystem Hydrastep 2468CB and 2468CD Manual 1-4 24685034 Figure 1.3 - Typical Hydrastep 2468 System Ins tallation.
Hydrastep 2468CB and 2468CD Manual Introduction to th e Hydrastep 2468 Electronic Gauging S ystem 24685034 1-5 1.2 HYDRASTEP 2468 ELECTR ONIC GAUGING SYSTEM The Hydrastep 2468 is a sophisticate d and flexible electro nic g auging system.
Introduction to the Hydrastep 2468 Electronic Gauging S ystem Hydrastep 2468CB and 2468CD Manual 1-6 24685034 1.2.3 SYSTEM FAULTS (2468CB OR 2468CD) System fault indication, a yellow LED a nd an opto -isolated output, is provided for a ‘water above steam’ condition, an electro de fau lt or wiring failure and the detection of an internal fault.
Hydrastep 2468CB and 2468CD Manual Introduction to th e Hydrastep 2468 Electronic Gauging S ystem 24685034 1-7 1.4 HYDRASTEP 2468 UPGRAD E PATHS AND AVAILABLE OPTIONS Table 1.1 describes the available versio ns of the Hyd rastep 2468 Electronic Gauging System and their possible options.
Introduction to the Hydrastep 2468 Electronic Gauging S ystem Hydrastep 2468CB and 2468CD Manual 1-8 24685034.
Hydrastep 2468CB and 2468CD Manual 2468CB & 2468CD Dual Power Supply Version 24685034 2-1 2 2468CB & 2468CD Dual Power Supply V ersion Contents Page No. 2.1 INTRODUCTION .........................................................................
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 ..................................
Hydrastep 2468CB and 2468CD Manual 2468CB & 2468CD Dual Power Supply Version 24685034 2-3 2.1 INTRODUCTION This chapter introduce s the dual power suppl y version of the Hydra step 2468 Electronic Gauging System, its mechanical installation, system configuration, simple fault analysis/corrective action capability and its specificati on.
2468CB & 2468CD Dual Power Supply Version Hydrastep 2468CB and 2468CD Manual 2-4 24685034 Figure 2.1: Outline drawing showing PCB layout and inter connections.
Hydrastep 2468CB and 2468CD Manual 2468CB & 2468CD Dual Power Supply Version 24685034 2-5 2.3.1 INPUT BOARD (PCB 24680501 AND PCB 24 680516) The input board processes t he electrode inputs to provide water level data for display purposes and a current output rep resenting the water level.
2468CB & 2468CD Dual Power Supply Version Hydrastep 2468CB and 2468CD Manual 2-6 24685034 2.3.3 DISPLAY BOARD (PCB 24680 515 ) The display board receives its powe r supplies and electrode data f rom the input boards. This data is decoded and used to illumin ate the requi red LEDs mounted on the display board.
Hydrastep 2468CB and 2468CD Manual 2468CB & 2468CD Dual Power Supply Version 24685034 2-7 2.3.3.2 Links LK2, LK3, LK4 and LK5 These links are used to select either the 8 - 16 display mode (two LE Ds pe r electrode) or the 18 - 32 display mode (one LED per ele ctrode).
2468CB & 2468CD Dual Power Supply Version Hydrastep 2468CB and 2468CD Manual 2-8 24685034 2.4 INSTALLATION This section deals with the mecha nical insta llation of the electronic enclosure an d the electrical connections requ ired for the basic sy ste m.
Hydrastep 2468CB and 2468CD Manual 2468CB & 2468CD Dual Power Supply Version 24685034 2-9 Figure 2.2: Installation diagram for Hydrastep 246 8 Electronic Gauging System unit.
2468CB & 2468CD Dual Power Supply Version Hydrastep 2468CB and 2468CD Manual 2-10 24685034 2.4.2 ELECTRICAL INSTALLATION This section deals with the interco nnecti on between the ele ctrod es and .
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 electrod es have been fitted to the water column.
2468CB & 2468CD Dual Power Supply Version Hydrastep 2468CB and 2468CD Manual 2-12 24685034 Figure 2.3: Enclosure cable layout for 16 electr ode system 2.4.2.3 Connecting the Electrode Ca ble Asse mblies 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 2-13 Wiring to the ‘hinge-side’ 24680 501 board (even-num bere d electrodes) should not be pressed hard against the ribbon cables, but instead run forwa rd of the co nne ctors and away from the side of the casing.
2468CB & 2468CD Dual Power Supply Version Hydrastep 2468CB and 2468CD Manual 2-14 24685034 6. With power disconnected relea se voltage selection plug PL9 by squee zing lugs. Insert appropriate selector plug. 7 . Remove fuse and fit 200mA ceramic ant i-su rge fuse for 240Vac n ominal and 400mA ceramic anti-surge fuse for 110Vac nominal.
