2468ca DB

process measurement solutions
Hydrastep 2468CA & 2468CC

Electronic Gauging System
Operating Manual
24685033
Copyright 2001
Solartron Mobrey
All rights reserved
Solartron Mobrey pursues a policy of continuous development and product improvement. The specification in this
document may therefore be changed without notice.
To the best of our knowledge, the information contained in this document is accurate and Solartron Mobrey cannot be
held responsible for any errors, omissions or other misinformation contained herein. No part of this document may be
photocopied or reproduced without prior written consent of Solartron Mobrey.
About this manual

This manual describes the Hydrastep 2468CA and 2468CC 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 two parts, the first covers the electrical/electronic system and the
second describes the pressure parts.
Part 1 - Electrical/Electronic System

Chapter 1 introduces the Hydrastep 2468 Electronic Gauging System and its operating
principles.
Chapter 2 covers the installation, configuration and fault analysis procedures.
Chapter 3 covers the installation, configuration and fault analysis procedures for the Relay
Output Board (Ch. 3a), the Delay Relay Output Board (Ch. 3b) and the Opto-isolated Output
Board (Ch. 3c).
Chapter 4 covers the installation, configuration and fault analysis procedures for the two
versions of the Remote Display Unit.
Part 2 - Pressure Parts

Chapter 1 is a general introduction to the Hydrastep system of water level determination.
Chapter 2 describes the water column and its components. The preparation, installation of
the water column on to the boiler, acid and steam purging of the boiler system and the fitting
of the electrode sensors.
Chapter 3 details the fault repair procedures carried out on the system pressure parts and
their commissioning.
Chapter 4 provides a general description of the pressure parts used in the Hydrastep
systems.
Chapter 5 details the Pressure Parts specifications.
Appendices
All appendices are located at the end of this manual for easy reference.
Appendix A Approval Certificates contains copies of certificates complying with the
necessary safety approvals for the Hydrastep 2468.
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)
Part 1
24685033_DA
Pt.1-1
Pt.1-2
24685033_DA
DANGEROUS VOLTAGES ARE PRESENT IN

THIS EQUIPMENT. ANY WARNING NOTICES
OR PROCEDURES CONTAINED IN THIS
MANUAL OR ON THE EQUIPMENT SHOULD BE
STRICTLY OBSERVED TO MAINTAIN SAFETY.
THE USE OF THIS EQUIPMENT IN A MANNER
NOT SPECIFIED IN THIS MANUAL MAY IMPAIR
THE PROTECTION PROVIDED BY THIS
EQUIPMENT. GREAT CARE SHOULD BE
EXERCISED
WHEN
SERVICING
THIS
EQUIPMENT.
TO ENSURE COMPLIANCE WITH THE EMC
DIRECTIVE
(WHERE
APPLICABLE)
THE
INSTRUCTIONS ON CABLE SCREENING,
ROUTING AND TERMINATION GIVEN IN THIS
MANUAL MUST BE FOLLOWED.
24685033_DA
Pt.1-3
Pt.1-4
24685033_DA
Part 1
Contents
Chapter 1
Introduction to the Hydrastep 2468 Electronic

Gauging System
Chapter 2
2468CA & 2468CC Single 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
Chapter 4
Remote Display Options 24683B C & D
24685033_DA
Pt.1-5
Pt.1-6
24685033_DA
Hydrastep 2468CA and 2468CC Manual
Introduction to the Hydrastep 2468 Electronic Gauging System
Introduction to the Hydrastep 2468

Contents
Page No.
1.1
WATER LEVEL MEASUREMENT .........................................................3
1.2
HYDRASTEP 2468 ELECTRONIC GAUGING SYSTEM .......................5

1.2.1
1.2.2
1.2.3
1.3
SYSTEM OPTIONS................................................................................6
1.3.1
1.3.2
1.3.3
1.4
INPUT BOARDS ................................................................................... 5

DISPLAY BOARDS............................................................................... 5
SYSTEM FAULTS (2468CB OR 2468CD) ........................................... 6
OUTPUT BOARDS ............................................................................... 6

REMOTE DISPLAY UNITS .................................................................. 6
OPTION DETAILS ................................................................................ 6
HYDRASTEP 2468 UPGRADE PATHS AND AVAILABLE OPTIONS ..7

