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Operating Manual

24685033, Rev BA

Jan 2022

Delta Mobrey Hydrastep 2468CA and 2468CC

Electronic Gauging System (Single Input Board)

Summary of Contents for 2468CA

Page 1: ...Operating Manual 24685033 Rev BA Jan 2022 Delta Mobrey Hydrastep 2468CA and 2468CC Electronic Gauging System Single Input Board...

Page 2: ......

Page 3: ...nit must be connected to ground earth using the marked case stud before control or signal leads are connected The ground earth connection must have a rating of 25 Amps Avoid using unsafe equipment If...

Page 4: ...heck the fuse accessible from the interior is the correct rating before powering the equipment The rating of the ac line fuse must be in accordance with the voltage of the ac supply Should any fuse co...

Page 5: ...Title Page Jan 2022 Hydrastep 2468CA and 2468CC iii Direct Current Alternating Current Earth ground terminal Protective conductor terminal Caution refer to accompanying documents Symbols used in this...

Page 6: ...Title Page Jan 2022 Operating Manual 24685033 Rev BA iv Hydrastep 2468CA and 2468CC...

Page 7: ...les and connections for the Input board ac mains version 3 3 3 1 3 Power cables and connections for the Input board dc supply version 3 4 3 1 4 Electrode cables and connections on the Input board 3 5...

Page 8: ...8 5 3 1 Fault analysis and corrective actions 5 8 5 4 TROUBLESHOOTING THE WATER COLUMNS 5 12 5 4 1 Background 5 12 5 4 2 Safety precautions 5 12 5 4 3 Water column isolation 5 13 5 4 4 Electrode and e...

Page 9: ...rd B 2 B 2 REMOTE DISPLAY UNIT SPECIFICATIONS B 3 B 2 1 Core specifications for the controller unit B 3 B 2 3 Cabling specifications for the remote display units B 3 B 3 ELECTRODES AND WATER COLUMNS S...

Page 10: ...es D 8 D 6 3 Loop resistance D 10 D 6 4 Connecting cables to the remote display D 10 D 6 5 Connecting the display cables to the controller unit D 10 D 7 SYSTEM OPERATION D 11 Appendix E Hydrastep Wate...

Page 11: ...gives an exceptionally reliable and safe water level indication high visibility local and remote displays and alarm output trips This operating manual is for the single channel version of the Hydrast...

Page 12: ...mn of 32 green LEDs indicates which electrodes are in the water The other column of 32 red LEDs indicates which electrodes are in the steam The electrical resistance is measurable between each electro...

Page 13: ...Operating Manual 24685033 Rev BA Introduction Jan 2022 1 3 Hydrastep 2468CA and 2468CC Figure 1 2 Front panel of the Hydrastep controller unit...

Page 14: ...Introduction Jan 2022 Operating Manual 24685033 Rev BA 1 4 Hydrastep 2468CA and 2468CC Figure 1 3 Typical Hydrastep 2468 system installation...

Page 15: ...ains and an extra sixteen level measurement points electrodes It changes a 2468CA model to the 2468CB model i e a dual channel version of Hydrastep See operating manual 24685034 for instructions on th...

Page 16: ...play Additional remote displays must be locally powered See Appendix D for installation information Display board PCB number Standard LED display 24680515 Note The number of illuminated LEDs is depend...

Page 17: ...Operating Manual 24685033 Rev BA Introduction Jan 2022 1 7 Hydrastep 2468CA and 2468CC Figure 1 4 Position of boards in the Hydrastep Controller Unit...

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Page 19: ...a template derived from the dimensional details given in Figure 2 1 drill the four holes in the prepared surface Secure the unit with M10 bolts or equivalent fixings Cables enter the controller unit...

Page 20: ...Mechanical Installation Operating Manual Jan 2022 24685033 Rev BA Figure 2 1 Installation diagram for the Hydrastep 2468 Controller Unit 2 3 REMOTE DISPLAY UNIT INSTALLATION See Appendix D for mechan...

Page 21: ...fety regulations governing the plant shutdown procedures 3 1 INPUT BOARD 3 1 1 Power supply options on the Input board The Input board is available as Ac Mains and Dc supply versions see Chapter 1 Pro...

Page 22: ...plug Figure 3 2 Figure 3 2 240 Vac selection b Check the board has the correct fuse fitted Voltage selection Fuse 240 Vac 200 mA anti surge fuse 110 Vac 400 mA anti surge fuse 2 Dc powered unit a No c...