Hydrastep 2468CB and 2468CD Manual 2468CB & 2468CD Dual Power Supply Version 24685034 2-15 2.4.2.5 Analogue Output Conne ction WARNING Mains voltages are present in this instrument when power is connected. De-energise befor e ope ning front cover.
2468CB & 2468CD Dual Power Supply Version Hydrastep 2468CB and 2468CD Manual 2-16 24685034 2.4.2.6 Opto-Isolated Fault Output Con nection WARNING Mains voltages are present in this instrument when power is connected. De-energise befor e ope ning front cover.
Hydrastep 2468CB and 2468CD Manual 2468CB & 2468CD Dual Power Supply Version 24685034 2-17 This concludes the electrical in stallation require ments for the ba sic instrument config uration.
2468CB & 2468CD Dual Power Supply Version Hydrastep 2468CB and 2468CD Manual 2-18 24685034 2.5.1.2 Pulsed Output Setting As configured at the factory, the analogu e output pulses if a fault condition occu rs. 1. To disable this feature the split pad SP10 must be broken by cutting the track that passes between the pad s.
Hydrastep 2468CB and 2468CD Manual 2468CB & 2468CD Dual Power Supply Version 24685034 2-19 2.5.1.4 Configuring the Unit to Detect Electrode Error WARNING Mains voltages are present in this instrument when power is connected. De-energise befor e ope ning front cover.
2468CB & 2468CD Dual Power Supply Version Hydrastep 2468CB and 2468CD Manual 2-20 24685034 2.5.2 DISPLAY BOARD 24680515 The Display Board needs to know how many electrodes a re being used and if one or two inp ut boards are being used.
Hydrastep 2468CB and 2468CD Manual 2468CB & 2468CD Dual Power Supply Version 24685034 2-21 Figure 2.5- Location of display board links LK1 to LK5 & switc h SW1 with configuration details Note:.
2468CB & 2468CD Dual Power Supply Version Hydrastep 2468CB and 2468CD Manual 2-22 24685034 2.5.2.3 ‘Switching Threshold’ Setting WARNING Mains voltages are present in this instrument when power is connected. De-energise befor e ope ning front cover.
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 fro nt panel an d by the fault output on the displ ay board.
2468CB & 2468CD Dual Power Supply Version Hydrastep 2468CB and 2468CD Manual 2-24 24685034 Indication Fault(s) Analysis and Correctiv e Action State 1 (contd.) Incorrect wiring, broken connection or damaged cable assembly Affected electrode(s) alternate between water and steam.
Hydrastep 2468CB and 2468CD Manual 2468CB & 2468CD Dual Power Supply Version 24685034 2-25 Indication Fault(s) Analysis and Correctiv e Action State 1 (contd.) 3. Insert these sockets in place of the electrode cable sockets in the input boards, the level disp lay shoul d now show an all steam state and no fault indication.
2468CB & 2468CD Dual Power Supply Version Hydrastep 2468CB and 2468CD Manual 2-26 24685034 Indication Fault(s) Analysis and Correctiv e Action State 3 (contd.
Hydrastep 2468CB and 2468CD Manual 2468CB & 2468CD Dual Power Supply Version 24685034 2-27 Indication Fault(s) Analy sis and Corrective Action State 5 Bottom half of fault LED illuminated One or m.
2468CB & 2468CD Dual Power Supply Version Hydrastep 2468CB and 2468CD Manual 2-28 24685034 Indication Fault(s) Analysis and Correctiv e Action State 5 (contd.
Hydrastep 2468CB and 2468CD Manual 2468CB & 2468CD Dual Power Supply Version 24685034 2-29 Indication Fault(s) Analysis and Correctiv e Action State 7 Only odd or even LEDs illuminated No power to one input board or a power supply fault Only odd LEDs illuminating indicates a problem with the left hand input board.
2468CB & 2468CD Dual Power Supply Version Hydrastep 2468CB and 2468CD Manual 2-30 24685034 2.6.1 COMPONENT REPLACEMENT The Hydrastep 2468 contains no u ser-replaceabl e components. Board failure requires the replacement of the entire printed circuit board.
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.
2468CB & 2468CD Dual Power Supply Version Hydrastep 2468CB and 2468CD Manual 2-32 24685034 2.7 SPECIFICATION Enclosure: 425mm x 325mm x 163mm (16.7in x 12.8in x 6.4in) Brushed stainless steel Wall-mounting lP65 / NEMA4X Gland plate - stainless steel 250mm x 12 0mm (9.
Hydrastep 2468CB and 2468CD Manual Wiring Diagrams for Dual Power Suppl y Version 24685034 2-WD.1 2 Wiring Diagrams for Dual Power Supply V ersion Contents Page No. Figure 2.1 - Electrode cable connections to 8 port col umn ...........................
Wiring Diagrams for Dual Power Supply Ve rsion Hydrastep 2468CB and 2468CD Manual 2-WD. 2 24685034.