Illustrations
Figure 1.1 - Front panel of the Hydrastep 2468 gauging system, with local display........... 2
Figure 1.2 - Schematic of resistance measuring cell and electrodes.................................. 3
Figure 1.3 - Typical Hydrastep 2468 System Installation .................................................... 4
Tables
Table 1.1 - Upgrade paths and available options................................................................ 7
24685033_DA
1-1
HYDRASTEP
FM
APPR O VED
STAS
TYPE APPR O VED
Ex
B86941:1988
Ex N IIC T4
Tam b 70 C
CERT No. Ex94Y4362X
Do Not O pen W hen Energised
TYPE 2468
Rating 110/240V
48-65Hz 30VA
24V
30W
Tem p : -20 C to +70 C
Ingress P rotection : IP65/N EM A 4X
M ade in U .K by Solartron M obrey
Slough, B erkshire, SL1 4U E, UK.
Houston, Texas 77084, US A. Tel: +1 281-398-7890
Figure 1.1 - Front panel of the Hydrastep 2468 gauging system, with local display
1-2
24685033_DA
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. It uses the significant difference in resistivities of water and
steam in temperatures up to 370C (698F) to determine the water level.
Figure 1.2 - Schematic of resistance measuring cell and electrodes
A vertical row of electrodes is installed in the water level column attached to boiler and
typically aligned so that half the electrodes are above and half below the normal water level
(see Figure 1.2). The resistance measurement is made between the insulated tip of each
electrode and the wall of the column.
The cell constant defining the actual resistance measured is determined by the length and
diameter of the electrode tip and the column bore. In practice, the cell constant is chosen so
that the resistance in water is less than 100k ohms and the steam resistance is greater than
10M ohms. Since the resistivities of water and steam are substantially different, the system
is simple and requires no setting up adjustments. It is not susceptible to power supply
variations, ambient temperature changes, etc., resulting in a highly reliable system.
A general overview showing how a typical Hydrastep 2468 System is installed is illustrated
in Figure 1.3.
24685034_DA
1-3
Figure 1.3 - Typical Hydrastep 2468 System Installation
1-4
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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 with Local Level Display
A Dual Power Supply System with Local Level Display
For both systems, the printed circuit boards are housed in the same enclosure, allowing
customers full capability to expand their system as and when conditions dictate.
Table 1.1 on page 1.7 is a summary of all upgrade paths and options for the Hydrastep 2468
system.
1.2.1
INPUT BOARDS
All versions of the Hydrastep 2468 unit contain one or two input boards. The input boards
mount on to the base plate in the enclosure. Each input board provides power supplies,
electrode drive, signal processing, fault analysis and an analogue output.
The input board can accept inputs from 8, 10, 12, 14 or 16 electrodes. When two input
boards are used (in a dual power supply system) the electrodes are interlaced; that is, the
odd numbered electrodes are connected to one input board and the even numbered
electrodes are connected to the other. Full details of the wiring are covered in Chapter 2
under Installation.
Each input board also includes a current output circuit that provides an analogue
representation of the water level in the column. The analogue output can be configured to
give a current output in one of the following ranges:
1.2.2
0 to 20mA
4 to 20mA
20 to 0mA
20 to 4mA
DISPLAY BOARD
The display board is mounted on to the hinged lid of the unit and provides indication through
the viewing window on the enclosure. It also supplies configuration information to the input
board(s); that is, the number of electrodes connected to the unit and the required
water/steam switching threshold.
Figure 1.1 shows the local display with water level and system fault indication. Water level
is indicated by two columns of LEDs, one red to indicate steam and one green to indicate
water. The number of LEDs illuminated is dependent on the number of electrodes present
and a blanking panel is available to mask the LEDs not used. In addition to the system fault
indication is an opto-isolated system fault output. Switches are provided to allow the
number of electrodes to be selected (8, 10, 12, 14, 16, 18, 20, 22, 24, 26, 28, 30 or 32). Two
solder link pads are provided to select the water/steam switching-threshold (0.6S/cm or
1.6S/cm).
24685034_DA
1-5
1.2.3
SYSTEM FAULTS (2468CA OR 2468CC)

System fault indication, a yellow LED and an opto-isolated output, is provided for a water
above steam condition, an electrode fault or wiring failure and the detection of an internal
fault. A further fault is indicated when the electrode number switch is incorrectly set. This
fault is indicated by a chequered display of red and green LEDs on the level display.
Faults and their remedies are covered in Chapter 2 under Fault Analysis & Corrective
Action.
1.3
SYSTEM OPTIONS
1.3.1
OUTPUT BOARDS
Each input board can accept one or two output boards that can be used for water level
signalling, alarm or trip functions. Each output board provides four relay outputs or four optoisolated outputs. The first output board is fitted directly on top of the input board using three
nylon pillars. A second output board (when required) can be fitted on top of the first output
board using the same type of fixture. The various output boards are described in Chapter 3.
1.3.2
REMOTE DISPLAY UNITS

Provision is made to drive Remote Display Units. The display board is capable of driving up
to 6 remote display units. Only one of these can be powered by the Hydrastep unit, any
additional remote displays must be locally powered.
A remote display unit mimics the display on the Hydrastep 2468 and is as described in
Chapter 4.
1.3.3
OPTION DETAILS
1. Relay Board 24680504 has 4 fully configurable relay outputs
Chapter 3a
2. Relay with Time Delay board 24680509 has 4 fully configurable relay outputs Chapter 3b
3. Opto-isolator board 24680505 has 4 fully configurable opto-isolated outputs Chapter 3c
4. Remote Display 24683B. Panel mounted DIN size 8 to 32 electrode display
Chapter 4
5. Remote Display 24683C Panel mounted large LED 8 to 32 electrode display Chapter 4
6. Remote Display 24683D Wall mounted splash proof version of 24683C
1-6
Chapter 4
24685033_DA
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
Available Options
Description
2468 CA or
2468 CC
16 point EGS with
local display.
Single Power
Supply.
2468 CB or
2468 CD
32 point EGS with
local display.
Comments
Part No.
Relay output board
24680504C
Time delay relay

output board
24680509B
Opto-isolated
output board
24680505A
}
}
} Up to two boards (of any one
} type) can be fitted.
}
}
Remote display
unit
24683B, C, or D
Up to 6 can be used
Input board
upgrade (ac)
24680501C
Provides an additional power

supply (ac mains source) and
16 point input circuit. Upgrades
2468CA to 2468CB.
Input board
upgrade (dc)
24680516B
Provides an additional power

supply (24V dc source) and 16
point input circuit. Upgrades
2468CC to 2468CD.
Relay output board
24680504C
Time delay relay

output board
24680509B
Opto-isolated
output board
24680505A
}
}
} Up to four boards (of any one
} type) can be fitted.
}
}
Remote display
unit
24683B, C, or D
Up to 6 can be used
Dual Power Supply.
Note: If required, a 24680501C board can be fitted to a 2468CC (or a 24680516B board
can be fitted to a 2468CA) to upgrade to a 2468CE. The 2468CE is a 32 point
Electronic Gauging System (EGS) with one ac mains source power supply and one
24Vdc source power supply.
Table 1.1 - Upgrade paths and available options
24685034_DA
1-7
1-8
24685033_DA
Hydrastep 2468CA and 2468CC Electronic Gauging Systems
2
2468CA & 2468CC
Single Power Supply Version
Contents
Page No.
2.1
INTRODUCTION ..................................................................................... 2-3
2.2
ELECTRODE CABLING SYSTEM.......................................................... 2-3
2.3
ELECTRONIC ENCLOSURE .................................................................. 2-3