Page 23: ...braided and shielded cable 18AWG 24 x 0 2 mm 0 7 mm It must be capable of withstanding at least 10 Amps Two separate protected AC mains circuits of the same electrical phase are possible with a suita...

Page 24: ...E terminal Procedure 1 Ensure that the 2 core shielded cable is safely isolated from power before starting work 2 Prepare a sufficient cable length for a stress free route described in steps 5 and 6 N...

Page 25: ...to the water column electrodes Connecting electrode cables to the Input board inside the controller unit Connecting electrode cables to water column electrodes The connection procedure for a 16 elect...

Page 26: ...d electrode EL 2 a Undo the two knurled nuts on the stud of the next highest electrode EL 2 on the wiring diagrams remove the nuts and the washers and keep them safe b Connect a ring clamped brown con...

Page 27: ...de the controller unit Note It is considered good practice to twist colour paired wires together for each electrode and then twist those twisted pairs of the same cable together into one bundle Wiring...

Page 28: ...PL4 and PL5 10 way socket Pin number Pin descriptions 1 Electrode drive 2 Electrode pickup 3 Functional earth 4 Electrode drive 5 Electrode pickup 6 Electrode drive 7 Electrode pickup 8 Functional ear...

Page 29: ...s of Cable 2 to the sockets according to the schedule in Table 3 4 a Prepare the conductor core ends b Fit the crimp terminals c Connect the conductors to the sockets Table 3 4 Cable 2 schedule for In...

Page 30: ...side the controller unit 3 1 5 Input board Analogue output optional Terminal block SK1 PL1 on the Input board is for the optional analogue output connections Configuration of the analogue output The o...

Page 31: ...to a supplied two way socket SK1 such that The positive output VE core terminates in pin 1 The negative output VE core terminates in pin 2 Socket SK1 is then attached to plug PL1 on the board Procedu...

Page 32: ...ay outputs An oscillating waveform 0 5 Hz is superimposed on the analogue signal to indicate faults 3 1 6 Electrode error configuration standard on the Input board Standard factory configuration of el...

Page 33: ...ter default 104 S cm open circuit open circuit High conductivity water 300 S cm bridged open circuit Disabled feature Not applicable open circuit bridged Disabled feature Not applicable bridged bridge...

Page 34: ...atively high compared to the ac voltage this can cause a false switching point for water to steam It results in electrode LEDs flashing rapidly as the detection circuits alternate between steam and wa...

Page 35: ...ders 1 2 3 4 In water column LK2 LK4 LK3 LK5 Off Off Off On 8 Installed Not installed Off On On Off 10 Off Off On Off 12 Off On Off Off 14 Off Off Off Off 16 Single power supply versions of the Hydras...

Page 36: ...t cover 2 Select the number of electrodes a Configure switch SW1 see Table 3 6 b Configure LK2 LK3 LK4 and LK5 see Table 3 6 c Configure LK1 by installing a link header see Table 3 7 3 Select the wate...

Page 37: ...sed with a 24680501A 24680501B or 24680516A input board split pads SP5 and SP6 should be bridged with solder With legacy Input cards the LEDs corresponding to an electrode error do not alternate and r...

Page 38: ...lies before opening the hinged front cover 2 Pass the cable into the controller unit through a good quality RF gland fitted at the base 3 Prepare the cable for a stress free run to the terminal block...

Page 39: ...ay Berg connectors SK1 on the Input board and PL1 on the Output board Each Input board supports a maximum of two of these Output option boards The second one is mounted on top of the first by nylon sp...

Page 40: ...an energise the relays with an individual choice of being energised when its selected electrode is in steam or is in water Furthermore relay RL1 can monitor an electrode state or indicate an alarm con...

Page 41: ...w Output board See Chapter 5 for the procedure to install a new board After installation is complete configure the options and make the cable connections Note The storage area must be dry dust free an...

Page 42: ...L3 Selects individual electrode s for relay RL3 See Table 3 9 SW4 RL4 Selects individual electrode s for relay RL4 See Table 3 9 SW5 All Selects if RL1 to RL4 energises when selected electrodes are in...

Page 43: ...s when the selected electrode is in water or is in steam Electrode Alarm operation RL1 function only SW6 selects if relay RL1 is driven by an electrode input i e in steam water or used as the system f...