Hydrastep 2468CB and 2468CD Manual Wiring Diagrams for Dual Power Suppl y Version 24685034 2-WD.3 Figure 2.1 - Electrode cable connections to 8 por t column.
Wiring Diagrams for Dual Power Supply Ve rsion Hydrastep 2468CB and 2468CD Manual 2-WD. 4 24685034 Figure 2.2 - Electrode cable connections to 10 p o rt column.
Hydrastep 2468CB and 2468CD Manual Wiring Diagrams for Dual Power Suppl y Version 24685034 2-WD.5 Figure 2.3 - Electrode cable connections to 12 p o rt column.
Wiring Diagrams for Dual Power Supply Ve rsion Hydrastep 2468CB and 2468CD Manual 2-WD. 6 24685034 Figure 2.4 - Electrode cable connections to 14 p o rt column.
Hydrastep 2468CB and 2468CD Manual Wiring Diagrams for Dual Power Suppl y Version 24685034 2-WD.7 Figure 2.5 - Electrode cable connections to 16 p o rt column.
Wiring Diagrams for Dual Power Supply Ve rsion Hydrastep 2468CB and 2468CD Manual 2-WD. 8 24685034 Figure 2.6 - Electrode cable connections to 18 p o rt column.
Hydrastep 2468CB and 2468CD Manual Wiring Diagrams for Dual Power Suppl y Version 24685034 2-WD.9 Figure 2.7 - Electrode cable connections to 20 p o rt column.
Wiring Diagrams for Dual Power Supply Ve rsion Hydrastep 2468CB and 2468CD Manual 2-WD. 10 24685034 Figure 2.8 - Electrode cable connections to 22 p o rt column.
Hydrastep 2468CB and 2468CD Manual Wiring Diagrams for Dual Power Suppl y Version 24685034 2-WD.11 Figure 2.9 - Electrode cable connections to 24 p o rt column.
Wiring Diagrams for Dual Power Supply Ve rsion Hydrastep 2468CB and 2468CD Manual 2-WD. 12 24685034 Figure 2.10 - Electrode cable connections to 26 port column.
Hydrastep 2468CB and 2468CD Manual Wiring Diagrams for Dual Power Suppl y Version 24685034 2-WD.13 Figure 2.11 - Electrode cable connections to 28 port column.
Wiring Diagrams for Dual Power Supply Ve rsion Hydrastep 2468CB and 2468CD Manual 2-WD. 14 24685034 Figure 2.12 - Electrode cable connections to 30 port column.
Hydrastep 2468CB and 2468CD Manual Wiring Diagrams for Dual Power Suppl y Version 24685034 2-WD.15 Figure 2.13 - Electrode cable connections to 32 port column.
Wiring Diagrams for Dual Power Supply Ve rsion Hydrastep 2468CB and 2468CD Manual 2-WD. 16 24685034.
Hydrastep 2468CB and 2468CD Manua l 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-INST ALLATION INSPECTION ........................
Relay Output Board Option Hydrastep 2468CB and 2468 CD Manua l 3a-2 24685034 Illustrations Figure 3a.1 - View of relay output board sho wing switch positions and output pin details . 3a-6 Tables Table 3a.1 - Electrode selections for rel ays RL 1 to RL4 .
Hydrastep 2468CB and 2468CD Manua l Relay Output Board Option 24685034 3a-3 3A.1 GENERAL DESCRIPTION The Relay Output Board (PCB 24680504) has fou r relays and is mounted o n top of the input board using 3 nylon spacers.
Relay Output Board Option Hydrastep 2468CB and 2468 CD Manua l 3a-4 24685034 3a.2.2.1 Fitting the Nylon Spacers to the Rela y Output Board The spacers fit into the holes within the wh ite-bordered area s on th e output board (see Figure 3a.1 on page 3a-6).
Hydrastep 2468CB and 2468CD Manua l Relay Output Board Option 24685034 3a-5 3A.2.3 ELECTRICAL INSTALLATION This sub-section deal s with the output of the st ates of the four relays. Two 8-way sockets are provided with each output board through wh ich the relay outputs are delivered to their external destinations.
Relay Output Board Option Hydrastep 2468CB and 2468 CD Manua l 3a-6 24685034 3A.3 RELAY BOARD CONFIGURATION The 24680504 Relay Output Board ha s three configuration switches: SW6: Selects Electrode or Alarm state for RL1. SW1 - SW4: Selects individual electrode for relay s RL1 to RL4.
Hydrastep 2468CB and 2468CD Manua l 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 befor e ope ning front cover.
Relay Output Board Option Hydrastep 2468CB and 2468 CD Manua l 3a-8 24685034 3a.3.1.3 Relay Energisation (‘In Steam’ or ‘In Water’) - SW5 This is a four-channel swit ch, one ch annel allocated per relay. The switch sel ect s whether the relay is energised whe n the selected electrode is in water or is in steam .