2.3.1
2.3.2
2.3.3
2.3.4
2.4
INSTALLATION ...................................................................................... 2-8

2.4.1
2.4.2
2.5
MECHANICAL INSTALLATION.............................................................. 2-8

ELECTRICAL INSTALLATION ............................................................. 2-10
2.4.2.1 Electrode Connections .......................................................... 2-10
2.4.2.2 Connecting Cables to Water Column Electrodes.................. 2-11
2.4.2.3 Connecting the Electrode Cable Assemblies to 2468
Enclosure ........................................................................... 2-11
2.4.2.4 Hydrastep Power Supply Cable ............................................ 2-12
2.4.2.5 Analogue Output Connection ................................................ 2-13
2.4.2.6 Opto-Isolated Fault Output Connection................................. 2-14
SYSTEM CONFIGURATION................................................................. 2-15

2.5.1
24685033_CB
INPUT BOARD (PCB 24680501 AND PCB 24680516) ......................... 2-5

2.3.1.1 Analogue Output Drive Capability ........................................... 2-5
REMOTE DISPLAY DRIVE CAPABILITY .............................................. 2-5
DISPLAY BOARD (PCB 24680515) ....................................................... 2-6
2.3.3.1 Link LK1................................................................................... 2-6
2.3.3.2 Links LK2, LK3, LK4 and LK5 ................................................. 2-7
PCB INTERCONNECTIONS .................................................................. 2-7
INPUT BOARD (PCB 24680501 OR 24680516).................................. 2-15

2.5.1.1 Analogue Output Configuration ............................................. 2-15
2.5.1.2 Pulsed Output Setting ........................................................... 2-16
2.5.1.3 Electrode Error Configuration................................................ 2-16
2.5.1.4 Configuring the Unit to Detect Electrode Error...................... 2-17
2-1
2.5.2
2.6
DISPLAY BOARD 24680515................................................................ 2-17

2.5.2.1 Link LK1 Setting .................................................................... 2-18
2.5.2.2 Configuring the Number of Electrodes Switch..................... 2-18
2.5.2.3 Switching Threshold Setting ................................................ 2-18
2.5.2.4 Compatibility Setting ............................................................ 2-19
FAULT ANALYSIS & CORRECTIVE ACTION ..................................... 2-20

2.6.1
2.6.2
2.7
COMPONENT REPLACEMENT .......................................................... 2-22

2.6.1.1 Removing the Input Board (24680501 or 24680516)............ 2-22
2.6.1.2 Refitting the Input Board........................................................ 2-22
2.6.1.3 Removing the Display Board 24680515................................ 2-23
2.6.1.4 Refitting the Display Board.................................................... 2-23
PARTS LIST - HYDRASTEP 2468 CA & CC VERSIONS.................... 2-23
SPECIFICATION................................................................................... 2-24
Illustrations
Figure 2.1 - Outline drawing showing PCB layout and interconnections .............................. 2-4
Figure 2.2 - Installation diagram for the Hydrastep 2468 electronic gauging system unit .... 2-9
Figure 2.3- Enclosure cable layout for 16 electrode system .... Error! Bookmark not defined.
Figure 2.4: Voltage Selection (110V or 240V)..................................................................... 2-12
Figure 2.5- Location of display board links LK1 to LK5 & switch SW1 with configuration
details............................................................................................................. 2-17
Figure 2.6- Split pads SP1, SP2, SP5 & SP6 locations and settings.................................. 2-19
Tables
Table 2.1 - Analogue output configurations......................................................................... 2-15
Table 2.2 - Number of electrodes being displayed.............................................................. 2-18
Table 2.3 - Fault analysis/corrective action chart ................................................................ 2-20
2-2
24685033_CB
2.1
INTRODUCTION
This chapter introduces the single power supply version of the Hydrastep 2468 Electronic
Gauging System, its mechanical installation, system configuration, simple fault
analysis/corrective action capability and its specification.
2.2
ELECTRODE CABLING SYSTEM

This system can have 8, 10, 12, 14, 16 electrodes and uses 18-core electrode cables. The
cables consist of nine pairs of coloured cores with the black cores in each cable used for the
EARTH terminations. Each electrode requires one pair of cores, one core for the signal drive
and one for the signal return.
Number of
Electrodes
Number of Cables
Required
10-16
The electrode cable is pre-formed for simple installation. The connections to the electrodes
are terminated on the connection stud of the electrode. Either core can be connected to the
electronic enclosure as the signal drive or return.
2.3
ELECTRONIC ENCLOSURE
The basic arrangement of boards in the electronic enclosure is as follows:
The input board supplies power to the system and to the input signal processing
circuits. This board may be PCB 24680501 for an ac (mains) input, or PCB 24680516
for a dc input. The board is mounted on the right hand side of the base plate.
A display board (PCB 24680515) contains the LED drive circuits for the two columns
(32 red LEDs and 32 green LEDs) and the system fault LEDs. The board is mounted
on the rear of the front panel, with the LEDs protruding through the front panel.
Up to two output boards, Relay Board (PCB 24680504), Relay with time delay Board
(24680509) or Opto-isolator Board (PCB 24680505) may be fitted. Output board
mounting pillars are fitted to the input board during manufacture to support the first
output board mounted.
Refer to Figure 2.1 for an annotated view of the internal layout of the unit.
24685033_CB
2-3
Figure 2.1 - Outline drawing showing PCB layout and interconnections
2-4
24685033_CB
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 detection is also carried
out where the condition of the electrode inputs are examined and a FAULT is indicated
when:
1. An open circuit in either of the electrode conductor cores is present.
2. A short circuit to EARTH on either the electrode or conductor cores.
3. A water above steam condition exists.
4. An internal circuit fault condition exists.
A current output circuit is also provided on the input board. This gives an analogue
representation of the water level. The sense (forward or reverse) and type (0-20mA or
4-20mA) is selectable and described in Section 2.5 of this chapter. Fault indication on the
analogue output is an oscillating waveform (of approximately 0.5 Hz) superimposed on the
main analogue signal.
Provision is made on the input board to accept one or two output boards, either relay outputs
or opto-isolated outputs. Both types of output board are offered as options.
The input board produces the power supplies for the whole instrument which are derived
either from the local mains voltage supply of 110V ac or 240V ac nominal for the 24680501
input board or 20V dc to 40V dc for the 24680516 input board.
Apart from the input voltage there are two other differences between the AC (24680501) and
DC (24680516) input board. These are the analogue output drive capability and the remote
display drive capability.
2.3.1.1 Analogue Output Drive Capability