Page 44: ...2 0 8 11 7 0 8 13 3 0 8 14 8 0 8 16 4 0 8 18 0 0 8 19 5 0 8 21 1 0 8 22 6 0 8 24 2 0 8 Procedure 1 Ensure that the controller unit is isolated from all power supplies before opening the hinged front...

Page 45: ...bridged with solder SP15 open circuited RL2 SP22 bridged with solder SP20 open circuited RL3 SP23 bridged with solder SP1 open circuited RL4 SP24 bridged with solder SP6 open circuited For no delayed...

Page 46: ...r a stress free run to the terminal block Note It is considered best practice to twist the cores of a cable together 4 Ensure the gland has a good annular ring shaped connection with the cable screen...

Page 47: ...ergised energise either one to trip Relays are in the de energised state The two out of two relay alarm system This system requires both relays to operate to cause an alarm when their assigned electro...

Page 48: ...ctrical Installation Jan 2022 Operating Manual 24685033 Rev BA 3 28 Hydrastep 2468CA and 2468CC Figure 3 18 Case 2b Relays normally de energised energise both to trip Relays are in the de energised st...

Page 49: ...ase make sure that all earth points are made and are of a good standard 4 Great care must be taken with the mounting of the water column the columns must be vertical angles stated in the manual should...

Page 50: ...en it is first started up The magnetite creates a small dc voltage on the electrodes and shows itself as a flickering in the bottom few electrodes When the system reaches its normal working conditions...

Page 51: ...r to Section 3 2 No display Incorrect configuration Refer to Section 3 2 Yellow LED illuminated Incorrect configuration Refer to Section 3 2 Remote display Chequered intermittent display Incorrect con...

Page 52: ...Make sure that there is sufficient condensate flow through the column If the normal water conductivity is high the electrode error circuitry can be de sensitised or disabled If the normal water conduc...

Page 53: ...rocedure checks the electrode wiring If the display does not show the correct results check for a break in either of the suspect electrode conductors Carry out repairs to any faulty connection or subs...

Page 54: ...nd no fault indication If a fault indication is still present then an internal circuit fault exists The circuit fault may be on either input board or the display board If spares are available change t...

Page 55: ...emove them and their washers Lift the Input board from the base plate 6 To fit a new Input board carry out the removal steps in the reverse order Replacing a Display board The Display board is attache...

Page 56: ...acers and out of the Berg plug socket connection c Undo the nut and washer securing the faulty spacer and extract it from its hole d Fit the new spacer in position align correctly on the board and sec...

Page 57: ...signs of damage Contact Delta Mobrey Limited if there any problems Procedure A prerequisite is that there are three nylon spacers already fitted to the first Output board The second Output board shoul...

Page 58: ...d 8 of PL3 If the voltage is less than 18 Vdc then the Display board in the controller unit may be faulty Replace this board with a serviceable item and check for the correct voltage between pins 5 an...

Page 59: ...ac voltages If there is a voltage of less than 1 Vac at the controller unit with PL3 removed the display board is faulty Remove this board and fit a serviceable item The bottom half of the fault LED...

Page 60: ...er pattern a circuit fault exists on the Display board display unit s Display board Remove this board and fit a serviceable replacement On and off pattern of red and green LEDs The wrong setting for t...

Page 61: ...Lift away the front and rear panels and use a suitable flat bladed screwdriver to prise apart the PCB interconnecting edge connectors f Both PCBs can now be removed from their securing slots in the u...

Page 62: ...damage 5 4 2 Safety precautions Ensure that tripping where fitted is disabled and that the operators are informed to expect erroneous indications or alarms Ensure that you know the valve positions and...

Page 63: ...lectrode insulator leaks is often difficult to determine before removing the electrode and unless the leak is small Steam wisps appearing to come from between the outside of the electrode body and the...

Page 64: ...o acceptable standards using a Hydrastep Service Tool See Appendix C for the part numbers Examining high pressure electrodes for leaks In the case of high pressure electrodes a tapered electrode body...

Page 65: ...using a Hydrastep Service Tool See Appendix C for the part numbers 5 4 5 Changing the low pressure electrodes and gaskets Note There is no need to switch off the Hydrastep controller unit Procedure 1...

Page 66: ...re is no damage to the ceramic insulators or the seating ferrules 8 Lightly coat the electrode threads with an anti seize compound see Appendix C for the part number and assemble the new electrode to...