Hydrastep 2468CB and 2468CD Manua l Relay Output Board Option 24685034 3a-9 3A.3.2 ALARM AND TRIPPING FACILITIES The relay boards provide hi gh and low water level alarm and trip facilities for the 2468 Hydrastep system. Four to eight relays can be made available for each input board fitted.
Relay Output Board Option Hydrastep 2468CB and 2468 CD Manua l 3a-10 24685034 3a.3.2.3 ‘One out of Two’ Relay Alarm System Either of the relays involved can cause an al arm when their assig ned electrode registers an alarm condition.
Hydrastep 2468CB and 2468CD Manua l Relay Output Board Option 24685034 3a-11 3a.3.2.4 ‘Two out of Two’ Relay Alarm System This system requires both relays to opera te to cause an alarm whe n their assig ned electrodes register an alarm condition.
Relay Output Board Option Hydrastep 2468CB and 2468 CD Manua l 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 sy stem (NO FAULTS) will perform a low level trip at electrode level 3 .
Hydrastep 2468CB and 2468CD Manua l Relay Output Board Option 24685034 3a-13 In the following diagrams (6A & 6B) indicate the electrode channel selected for each relay. A fully functioning sy stem (NO FAULTS) will perform a low level trip at electrode level 2 .
Relay Output Board Option Hydrastep 2468CB and 2468 CD Manua l 3a-14 24685034 3a.3.2.6 ‘Two out of Three’ Relay Alarm System In the following diagrams (7A & 7B) indicate the electrode chann el selected for each relay. A fully functioning system (NO FAULTS) will cause a lo w level trip at electrode level 2 .
Hydrastep 2468CB and 2468CD Manua l Relay Output Board Option 24685034 3a-15 3A.4 COMPONENT REPLACEMENT The relay board contains no repla ceable circuit component s, failure of the board requires replacement of the entire board. The on ly com ponent that can be replaced is the nylon spacer.
Relay Output Board Option Hydrastep 2468CB and 2468 CD Manua l 3a-16 24685034 3A.5 SPECIFICATION Outputs: 4 x Alarm/Trip Relays Relay Conta ct Ra ting: ac dc Maximum voltage: 250V 125V Maximum current.
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 D ESCRIPTION ........................................................................................ 3 3B.
Delay Relay Output Board Option Hydrastep 2468CB and 2468CD Manual 3b-2 24685034 3B.5 SPECIFI CATION ..................................................................................................... 18 Illustrations Figure 3b.1 - View of relay output board sh owing switch positions and output pin details .
Hydrastep 2468CB and 2468CD Manual Delay Relay Output Board Option 24685034 3b-3 3B.1 GENERAL DESCRIPTION The Delay Relay Output Board (PCB 246 8050 9) is mounted on top of the input board using 3 nylon spacers. Electrical connection between the two board s is via plug and socket (SK1 on the input board and PL1 on the delay relay output board).
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.
Hydrastep 2468CB and 2468CD Manual Delay Relay Output Board Option 24685034 3b-5 3B.2.3 ELECTRICAL INSTALLATION This sub-section deals with the output of the stat es of the four relays. Two 8-way sockets are provided with each output board throug h wh ich the relay outputs are delive red to their external destinations.
Delay Relay Output Board Option Hydrastep 2468CB and 2468CD Manual 3b-6 24685034 3B.3 DELAY RELAY BO ARD CONFIGURATION The 24680509 Delay Relay Output Board has th ree configuration switch es a nd twenty split pad links for delay time selection. The switch es are: SW6: Selects Electrode or Alarm state f or RL1.
Hydrastep 2468CB and 2468CD Manual Delay Relay Output Board Option 24685034 3b-7 3B.3.1 DELAY RELAY OUTPUT BOARD 3b.3.1.1 Configuring the Delay Relay Output Board WARNING Mains voltages are present in this instrument when power is connected. De-energise befor e ope ning front cover.
Delay Relay Output Board Option Hydrastep 2468CB and 2468CD Manual 3b-8 24685034 3b.3.1.3 Relay Energisation (‘In Steam’ or ‘In Water’) - SW5 This is a four-channel swit ch, one ch annel alloca ted per relay.
Hydrastep 2468CB and 2468CD Manual Delay Relay Output Board Option 24685034 3b-9 3b.3.1.6 Delay Circuit Configur ation By means of split pad links incorporated in each of the relay delay circuits, delays can be introduced or bypassed an d the following delays are made availab l e (se e also Figure 3b.
Delay Relay Output Board Option Hydrastep 2468CB and 2468CD Manual 3b-10 24685034 3b.3.1.7 Configuring the Delay Circuit Split Pads WARNING Mains voltages are present in this instrument when power is connected. De-energise befor e ope ning front cover.