With the minimum DC supply voltage of 20V for the DC input board (24680516) the
maximum load that can be driven by the analogue output is 470.
At the minimum mains input voltage of 110V ac for the AC input board (24680501), the
maximum load that can be driven by the analogue output is 600.
2.3.2
REMOTE DISPLAY DRIVE CAPABILITY

The remote display drive capability is only a consideration when the 2468C is providing
power for a remote display. The unit is capable of driving six remote displays at up to 1000m
(3280ft) from the unit but only powering one remote display (any others must be locally
powered). With the AC input board the maximum cable loop resistance to the remote display
is 27 whilst with the DC input the maximum cable loop resistance to the remote display is
7. (See remote display section for more details).
24685033_CB
2-5
2.3.3
DISPLAY BOARD (PCB 24680515)

The display board receives its power supplies and electrode data from the input board. This
data is decoded and used to illuminate the required LEDs mounted on the display board.
The data is also converted to serial format for transmission to remote display units.
The water level in the column is indicated on the front panel by two columns of 32 LEDs, one
green column to indicate the electrodes which are in water and one red column to indicate
the electrodes which are in steam. The number of LEDs illuminated is dependent on the
number of electrodes being used in the system. When 8 to 16 electrodes are being used,
the unit illuminates two LEDs per electrode, the unit illuminates one LED per electrode. The
display is top biased (unused LEDs are at the bottom of the display). A blanking label is
provided to mask any LEDs that are not used.
If a system fault which may be caused by a water above steam condition, electrode, wiring
or input related fault has been detected, both yellow LEDs are illuminated. Provision is also
made for external indication of a system fault. This takes the form of an opto-isolated
output which is normally in its short-circuit state. When an alarm condition exists, the optoisolated output is open-circuited. Faults are covered under Fault Analysis & Corrective
Action in section 2.4 of this chapter.
The switch that sets the number of electrodes to be scanned is also mounted on this board.
A chequered pattern is displayed by the RED and GREEN columns if an invalid switch
setting is made on the number of electrodes switch.
The water/steam switching threshold (0.6S/cm or 1.6S/cm) may be changed by solder
split pads.
2.3.3.1 Link LK1

The display board caters for both single input board and dual input boards versions of the
Hydrastep 2468 system. With dual input boards, the odd electrode inputs are connected to
one half of the display board circuit with the even electrode inputs connected to the other half
of the circuit.
With the single input board, only one half of the board is connected to the odd and even
electrode inputs. In this case the link LK1 must be fitted to connect the odd and even
halves of the display board circuit.
Note: This link MUST be fitted for the single input board system.
2-6
24685033_CB
2.3.3.2 Links LK2, LK3, LK4 and LK5

These links are used to select either the 8 - 16 display mode (two LEDs per electrode) or the
18 - 32 display mode (one LED per electrode).
Two plugable link headers are provided with the unit and must be fitted in LK2 and LK4, for
the single input board system. (LK3 and LK5 must be free of links.)
2.3.4
PCB INTERCONNECTIONS
Signal interconnection between the input board and the display board is by ribbon cable.
The power supplies to the display board come from the input board via a 6-core cable.
Grommeted slots are provided in the base plate to guide the cables towards the hinge-side
of the enclosure case, thus minimising any cable strain when the enclosure lid is opened.
See Figure 2.1 on page 2-4 for layout details.
24685033_CB
2-7
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
available for use on this version of the system are covered in Chapters 3 & 4.
Notes:
1. The electronic enclosure cover should not be removed or opened until the equipment is
ready for physical installation to its fixing point. Under no circumstances should the
electronic enclosure be left open unless internal work is actually in progress.
2. When working on a bench with the enclosure open, the lid should be supported in its
open position.
2.4.1
MECHANICAL INSTALLATION
The electronic enclosure must be sited within electrode cable length of the water column
fixture. The preferred site for the electronic enclosure is a wall or vertical bracket structure
where easy access is available for viewing and servicing. It is assumed that the water
column is fully installed.
The electronic enclosure is equipped with four welded feet, allowing it to be secured in a
vertical position. Using a template derived from the enclosure details given in Figure 2.2 (on
page 2-9), drill the necessary holes in the prepared surface. Secure the electronic enclosure
with M10 bolts or equivalent fixings.
The wiring enters the unit through a gland plate in the bottom of the enclosure. A blank
gland plate is provided to give users a choice in the type of glands and gland configuration
for the required system. Alternatively, cable entry can be made directly via trunking. Note
that the gland plate should be removed for fitting of the glands.
The cabling involved is:
Mains Supplies (1 cable)
Remote Display (up to 6 cables)
Electrode Inputs (up to 2 cables)
Analogue Outputs (1 cable)
Relay or Opto-isolated Outputs
Opto-isolated Fault Output (1 cable)
(Up to 8 relay or opto-isolated outputs)
2-8
24685033_CB
Figure 2.2 - Installation diagram for the Hydrastep 2468 electronic gauging system unit
24685033_CB
2-9
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 the
analogue output connections from the electronic enclosure.
2.4.2.1 Electrode Connections