Page 67: ...note the lowest steam indicating channel at this stage and fully close the water isolating valve nearest the water column quickly Time the rise in water level due to the condensate flow until the topm...

Page 68: ...n the water isolating valve until completely clearing the water line 5 Close the water valve fully 6 Close the drain valve and re check the transient response If the response times are still seriously...

Page 69: ...ECTRODES Figure A 1 Wiring diagram for a system with eight electrodes A 2 Figure A 2 Wiring diagram for a system with ten electrodes A 3 Figure A 3 Wiring diagram for a system with twelve electrodes A...

Page 70: ...Wiring Diagrams Jan 2022 Operating Manual 24685033 Rev BA A 2 Hydrastep 2468CA and 2468CC Figure A 1 Wiring diagram for a system with eight electrodes...

Page 71: ...Operating Manual 24685033 Rev BA Wiring Diagrams Jan 2022 A 3 Hydrastep 2468CA and 2468CC Figure A 2 Wiring diagram for a system with ten electrodes...

Page 72: ...Wiring Diagrams Jan 2022 Operating Manual 24685033 Rev BA A 4 Hydrastep 2468CA and 2468CC Figure A 3 Wiring diagram for a system with twelve electrodes...

Page 73: ...Operating Manual 24685033 Rev BA Wiring Diagrams Jan 2022 A 5 Hydrastep 2468CA and 2468CC Figure A 4 Wiring diagram for a system with fourteen electrodes...

Page 74: ...Wiring Diagrams Jan 2022 Operating Manual 24685033 Rev BA A 6 Hydrastep 2468CA and 2468CC Figure A 5 Wiring diagram for a system with sixteen electrodes...

Page 75: ...C to 65 C 4 F to 149 F Relative humidity up to 100 Location Indoor or outdoor Power supply requirements ac input 115 Vac nominal 93 5 130 Vac 48 Hz 65 Hz 240 Vac nominal 187 256 Vac 48 Hz 65 Hz Power...

Page 76: ...mum Distance 1000 m 3280 ft maximum Electrical connections Plug in screw terminals B 1 2 Specifications for the optional Relay Output board Outputs 4 x alarm trip relays Relay contact ratings Ac suppl...

Page 77: ...bling specifications for the remote display units Note The following cables fulfil the minimum requirements or heavier cables Maximum gauge accepted by connectors is 16AWG 1 5 mm2 Powered from the con...

Page 78: ...his approval requires that armoured cable is used to connect a remote display to the controllerunit A remote display must not be used in a hazardous environment B 3 ELECTRODES AND WATER COLUMNS SPECIF...

Page 79: ...umina ceramic Rating 300 bar 4350 psi max at 560 C 1040 F pH range 7 11 Hydrostatically tested to 450 bar 6525 psi at ambient temperature Note For supercritical applications only B 3 2 Core specificat...

Page 80: ...Specifications Jan 2022 Operating Manual 24685033 Rev BA B 6 Hydrastep 2468CA and 2468CC...

Page 81: ...T ceramic K9634 Fuse link 400mA T ceramic K9635 Input PCB assembly 2468CC 24680516B Fuse link 1 25A T ceramic 360190320 Cable assembly 10 way 24680210A Input Adapter Board 24680523A Display PCB assemb...

Page 82: ...ts Lists Operating Manual Jan 2022 24685033 Rev BA C 2 ACCESSORIES C 2 1 Water column and electrode accessories Item description Part number Low pressure sealing plug 24569A Series 3 sealing plug 4506...

Page 83: ...isplay operates in the same way The only difference between them is in their mechanical construction Table D 1 Remote Display Units RDU model Form factor Mounting style Other features 24683BB Small LE...

Page 84: ...nected formation The controller unit can power one remote display All other remote displays must be locally powered Figure D 2 Star and daisy chain connections of remote displays The maximum cable len...

Page 85: ...column and connected to the Hydrastep Controller Unit 1 Ensure that the remote display is isolated from all power supplies before starting work 2 Undo the four screws securing the rear panel and then...

Page 86: ...h 18 to 32 electrodes reconfigure the display s decoding PCB Procedure A pre requisite is 18 to 32 electrodes installed in the water column and connected to the Hydrastep Controller Unit 1 Ensure that...

Page 87: ...clamps on the 24683BB and 24683C each clip onto two metal studs on the unit s case b Adjust the clamps from the rear of the unit with a suitable flat bladed screwdriver c Tighten the clamps until they...

