Delta-mobrey 2468CA User manual

Operating Manual

24685033, Rev BA

Jan 2022

Delta Mobrey Hydrastep 2468CA and 2468CC

Electronic Gauging System (Single Input Board)

Operating Manual

24685033, Rev BA

Title Page

Jan 2022

Hydrastep 2468CA and 2468CC

Mobrey™Hydrastep 2468CA and 2468CC

Read this manual before working with the product. For personal and system safety, and optimum

product performance, make sure you thoroughly understand the contents before installing, using, or

maintaining this product.

Failure to follow these guidelines could result in death or severe injury.

Avoid contact with the leads and terminals. High voltage that may be present on leads can cause

electrical shock.

Explosive atmospheres

Never operate the equipment, or any sensors connected to the equipment, in a potentially explosive

atmosphere. It is not intrinsically safe and could possibly cause an explosion.

Grounding

To minimise the risk of electrical shocks, connect equipment to a protective ground (earth) at all times.

Grounding is essential not just when the power supply, measurement, or control circuits are connected,

but also while equipment is not powered-up.

The Hydrastep Controller Unit 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 in any doubt as to the serviceability of the equipment, do not use it. Get the equipment checked by a

qualified service technician.

The equipment may be unsafe if any of the following statements apply:

▪It shows visible damage.

▪It failed to perform an intended operation.

▪It was subjected to severe physical stress.

▪Storage conditions were unfavourable.

Live electrical wires

When connected to a power supply, the opening of the lid and removal of parts could expose live

electrical wires. Never open the Hydrastep Controller Unit while it is powered-up.

Isolate the equipment from all power and signal sources before opening the hinged lid to make an

adjustment, replace a replacement, perform maintenance, or make repairs. Only authorised, qualified

personnel should perform these tasks.

Equipment modification

To avoid introducing safety hazards, never install non-standard parts in the equipment or make any

unauthorised modification. Return the equipment to Delta Mobrey Limited for service and repair.

Warning

Title Page

Jan 2022

Operating Manual

24685033, Rev BA

Hydrastep 2468CA and 2468CC

Cleaning

To clean the instrument, use a damp cloth with a mild, water-based cleaner. Clean the exterior of the

equipment only. Do not allow liquids to enter or spill onto the equipment.

Mains ac power supply

Never operate the equipment from a line voltage or frequency more than specified. Otherwise, the

insulation of internal components may break down and cause excessive leakage currents.

To allow the controller unit to be isolated from the ac supply, route the supply through a switch (or

circuit breaker). The device must be within easy reach of the operator and identified clearly as the

means of supply isolation.

Fuses

Check 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 continually blow, do not insert a fuse of a higher rating. Switch the equipment off,

clearly label it as “unserviceable” and inform a service technician.

Not designed for nuclear-qualified applications

Hydrastep products are not for nuclear-qualified applications. Using non-nuclear qualified products in

applications that require nuclear-qualified hardware or products may cause inaccurate readings.

For information on nuclear-qualified products, contact Delta Mobrey Limited.

Pressure parts

For installation under the Pressure Equipment Directive (PED) 2014/68/EU, refer to safety

instructionmanual 24688006/SI.

For installation under ATEX directive 2014/34/E, refer to safety instruction manual 24685033/SI.

Caution

Operating Manual

24685033, Rev BA

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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 manual and on the control unit

Title Page

Jan 2022

Operating Manual

24685033, Rev BA

Hydrastep 2468CA and 2468CC

Operating Manual

24685033, Rev BA

Contents

Jan 2022

Hydrastep 2468CA and 2468CC

Contents

Chapter 1 - Introduction

1.1 HYDRASTEP 2468 STEAM AND WATER GAUGING SYSTEM ................................................... 1-1

1.2 HOW IT WORKS............................................................................................................................. 1-2

1.3 ELECTRONICS IN THE CONTROLLER UNIT............................................................................... 1-5

1.3.1 Input board....................................................................................................................... 1-5

1.3.2 Display board................................................................................................................... 1-6

1.3.3 Output boards (optional) .................................................................................................. 1-6

Chapter 2 –Mechanical Installation

2.1 WATER COLUMN AND ELECTRODES INSTALLATION.............................................................. 2-1

2.2 CONTROLLER UNIT INSTALLATION............................................................................................ 2-1

2.3 REMOTE DISPLAY UNIT INSTALLATION..................................................................................... 2-2

Chapter 3 –Electrical Installation

3.1 INPUT BOARD................................................................................................................................ 3-1

3.1.1 Power supply options on the Input board......................................................................... 3-1

3.1.2 Power cables 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

3.1.5 Input board: Analogue output (optional) ........................................................................ 3-10

3.1.5 Electrode error configuration (standard) on the Input board.......................................... 3-12

3.2 DISPLAY BOARD ......................................................................................................................... 3-15

3.2.1 Configuration options for the Display board................................................................... 3-15