Hydrastep Electrode Cables
Special electrode cable assemblies of length 3, 10, 18 or 30 metres are provided with the
system for connecting the Hydrastep 2468 Electronic Enclosure to the Water Column
Electrodes. The cable looms are 18-core multi-strand conductors.
The conductors are colour coded for ease of installation and have pure nickel ring clamps
fitted at one end for connection to the electrodes. A set of wire crimps is provided for use on
the enclosure connections.
The black conductors in each cable are used for the EARTH terminations, leaving eight
pairs of coloured conductors for connection to the electrodes. At least one cable assembly is
required and certain conductor pairs in the cables will be redundant. The exceptions are the
8 and 16 electrode systems where all the conductors in the cables are fully used.
Electrode connections
2-10
Pin
Number
Function PL2, PL3, PL4, PL5
Electrode Drive
Electrode Pickup
Functional Earth
Electrode Drive
Electrode Pickup
Electrode Drive
Electrode Pickup
Functional Earth
Electrode Drive
10
Electrode Pickup
The connection requirements for

the 16 electrode system is used as
the example case. A full set of
electrode connection diagrams is
included at the end of Chapter 2
covering the pin-by-pin pairings for
all electrode systems mentioned.
24685033_CB
2.4.2.2
Connecting Cables to Water Column Electrodes

(16 Electrode System See page 2.WD.7 in the Wiring Drawings Section)
The following assumes that the electrodes have been fitted to the water column.
1. Gain access to the electrodes mounted on the water column.
2. Undo both knurled nuts on the stud of the bottom electrode (referenced EI.1 on the
wiring drawings) and remove both the nuts and washers.
3. Take one of the brown (BN) conductors in Cable 1 and fit the ring clamp of the
conductor over the stud, followed by a washer and a knurled nut. Tighten the nut to form
a good secure contact, ensuring the conductor run to the cable from clamping bar is free
from snags and sharp bends. Repeat the operation for the remaining brown (BN)
conductor of Cable 1.
4. Take the next electrode up, referenced EI.2 on wiring drawings, and repeat the
operations detailed in paragraph 2 above.
5. Take the brown (BN) conductors of Cable 2 and repeat the fitting instructions detailed in
paragraph 3 above.
6. Repeat the operations of paragraphs 2 and 3 for the remaining tabulated conductor/
electrode pairings on the next page and connect as detailed on page 2.WD.7.
7. Check that all conductor runs affecting Cables 1 and 2 on the water column are
satisfactory then clamp the cable securely to its clamping bar.
8. Refit any Electrode Protection Covers to the water column.
2.4.2.3 Connecting the Electrode Cable Assemblies to 2468 Enclosure

WARNING
Mains voltages are present in this instrument when power is

connected. De-energise before opening front cover.
Four 10-way plugs are provided on each PCB1 to terminate all the necessary connections
from the electrode cables.
1. Ensure power is removed from electronic enclosure and open the front cover.
2. Feed Cables 1 and 2 into the enclosure through its gland (if applicable). Prepare the
cable screens and terminate the screens at the gland plate.
3. Prepare the individual conductor lengths to suit their orientation in the terminal blocks
PL2, PL3, PL4 and PL5 on PCB 24680501. Ensure that the cables run along the sides
of the box at or below base plate level.
4. Fit the free sockets into the terminal blocks PL2 and PL3, PL4 and PL5.
5. Prepare the conductor core ends, fit the crimp terminals and connect the conductors to
their respective free sockets.
6. Ensure that both cables have a stress-free run inside the enclosure.
24685033_CB
2-11
2.4.2.4 Hydrastep Power Supply Cable

WARNING

AC Powered Units (input board 24680501)

The Hydrastep 2468C must be installed with a fuse or circuit breaker with a maximum rating
of 5A mounted as close as practicable, in an easily reached location. The fuse or circuit
breaker must be uniquely identified as the disconnecting device.
The cable gland used must have an inlet or bushing with a smoothly rounded bell-mouthed
opening with a radius of curvature of at least one and a half times the overall diameter of the
mains cable fitted. Alternatively, a fixed guard made of insulating material protruding beyond
the inlet opening by at least five times the cable diameter may be used.
A shielded mains cable should be used for all units that need to comply with the
requirements of the European EMC regulations. A suitable cable would be a 2-core braided
shield cable, 18AWG (24 x 0.2mm, 0.7mm). Gain access to each input board and proceed
as follows:
1. Check that the mains supply cable is not live and pass through its gland (if applicable).
2. The cable screen must be terminated at the gland plate.
3. Route the cables along the right hand side of the ensuring a stress-free run.
4. Connect the live and neutral conductor to their respective terminals.
5. Check the voltage setting by checking which voltage selection plug is fitted (set to 240V
at the factory) and, if required, adjust as guided in Figure 2.3.
6. With power disconnected release voltage selection plug PL9 by squeezing lugs. Insert
appropriate selector plug.
7. Remove fuse and fit 200mA ceramic anti-surge fuse
for 240V ac nominal and 400mA ceramic anti-surge
fuse for 110V ac nominal.
The Hydrastep 2468C unit must be earthed via the protective earth terminal (stud) on
the enclosure. The cable or braid used to attach the unit to the protective earth must
be capable of carrying a current of at least 10A. No disconnecting device should be
fitted to the protective earth conductor.
Voltage Selection Plug

(Set to 240V)
Fuse
Voltage Selection Plug

(Set to 110V)
Fuse
(A) 240V
L N
L N
TRANSFORMER
TRANSFORMER
(B) 110V
Figure 2.3: Voltage Selection (110V or 240V)
2-12
24685033_CB
DC Powered Units (input board 24680516)