Page 88: ...ecuring the front panel b Place the cover with ribbon cable still attached carefully on top of the case 6 Loosen the cable gland nuts and then pass the cable s through the glands Note The number of ca...

Page 89: ...ep 2468CA and 2468CC D 6 ELECTRICAL CONNECTIONS Remote Display Units have dual serial data inputs and dual power inputs D 6 1 One Remote Display Unit powered by the Controller Unit An eight core cable...

Page 90: ...re than one remote display is in use local supplies with isolated outputs must power the extra units Up to six remote displays can be supported less their power requirements With all six units in use...

Page 91: ...lections from corrupting data it may be necessary to fit termination resistors to the chain s last unit The resistor values should match the characteristic impedance of the cable 120 typical A termina...

Page 92: ...ble ends and fit identity sleeves to the leads 4 Screw leads into the respective terminals Figure D 7 and Figure D 4 Note Interconnections for remote displays are in Figure D 5 and Figure D 6 5 Ensure...

Page 93: ...468CC 8 Terminate the cable screen at the gland plate Figure D 7 Terminal connections on the remote display D 7 SYSTEM OPERATION When the Hydrastep system starts check for complete agreement between t...

Page 94: ...Remote Display Units Jan 2022 Operating Manual 24685033 Rev BA D 12 Hydrastep 2468CA and 2468CC...

Page 95: ...el with support blocks attached to the column body The covers are held in place by screw fasteners The complete assembly is of welded construction with the welding to ASME IX requirements The material...

Page 96: ...he drain components being available in and 1 sizes A lug is machined on the top cap to accept a vertical forked member for supporting the water column when in situ The steam and water connections are...

Page 97: ...Operating Manual 24685033 Rev BA Water Columns and Electrodes Jan 2022 E 3 Hydrastep 2468CA and 2468CC Figure E 1 Low pressure water column 120 bar 1740 psi...

Page 98: ...Water Columns and Electrodes Jan 2022 Operating Manual 24685033 Rev BA E 4 Hydrastep 2468CA and 2468CC Figure E 2 High pressure water column 210 bar 3045 psi and 300 bar 4350 psi...

Page 99: ...ssure electrodes Low pressure electrodes are for the low pressure water column Figure E 1 on page E 3 These electrodes are suitable for pressures of up to 120 bar 1740 psi for type 459600602 See Figur...

Page 100: ...are for the high pressure water column Figure E 2 on page E 4 These electrodes are suitable for pressures in the range 50 bar 725 psi to 300 bar 4350 psi See Figure E 4 for feature details and Append...

Page 101: ...ry dust free and under covers Storage conditions should be controlled within the temperature range of 10 C to 40 C 50 F to 104 F with a maximum of 80 R H PHYSICAL PROTECTION The equipment shall be sto...

Page 102: ...ter column the following points must be checked Ensure that access to work on this part of the plant is clear and that the column isolating valves have been fitted to the steam and water connections o...

Page 103: ...re the pipework is not allowed to take the unsupported weight of a standard water column The column weight and associated pipework are to be fully supported There must not be any load on the welded pi...

Page 104: ...level falling below 0 C when the boiler is not operational it is essential to isolate drain and vent the column to prevent ice expansion damaging electrodes Ice expansion damage can also affect adjac...

Page 105: ...Operating Manual 24685033 Rev BA Water Columns and Electrodes Jan 2022 E 11 Hydrastep 2468CA and 2468CC Figure E 6 Typical water column installation showing optional column lagging...

Page 106: ...Water Columns and Electrodes Jan 2022 Operating Manual 24685033 Rev BA E 12 Hydrastep 2468CA and 2468CC Figure E 7 Typical water column suspension...

Page 107: ...umns and Electrodes Jan 2022 F 1 F CSA Certification Drawings F 1 CSA CONTROL DRAWINGS Drawings are given for planning purposes only Contact your sales office to be sure you have the current version o...

Page 108: ...Water Columns and Electrodes Jan 2022 Operating Manual 24685033 Rev BA F 2 Hydrastep 2468CA and 2468CC Figure F 2 Hydrastep Control Drawing Sheet 2...

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Page 110: ...44 0 1252 729168 mobrey delta mobrey com Standard Terms and Conditions of Sale can be found at www delta mobrey com Mobrey is a trademark of Delta Mobrey Ltd All other marks are the property of their...

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