Hydrastep 2468CB and 2468CD Manual Delay Relay Output Board Option 24685034 3b-11 3B.3.2 ALARM AND TRIPPING FACILITIES The relay boards provide hi gh and low water level alarm and trip facilities for the 2468 Hydrastep system. Four to eight relays can be made available for each input board fitted.
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 al arm when their assig ned electrode registers an alarm condition.
Hydrastep 2468CB and 2468CD Manual Delay Relay Output Board Option 24685034 3b-13 3b.3.2.4 ‘Two out of Two’ Relay Alarm System This system requires both relays to opera te to cause an alarm whe n their assig ned electrodes register an alarm condition.
Delay Relay Output Board Option Hydrastep 2468CB and 2468CD Manual 3b-14 24685034 3b.3.2.5 ‘Two out of Four’ Relay Alarm Sy stem In the following diagrams (5A & 5B) indicate the electrode channel selected for each relay. A fully functioning sy stem (NO FAULTS) will perform a low level trip at electrode level 3 .
Hydrastep 2468CB and 2468CD Manual Delay Relay Output Board Option 24685034 3b-15 3b.3.2.6 ‘Two out of Four’ Relay Alarm Sy stem (contd.) In the following diagrams (6A & 6B) indicate the electrode channel selected for each relay. A fully functioning sy stem (NO FAULTS) will perform a low level trip at electrode level 2 .
Delay Relay Output Board Option Hydrastep 2468CB and 2468CD Manual 3b-16 24685034 3b.3.2.7 ‘Two out of Three’ Relay Alarm System In the following diagrams (7A & 7B) indicate the electrode chann el selected for each relay. A fully functioning system (NO FAULTS) will cause a lo w level trip at electrode level 2 .
Hydrastep 2468CB and 2468CD Manual Delay Relay Output Board Option 24685034 3b-17 3B.4 COMPONENT REPLACEMENT The delay relay board contains n o repl aceabl e circuit components, failure of the board requires replaceme nt of the entire boa rd. The only component that can be repl aced is the nylon spacers.
Delay Relay Output Board Option Hydrastep 2468CB and 2468CD Manual 3b-18 24685034 3B.5 SPECIFICATION Outputs: 4 x Alarm/Trip Relays Relay Conta ct Ra ting: ac dc Maximum voltage: 250V 125V Maximum cur.
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 D ESCRIPTION ................................................................................
Opto-isolated Output Board Option Hydrastep 2468CB & 2468CD Manual 3c-2 24685034 Illustrations Figure 3c.1 - View of opto-isolated board showing switch po sition s and output pin details ............................................................
Hydrastep 2468CB & 2468CD Manual Opto-isolated Output Board Option 24685034 3c-3 3C.1 GENERAL DESCRIPTION The Opto-isolated Output Board (P CB 2468 0505 ) has four opto-isolate d outpu ts and is mounted on top of the input board using 3 nylon spacers.
Opto-isolated Output Board Option Hydrastep 2468CB & 2468CD Manual 3c-4 24685034 3C.2.2 MECHANICAL INSTALLATION The output board is mounted directly on top of the input board.
Hydrastep 2468CB & 2468CD Manual Opto-isolated Output Board Option 24685034 3c-5 3C.2.3 ELECTRICAL INSTALLATION 3c.2.3.1 PCB Interconnections Signal interconnection between the inp ut board (PCB 1) and the output board (PCB 5) is direct via the SK1/PL1 12-way Berg connectors.
Opto-isolated Output Board Option Hydrastep 2468CB & 2468CD Manual 3c-6 24685034 3C.3 OPTO-ISOLATED OUTP UT BOARD CONFIGURATION The 24680505 Opto-isolat ed Output Board has three configuration switche s: SW6: Selects Electrode or Alarm state for Opto -output 1.
Hydrastep 2468CB & 2468CD Manual Opto-isolated Output Board Option 24685034 3c-7 3C.3.1 CONFIGURING THE OPTO-ISOLATED OU TPUT BOARD WARNING Mains voltages are present in this instrument when power is connected. De-energise befor e ope ning front cover.
Opto-isolated Output Board Option Hydrastep 2468CB & 2468CD Manual 3c-8 24685034 3c.3.1.2 Electrode/Alarm Operati on (output 1 function onl y ) - SW6 Opto-isolated output from TR2 can be configured to receive either an electrode input or it can be used as the ‘system fault’ output.
Hydrastep 2468CB & 2468CD Manual Opto-isolated Output Board Option 24685034 3c-9 3C.3.2 ALARM AND TRIPPING FACILITIES The output boards provide high and low water level al arm and trip facilities for the 2468 Hydrastep system. Four to eight opto-isolated outputs can be ma de available f or each input board fitted.
Opto-isolated Output Board Option Hydrastep 2468CB & 2468CD Manual 3c-10 24685034 3c.3.2.3 ‘One out of Two’ Opto-output Alarm System Either of the opto-outputs involved can signal an alar m when their assigned elec trode dete cts a water/steam interface change.