3.2.2 Compatibility setting for new and legacy Input boards .................................................. 3-17

3.2.3 Remote display unit connections................................................................................... 3-17

3.2.4 Opto-isolated fault output connection (optional) ............................................................ 3-17

3.3 OUTPUT OPTION BOARDS......................................................................................................... 3-19

3.2.1 Installing a new Output board........................................................................................ 3-21

3.2.2 Configuration options on an Output board..................................................................... 3-22

3.2.3 Connections to an Output board.................................................................................... 3-26

Chapter 4 –Starting-up The First Time

4.1 HYDRASTEP START-UP ............................................................................................................... 4-1

Contents

Jan 2022

Operating Manual

24685033, Rev BA

Hydrastep 2468CA and 2468CC

Chapter 5 –Troubleshooting

5.1 QUICK TROUBLESHOOTING CHART .......................................................................................... 5-1

5.2 TROUBLESHOOTING THE CONTROLLER UNIT......................................................................... 5-2

5.2.1 Fault analysis and corrective actions............................................................................... 5-2

5.2.2 Replacing Input and Display boards................................................................................ 5-5

5.2.3 Fitting or replacing an optional Output board................................................................... 5-6

5.3 TROUBLESHOOTING THE REMOTE DISPLAYS......................................................................... 5-8

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 electrode seal leaks................................................................................ 5-13

5.4.5 Changing the low-pressure electrodes and gaskets...................................................... 5-15

5.4.6 Changing the high-pressure electrodes and gaskets .................................................... 5-16

5.4 WATER COLUMN COMMISSIONING OR RECOMMISSIONING............................................... 5-16

5.5.1 Venting and draining for valve repairs ........................................................................... 5-17

5.5.2 Water column transient response.................................................................................. 5-17

5.5.3 Clearing water column and pipework blockages ........................................................... 5-18

5.5.4 Water column life ........................................................................................................... 5-18

Operating Manual

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Contents

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Hydrastep 2468CA and 2468CC

vii

Appendix A –Wiring Diagrams

A.1 CONTROLLER UNIT AND ELECTRODES ....................................................................................A-1

Appendix B –Specifications

B.1 HYDRASTEP CONTROLLER UNIT SPECIFICATIONS .................................................................B-1

B.1.1 Core specifications for the controller unit.........................................................................B-1

B.1.2 Specifications for the optional Relay Output board..........................................................B-2

B.1.3 Specifications for the optional Delay-Relay Output board................................................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 SPECIFICATIONS .......................................................B-4

B.3.1 Core specifications for the electrodes..............................................................................B-4

B.3.2 Core specifications for the water columns .......................................................................B-5

Appendix C –Parts Lists

C.1 HYDRASTEP CONTROLLER UNIT PARTS ..................................................................................C-1

C.1.1 Core parts for the controller unit.......................................................................................C-1

C.1.2 Relay Output option board (PCB 24680504)....................................................................C-1

C.1.3 Delay Relay Output option board (PCB 24680509)............................................................C-1

C.2 ACCESSORIES ...............................................................................................................................C-2

C.2.1 Water column and electrode accessories.........................................................................C-2

Contents

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Hydrastep 2468CA and 2468CC

Appendix D –Remote Display Units

D.1 REMOTE DISPLAY OPTIONS........................................................................................................D-1

D.2 RECONFIGURING THE 24683BB AND 24683C DISPLAYS.........................................................D-3

D.3 RECONFIGURING THE 24683D DISPLAY....................................................................................D-4

D.4 INSTALLING THE 24683BB AND 24683C UNITS IN A PANEL....................................................D-5

D.5 INSTALLING THE 24683D WALL MOUNTED UNIT......................................................................D-5

D.6 ELECTRICAL CONNECTIONS.......................................................................................................D-7

D.6.1 One Remote Display Unit powered by the Controller Unit ....................................................D-7

D.6.2 Other Remote Display Units powered by local supplies ...................................................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 Water Columns and Electrodes

E.1 WATER COLUMNS ........................................................................................................................E-1

E.1.1 Low-pressure water columns.............................................................................................E-1

E.1.2 High-pressure water columns............................................................................................E-1

E.1.3 Supercritical high-pressure water column.........................................................................E-2

E.2 ELECTRODES..................................................................................................................................E-5

E.2.1 Low-pressure electrodes...................................................................................................E-5

E.2.2 High-pressure electrodes..................................................................................................E-6

E.3 INSTALLATION PROCEDURES ......................................................................................................E-7

E.3.1 Scope of procedures..........................................................................................................E-7

E.3.2 Storage..............................................................................................................................E-7

E.4 INSTALLATION OF THE WATER COLUMN...................................................................................E-8

E.5 INSPECTION OF MECHANICAL INSTALLATION WORK..............................................................E-10

Appendix F -- CSA Certification Drawings

F.1 CSA CONTROL DRAWINGS..........................................................................................................F-1

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