The supply is connected to the unit in the same way as for the ac version. The dc supply
must be either negative earth or fully isolated from plant ground.
1. Positive (+Vs) is connected to the terminal marked L.
2. Negative (-Vs) is connected to the terminal marked N.
3. A separate ground wire is required which must be connected to the earth stud on the
enclosure.
4. For a non-isolated supply, the maximum difference between the plant earth at the water
column and the -Vs supply is 7V.
5. The cable screen must be connected to ground at the gland plate.
The Hydrastep 2468C unit must be earthed via the protective earth terminal (stud) on
the enclosure. The cable or braid used to attach the unit to the protective earth must
be capable of carrying a current of at least 10A. No disconnecting device should be
fitted to the protective earth conductor.
2.4.2.5 Analogue Output Connection

WARNING

Plug PL1 on each input board is used for the analogue output. A 2-core screened cable is
required and is connected into a 2-way socket such that:
The positive output conductor terminates in socket SK1 pin 1

The negative output conductor terminates in socket SK1 pin 2.
Gain access to each PCB 24680501 and connect the analogue output cable as follows:
1. Pass the analogue cable through its gland (if applicable) and into the enclosure.
2. Prepare the cable to give a stress-free run to PL1
on each PCB 24680501.
3. Screens must be terminated at the gland plate.
4. Prepare the conductor ends, fit the crimp
connectors and connect the cores into their
respective socket SK1 terminals.
5. Fit the socket into plug PL1 and check the cable
run.
24685033_CB
2-13
2.4.2.6 Opto-Isolated Fault Output Connection

WARNING
Plug PL4 is used for the FAULT output. A 2-core screened cable, capable of taking 1A and
30V is required and is connected into its 2-way terminal block such that:
Note:
No fault present = Short circuit, < 1.1V at 1 Amp

Fault present
= Open circuit, < 1 mA at 30V
The positive output conductor terminates in socket PL4 pin 2.
The negative output conductor terminates in socket PL4 pin 1.
Gain access to PCB 24680515 and connect the FAULT output cable as follows:
1. Pass the cable through its gland (if applicable) and into the enclosure. Prepare and
terminate the cable screen at the gland plate.
2. Prepare the cable to give a stress-free run to PL4 on PCB 24680515.
3. Prepare the conductor ends and connect the conductors into their respective terminal.
Check the cable run and tie it to the present loom. Tighten the gland nut (if applicable)
and close the instrument front cover.
Part of Display Board showing PL4
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 the appropriate Chapter 3a (Relay Outputs), 3b (Relay with time delay Outputs),
3c (Opto-isolated Outputs) or Chapter 4 (Remote Display).
2-14
24685033_CB
2.5
SYSTEM CONFIGURATION
This section describes user configuration of the input and display boards.
2.5.1
INPUT BOARD (PCB 24680501 OR 24680516)

Two settings may be configured on this board, the analogue output range and sense, and
the electrode error configuration.
2.5.1.1 Analogue Output Configuration

WARNING

Two sets of split pads are provided to select the required range (0-20mA or 4-20mA) and the
sense of the mA current output (normal sense as shown or in reverse, i.e. 4-20mA or 204mA).
To configure the analogue output, refer to Table 2.1 then:
1. Ensure the power supply is disconnected.
2. Locate the position of split pads SP1 and SP2 on the input board (PCB1) to select the
range of output current required. Table 2.1 shows how the pads should be bridged, or
left open-circuit, to select each range. The detail of PCB1 shows where SP1 and SP2
are located. Where a pad is to be left open-circuit, ensure that all solder is removed and
that the gap is clean.
3. Check the resistance across any altered pad for short- circuit or open-circuit, as
appropriate.
Table 2.1 - Analogue output configurations
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2-15
2.5.1.2 Pulsed Output Setting

As configured at the factory, the analogue output pulses if a fault condition occurs.
1. To disable this feature the split pad SP10 must be broken by cutting the track that
passes between the pads.
2. To re-enable the pulse for fault conditions the split pad can be bridged with solder.
2.5.1.3 Electrode Error Configuration

An electrode error is triggered if the electrode resistance measured falls below the set
electrode error threshold. Possible causes are a short to ground (short in cabling or dirty
electrode) or a break in the electrode wire (may also be very conductive water). This unit
can either be configured to take electrode error into account when measuring electrode
resistance or the facility can be disabled. When enabled, if an electrode error occurs the
alarm (yellow) LED relating to the board on which the error occurred is illuminated and the
LED pair (red and green) corresponding to the electrode, alternate between red and green.
Note: 104S/cm and 300S/cm are

approximate values
Input Board (Option Board Removed)
2-16
24685033_CB
2.5.1.4 Configuring the Unit to Detect Electrode Error

WARNING

1. Disconnect the power supply. Gain access to the input PCB by opening the cover and
removing the option board.
2. Check split pads SP6 & SP7 on the input PCB are open-circuit and clean (this is the
default setting).
3. To change the electrode error threshold value or to disable the feature, bridge the split
pads SP6 or SF7 with solder as shown in the table above.
This concludes the configuration on the input boards.
2.5.2
DISPLAY BOARD 24680515

Switch SW1 on the Display Board must be set in accordance with the number of electrodes
whose state is to be displayed. As shown in Table 2.2, the various switch settings allow you
to specify the number of electrodes as: 8, 10, 12, 14 or 16.
Since only one input board is used in the 2468CA or 2468CC, the display mode links, LK2,
LK3, LK4 and LK5, must be set for 8-16 operation (two LEDs per electrode). This means
that links LK2 and LK4 must be fitted and links LK3 and LK5 must not be fitted. See Figure
2.4. In addition, link LK1 must be fitted to link the two halves of the single display board
together. For applications in hazardous areas each fitted link must be secured in its socket
with a cable tie passed under the socket base.
Note: Links LK1, LK2 and LK4 must be fitted. Links LK3
and LK5 must NOT be fitted.
An invalid switch setting causes the main column LEDs
to display a chequered pattern
Figure 2.4- Location of display board links LK1 to LK5 & switch SW1 with
configuration details
24685033_CB
2-17
SWITCH SW1
NO. OF
ELECTRODES
LINKS
CHANNEL NO.
IN WATER
2&4
COLUMN
Off
Off
Off
On
Off
On
On
Off
10
Off
Off
On
Off
12
Off
On
Off
Off
14
Off
Off
Off
Off
16
Fitted
Table 2.2 - Number of electrodes being displayed
2.5.2.1 Link LK1 Setting