Hydrastep 2468CB & 2468CD Manual Opto-isolated Output Board Option 24685034 3c-11 3c.3.2.4 ‘Two out of T wo’ Opto-output Alarm System This system requires both opto-outputs to operate to cause an ala r m when thei r assigned electrodes register an alarm conditio n.
Opto-isolated Output Board Option Hydrastep 2468CB & 2468CD Manual 3c-12 24685034 3c.3.2.5 ‘Two out of Four’ Opto-output Alarm System In the following diagrams (5A & 5B) indi cate the electrode channel selected for each opto-output.
Hydrastep 2468CB & 2468CD Manual Opto-isolated Output Board Option 24685034 3c-13 3c.3.2.6 ‘Two out of Three’ Opto-output Alarm Sy stem In the following diagrams (6A & 6B) indicate the electrode chann el selected for each opto- output.
Opto-isolated Output Board Option Hydrastep 2468CB & 2468CD Manual 3c-14 24685034 3C.4 COMPONENT REPLACEMENT The components used on t he opto-i solated output board are fitted using ‘surfa ce mount technology’ and fault remedial action is by the replacement of the whol e output board.
Hydrastep 2468CB & 2468CD Manual Opto-isolated Output Board Option 24685034 3c-15 3C.5 SPECIFICATION Outputs: 4 x Alarm/Trip Opto-isolated outputs Opto-Isolated Output Rat i ng: Maximum Open-circuit Voltage: 30V dc. Maximum Short-circuit Current: 1A Short-circuit Voltage Drop: 1.
Opto-isolated Output Board Option Hydrastep 2468CB & 2468CD Manual 3c-16 24685034.
Hydrastep 2468CB & 2468CD Manual Remote Display Options 24683B, C & D 24685034 4-1 4 Remote Display Options 24683B, C, & D Contents Page No. 4.1 REMOTE DISPLAY OPTIONS .................................................................. 4-3 4.
Remote Display Options 24683B, C & D Hydrastep 2468CB & 2468CD Manual 4-2 24685034 Illustrations Figure 4.1 - Location of link headers for selecting the di splay mode .................................... 4-4 Figure 4.2 - Interconnection cable for a single remote display .
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 l evel state and fault alarm state of the Hydras tep 2468 Electronic Gauging System.
Remote Display Options 24683B, C & D Hydrastep 2468CB & 2468CD Manual 4-4 24685034 4.2 CONFIGURATION All remote displays can be configured for oper ation with 8 to 16 electrodes (two L E Ds pe r electrode) or 18 to 32 electrodes (one L E D per el ectrode).
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 246 83D for o peration with 18 to 32 electrodes is: 1. Undo the four screws securing the tr ansparent cover a nd 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 pan el mounting and type 24683D is intended for wall m ount ing.
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 2 468 u nit. One remote display can be powered from the main unit, but all the others must have a local supply.
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 con necte d to the main 2468 unit in two ways: ‘star’ or ‘daisy chain’. (See Figure 4.
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 conne cted in a ‘star’. Where more than one re mote display is in use, local supplies with i sola t ed outputs m ust be used to power the extra unit(s).
Remote Display Options 24683B, C & D Hydrastep 2468CB & 2468CD Manual 4-10 24685034 4.4.3 EXAMPLE OF A `DAISY CHAIN' SYSTEM Figure 4.5 shows two remote displays connected in a `daisy chain'. Where more than one remote display is in use, local supplies with isolated outputs must be used to power the extra unit(s).
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 ca n be used for each re mote display that is to be connected: 1. Gain access to the remote display terminal blo ck.
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 po we r is connected. De-energise before o pening the front cover.
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 complet e agreement between the remote display and the Hydrastep level indicator displ ay. 4.
Remote Display Options 24683B, C & D Hydrastep 2468CB & 2468CD Manual 4-14 24685034 Indication Fault Analysis and Correctiv e Action Bottom half of fault LED illuminated and odd LEDs flashing at 1Hz, or odd LEDs off. Power present, but loss of serial data.
Hydrastep 2468CB & 2468CD Manual Remote Display Options 24683B, C & D 24685034 4-15 Indication Fault Analysis and Correctiv e Action Flickering Display Corruption of signa l data Most probably caused b y bad shie l ding (screening) of the remote display cabling or b y bad shield connections to ground.
Remote Display Options 24683B, C & D Hydrastep 2468CB & 2468CD Manual 4-16 24685034 4.7 COMPONENT REPLACEMENT Hydrastep remote display units contain no us er-re pla ceable electronic components. Board failure requires the faulty PCB to be remov ed and returned fo r se rvice and a serviceable PCB to be fitted in its place.
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 24683 C: Pane l mounting; 24683D: Rugged enclos ure, to IP65/NEMA 4X DIMENSIONS 24683B: 14 4m m×72mm×200mm deep (5.
Remote Display Options 24683B, C & D Hydrastep 2468CB & 2468CD Manual 4-18 24685034.
Hydrastep Pressure Part s Operating Manual Part No: 24675030 Status: B Issue: A Authors: J. Smith / M. Le-Fevre / RCD Date: March 2006.
Pt.2 - 2 24675030.
24675030 Pt.2 - 3 About this manual This manual describes various proced ures involved in th e installation of the Hydrastep water columns, their attachments and the electrodes used in dete rminin g the level of water in the column. Part 2 - Pressure Parts Chapter 1 is a general introduction to the H y drastep s ystem of wate r level determination.
Pt.2 - 4 24675030.
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 ELECTR ODE. THIS CENTRES THE GASKET TO THE PROBE.
Pt.2 - 6 24675030.
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 DE BRIS 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.
Pt.2 - 8 24675030.
24675030 Pt.2 - 9 Part 2 - Hydrastep Pressure Part s Chapter 1 General Introduction Chapter 2 Installation Procedures Chapter 3 Fault Repair and Commissioning Chapter 4 Unit Description Chapter 5 Unit.
Pt.2 - 10 24675030.
Hydrastep Pressure Parts General Introduction 24675030 1-1 1 General Introduction 1.1 PRINCIPLE OF OPERATION ................................................................... 1-3 1.2 WATER LEVEL INDICATION ...........................................
General Introduction Hydrastep Pressure Parts 1-2 24675030.
Hydrastep Pressure Parts General Introduction 24675030 1-3 1.1 PRINCIPLE OF OPERATION The Hydrastep systems ha ve been de signed as elec tronic alternati ves to conventional visual water gauges on boilers, giving more reliable an d safer water level indication.
General Introduction Hydrastep Pressure Parts 1-4 24675030 Figure 1.2 - Low pressure water colu mn (120bar, 1740psi).
Hydrastep Pressure Parts General Introduction 24675030 1-5 Figure 1.3 - High pressure water column (210 ba r, 3045psi and 300 bar, 4350psi).
General Introduction Hydrastep Pressure Parts 1-6 24675030.
Hydrastep Pressure Parts Installation Procedures 24675030 2- 1 2 Inst allation Procedures Contents Page No. 2.1 SCOPE OF PROCEDURES ...................................................................... 2-3 2.2 STORAGE ................................
Installation Procedures Hydrastep Pressure Parts 2-2 24675030.
Installation Procedures Hydrastep Pressure Parts 24675030 2-3 2.1 SCOPE OF PROCEDURES The procedures apply to the Hydrastep Boile r Drum Wate r 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 schedule s.
Installation Procedures Hydrastep Pressure Parts 2-4 24675030 The water column is delivered along wit h the co rrect number of electrodes of the relevant pressure type (high or low) and complete with gaskets or ferrules and fixing nuts, where applicable.
Installation Procedures Hydrastep Pressure Parts 24675030 2-5 Figure 2.1 - Universal weld profile The Steam and Water connections o n the wate r column must be set to position the water column at the correct level before they are we lded in place, Figure 2.
Installation Procedures Hydrastep Pressure Parts 2-6 24675030 The water connection to the water colu mn must be fully insulated by lagging. The steam connection must also be lagged, but a minimum len g th of 0.5 metre of the steam leg must be left unlagged where the steam leg joins the water col umn (see Figure 2.
Installation Procedures Hydrastep Pressure Parts 24675030 2-7 Figure 2.2 - Typical water column installation, showing optional column lagging..
Installation Procedures Hydrastep Pressure Parts 2-8 24675030 Figure 2.3 - Typical water column suspension.
Hydrastep Pressure Parts Fault Repair and Commissioning 24675030 3-1 3 Fault Rep air 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 3-2 24675030.
Hydrastep Pressure Parts Fault Repair and Commissioning 24675030 3-3 3.1 BACKGROUND With any steam/water detection gauge, a partial blo c kag e or leak within the pressurised system may result in incorrect water level indication.
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 cl osed drain, op en the drai n valve and, when the pressure equalises, close the drai n valve.
Hydrastep Pressure Parts Fault Repair and Commissioning 24675030 3-5 Where scoring or erosi on of the electrode por t seat has occurred in the water column, the seat can be re-cut to acceptable standard s using a service tool a s listed belo w.
Fault Repair and Commissioning Hydrastep Pressure Parts 3-6 24675030 f) Refit the electrical lead(s) and guard. Recommission a s detaile d later in this Cha pter. 3.1.5 PROCEDURE FOR CHANGING HIGH PRESSURE ELECTRODES Carry out the isolation procedure as detailed in sub-section 3.
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 mi d-gauge, note the lowest ‘steam’ indicating channel at this stage and fully close the wa ter isolating valve neare st the water column quickly.