Ensure that link header LK1 is fitted, see Figure 2.4.
2.5.2.2 Configuring the Number of Electrodes Switch

WARNING

1. Disconnect the power supply. Gain access to PCB 24680515 by opening the cover.
2. Locate position of Number of Electrodes switch SW1 (see Figure 2.4).
3. Depending upon the number of electrodes being used, set the switch SW1 as shown in
Table 2.2. The switch positions in the example in Figure 2.4 are for a 12-electrode
system.
2.5.2.3 Switching Threshold Setting

WARNING

1. Disconnect the power supply. Gain access to PCB 24680515 by opening the cover.
2. Check split pads SP1 and SP2 on the PCB are open-circuit and clean (this is the normal
setting 0.6S/cm). (See Figure 2.5 on page 2-19)
3. If the preferred setting is 1.6S/cm (low temperature), bridge the split pads SP1 and SP2
with solder.
2-18
24685033_CB
Figure 2.5- Split pads SP1, SP2, SP5 & SP6 locations and settings
2.5.2.4 Compatibility Setting

The split pads SP5 and SP6 should be open when used with a 24680501C or 24680516B
input board. When used with a 24680501A, 24680501B or 24680516A input boards these
split pads should be made. With these older input cards the LEDs corresponding to an
electrode error will not alternate but remain steady.
24685033_CB
2-19
2.6
FAULT ANALYSIS & CORRECTIVE ACTION

Faults in the system will generally be indicated by the YELLOW LEDs on the front panel and
by the fault output on the display board. The main faults which are catered for are:
Water above steam condition

Electrode or Wiring fault
Detection of an internal circuit fault

When any of the above mentioned conditions exist within the Hydrastep 2468CB system, the
yellow LEDs are illuminated to indicate the FAULT state. An opto-coupler output, normally
short-circuited, becomes open-circuited on a FAULT state, providing an ALARM indication
output for external use. The current output indicates an alarm condition by a 0.5Hz
waveform superimposed on the main analogue signal.
A further FAULT is indicated when the number of electrodes switch on the display board is
set to an invalid number. This error brings up an alternate LED illumination display, that is a
chequered display of GREEN and RED LEDs on the two front panel columns.
WARNING
Indication
Top and
bottom halves
of fault LED
illuminated

Fault(s)
Water conductivity
greater than
approximately
104S/cm
Analysis and Corrective Action

Check ac voltage on all electrodes immersed in water with
a true rms voltmeter. If several of the immersed
electrodes show a voltage of less than approximately 0.1V
ac then very high water conductivity is probable.
Check water column installation is correct; sloping
pipework and insulation details. Make sure that there is
sufficient condensate flow through the column.
If the normal water conductivity is greater than
approximately 104S/cm then the electrode error circuitry
will have to be configured for approximately 300S/cm or
disabled - refer to the electrode error configuration
section.
Water above steam,

caused by electrode
wiring or internal fault
The electrode channel(s) causing the problem will be

evident from the unit display by an alternating indication
in the steam area.
Electrode connection
open-circuit or shortcircuit to earth
Check the suspect electrode has the correct pair of

conductors connected, check the connections to the input
board. Rectify if incorrect.
Affected electrode
indicates water
Incorrect wiring,
broken connection or
damaged cable
assembly
Check ac voltage on electrode with a true rms voltmeter.

A voltage of less than approximately 0.1V ac indicates a
fault condition.
If wiring to the electrode is correct and the electrode gives
a voltage reading of greater than approximately 0.1V ac
and a fault is still indicated, carry out the following
procedure:
1. Remove both conductors from suspect electrode.
With the conductors isolated from each other, the
level display should show electrode as alternating
between water and steam.
Table 2.3 - Fault analysis/corrective action chart
2-20
24685033_CB
Indication
Top and bottom
halves of Fault
LED illuminated
(contd.)
Fault(s)
Incorrect wiring,
broken connection
or damaged cable
assembly

2.
With the conductors touching each other, the level

display should show electrode as being in steam.
The above procedure checks the electrode wiring. If the

display does not show the correct results, then check for a
break in either of the suspect electrode conductors.
Carry out repair to any faulty connection or substitute a new
conductor or cable assembly in place of the defective item.
Dirt on electrode
If the wiring checks carried out as described in the previous

page have not located a fault, then dirt on an electrode
insulator may be the cause of the problem giving an
effective short-circuit to ground.
Check the electrodes for dirt over the external insulator and
clean with a cloth as required.
Checking for dirt on the internal insulator of the electrode
requires the draining of the water column (refer to the
appropriate manual for the correct procedure).
Once the water column is drained, check the ac voltage on
each electrode using a true rms voltmeter. Any electrode
showing a voltage of less than 3V ac needs cleaning or
replacement. Electrodes must be removed from the column
for inspection and cleaning.
Note: The electrode insulator can be cleaned using a clean
cloth
Internal circuit fault
If the wiring checks carried out as described and in the

previous page have not located a fault, then it is possible an
internal fault exists.
1.
Disconnect the electrode cable sockets from the input

board.
2.
Make up four 10-way sockets with wire links connecting;

pin 1 to pin 2, pin 4 to pin 5, pin 6 to pin 7 and pin 9 to
pin 10 on each socket.
3.
Insert these sockets in place of the electrode cable

sockets in the input boards, the level display should now
show an all in steam state and 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 the input board first
and if that does not rectify the problem, change the display
board. If spares are not available, call the service engineer.
Table 2.3- Fault analysis/corrective action chart (continued)
24685033_CB
2-21
Indication
Fault(s)
Chequered
pattern on RED
& GREEN LED
display
Wrong setting of
Number of
Electrodes switch
on display board
ON/OFF pattern
on RED &
GREEN LED
display
Wrong setting of
Number of
Electrodes switch
or linking on LK2,
LK3, LK4, LK5
incorrect on Display
Board