Fault Repair and Commissioning Hydrastep Pressure Parts 3-8 24675030.
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 .....................................
Unit Description Hydrastep Pressure Parts 4-2 24675030.
Hydrastep Pressure Parts Unit Description 24675030 4-3 4.1 LOW PRESSURE ELECTRODES These electrodes can be u sed for pressures of 50bar (725psi ) for 459600802 units, and up t o 120bar (1740psi) for 459 600602 units - see Chapter 5 for Specifi cations.
Unit Description Hydrastep Pressure Parts 4-4 24675030 4.2 HIGH PRESS URE ELECTRODES High pressure electrodes can be used for pres su res in the range 50bar (72 5psi) to 300bar (4350psi) se e Cha pter 5 for Specifications. These electrode s are used with the high pressure water column sh own in Fig ure 1.
Hydrastep Pressure Parts Unit Description 24675030 4-5 4.3 WATER COLUMN (L.P.) The low pressure water column is ma nufactured from carbon ste el, extruded rectangular hollow bar. The electrode ports are d rill ed and fitted with ‘helicoil’ inserts to accept the electrodes.
Unit Description Hydrastep Pressure Parts 4-6 24675030 4.4 WATER COLUMN (H.P.) The high pressure water column is ma nu factured from 2” NB SCH S carbon steel pipe. The inserts used are made from high grade stai nless steel and are weld ed into position on the water column body.
Hydrastep Pressure Parts Unit Description 24675030 4-7 4.5 WATER COLUMN (H.P. SUPERCRITICAL) The high pressure water column is ma nu factured from 2” NB SCH S stainless steel pipe. The inserts used are made from Stainless steel a nd are welded into position on the water column body.
Unit Description Hydrastep Pressure Parts 4-8 24675030.
Hydrastep Pressure Parts Unit Specificatio ns - Hy drastep 24675030 5-1 5 Unit S pecifications - Hydrastep 5.1 ELECTRODES Type 459600602 Complete with sealing gasket: Metaflex.
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 (30.
Pt.3 - 1 Part 3 Hydrastep 2468CA, CB, CC & CD Electronic Gauging System.
Pt3-2.
Hydrastep 2468 - Technical Manual Appendix A: CSA Approval A-1 A CSA Certified A.1 GENERAL All drawings in this manual ar e given here for planning pur poses only. Before commencing with implementation, reference should always be made to the current issue of the appropriate dra wings.
Appendix A: CSA Approval H ydrastep 2468 - Technical Manual A-2 Drawing 24685037 Sheet 1 of 2: Hydrastep Control Diagram, CS A Certified Connections.
Hydrastep 2468 - Technical Manual Appendix A: CSA Approval A-3 Drawing 24685037 Sheet 2 of 2: Hydrastep Control Diagram, Notes for Sheet 1.
Appendix A: CSA Approval H ydrastep 2468 - Technical Manual A-4.
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Hydrastep 2468 Operating Manual 24685034, Rev. AE June 2011 The Emerson l ogo is a t rade mark a nd service mar k of Emers on Electric Co. Mobrey is a registere d trademark of Mobr ey Ltd. A ll other marks a re the pr operty of thei r respecti ve owners.
Un point important après l'achat de l'appareil (ou même avant l'achat) est de lire le manuel d'utilisation. Nous devons le faire pour quelques raisons simples:
Si vous n'avez pas encore acheté Emerson 2468CB c'est un bon moment pour vous familiariser avec les données de base sur le produit. Consulter d'abord les pages initiales du manuel d'utilisation, que vous trouverez ci-dessus. Vous devriez y trouver les données techniques les plus importants du Emerson 2468CB - de cette manière, vous pouvez vérifier si l'équipement répond à vos besoins. Explorant les pages suivantes du manuel d'utilisation Emerson 2468CB, vous apprendrez toutes les caractéristiques du produit et des informations sur son fonctionnement. Les informations sur le Emerson 2468CB va certainement vous aider à prendre une décision concernant l'achat.
Dans une situation où vous avez déjà le Emerson 2468CB, mais vous avez pas encore lu le manuel d'utilisation, vous devez le faire pour les raisons décrites ci-dessus,. Vous saurez alors si vous avez correctement utilisé les fonctions disponibles, et si vous avez commis des erreurs qui peuvent réduire la durée de vie du Emerson 2468CB.
Cependant, l'un des rôles les plus importants pour l'utilisateur joués par les manuels d'utilisateur est d'aider à résoudre les problèmes concernant le Emerson 2468CB. Presque toujours, vous y trouverez Troubleshooting, soit les pannes et les défaillances les plus fréquentes de l'apparei Emerson 2468CB ainsi que les instructions sur la façon de les résoudre. Même si vous ne parvenez pas à résoudre le problème, le manuel d‘utilisation va vous montrer le chemin d'une nouvelle procédure – le contact avec le centre de service à la clientèle ou le service le plus proche.