Refer to Section 2.3 of this chapter and ensure that the
switch is set correctly. If the display still shows a
chequered pattern then a circuit fault exists on the display
board and the board will need replacing.
As above
Lower
electrodes not
displayed
As above
As above
Odd side only

electrodes
displayed
LK1 not fitted
As above
Table 2.3- Fault analysis/corrective action chart (continued)
2.6.1
COMPONENT REPLACEMENT
The Hydrastep 2468CA contains no user-replaceable components. Board failure requires
the replacement of the entire printed circuit board.
WARNING

2.6.1.1 Removing the Input Board (24680501 or 24680516)

The input board is secured on to the base plate of the electronic enclosure by seven set
screws and washers, distributed one at each corner of the board and three in the board
centre, see Figure 2.1 on page 2-4. To remove the input board, carry out the following
procedure:
1. Isolate the electronic enclosure from the ac (mains) or dc supply and open the lid.
2. Unplug the supply connector TB1.
3. Unplug the electrode input connectors PL2, 3, 4 and 5 as necessary and the analogue
output connector PL1 (if used) from the input board.
4. Disconnect the ribbon cable connector on the display board and the display board power
cable socket on the input board, see Figure 2.1 on page 2-4.
5. Undo the seven securing screws and remove them and their washers. Lift off the input
board from the base plate.
2.6.1.2 Refitting the Input Board

To refit the input board, carry out the removal procedure in the reverse order.
2-22
24685033_CB
2.6.1.3 Removing the Display Board 24680515

The display board is attached to pillars mounted on the rear of the front panel by five
securing nuts and washers. See Figure 2.1 on page 2-4.
To remove the display board, carry out the following procedure:
1. Isolate the electronic enclosure from the mains supply and open the lid.
2. Disconnect the ribbon cable socket and the display board power cable socket from the
display board, see Figure 2.1 on page 2-4. Remove remote display and system fault
connections if applicable.
3. Undo the five securing nuts and remove them and their washers. Lift off the display
board from the attachment pillars.
2.6.1.4 Refitting the Display Board

To refit the display board, carry out the removal procedure in the reverse order.
Note: Special attention must be taken to ensure the lid screening is satisfactory after any
display board refitting. The screening cable is taken to the bottom left hand securing
screw and this connection must have good conductivity.
2.6.2
PARTS LIST - HYDRASTEP 2468 CA & CC VERSIONS

Item Description
Solartron
Mobrey
Part No.
Item Description
Solartron
Mobrey
Part No.
Electronic Enclosure
Input PCB assembly (2468CA)
Fuse link 200mA (T) ceramic
Fuse link 400mA (T) ceramic
24680501C
360190330
360190340
Display PCB assembly

Header programmable (10-way)
Header programmable (8-way)
24680515B
399100380
399100390
Input PCB assembly (2468CC)

Fuse link 1.25A (T) ceramic
24680516B
360190320
Socket SK3 free (10-way)

24682003A
24682011A
Cable assembly (10-way)
24680210A
Earth lead
24680216A

24682007A
24682002A
24682003A
24682004A
24682005A
Electrode Cables
Electrode cable (3 metre)
24680204A
24680205A
24680206A
24680207A
24685033_CB
2-23
2.7
SPECIFICATION
Enclosure:
400mm x 300mm x 163mm (15.7in x 11.8in x 6.4in)

Painted, zinc coated mild steel
Wall-mounting
lP65 / NEMA 4X
Gland plate - stainless steel 250mm x 120mm
(9.8in x 4.7in)
Weight:
12kg (26.4lb)
Operating temperature:
-20C to +70C (-4F to +158F)
Relative humidity:
up to 100%
Location:
Indoor or outdoor
Power supply requirements:

(ac input)
110V ac nominal
93.5V - 130V ac / 48Hz - 65Hz
240V ac nominal
187V - 256V ac / 48Hz - 65Hz
Power supply loading (ac):
30VA maximum
Power supply requirements:

(dc input)
24V dc nominal
20-40V dc negative earth or isolated
(absolute limits 19V-44V dc)
Power supply loading (dc):
30W maximum
Supply -Vs to plant ground:
7V maximum for non-isolated supply
Installation category:
III
Outputs:
Drive to remote display (6 or 8 wire)

Opto-isolated fault output
Analogue output
Analogue output:
Range:
Accuracy:
Drive capability:
2-24
0 - 20mA or 4 - 20mA, forward or reverse

0.2mA
600 at nominal supply voltage
500 at minimum supply voltage
Opto-isolated fault output:

Maximum open-circuit voltage:
Maximum short-circuit current:
Short-circuit voltage drop:
Open-circuit leakage current:
30V dc
1A dc
1.1V dc maximum at 1A dc
1mA maximum at 30V dc
Remote display drive:

Loop Resistance (ac powered unit):
Loop Resistance (dc powered unit):
Distance:
27 maximum
7 maximum
1000m (3280ft) maximum
Electrical connections:
Plug-in screw terminals

24685033_CB
Wiring Diagrams for Single Power Supply Version

(Single Power Supply Version)
Electrode Cable Wiring Diagrams
Contents
Page No.
Figure 2.WD.1 - Electrode cable connections to 8 port column ................................................3

Figure 2.WD.2 - Electrode cable connections to 10 port column ..............................................4
24685033_CC
2-WD.1
2-WD.2
24685033_CC
Wiring Diagrams for Dual Power Supply Version
Figure 2.WD.1 - Electrode cable connections to 8 port column
24685033_CC
2-WD.3
2-WD.4
24685033_CC
24685033_CC
2-WD.5
2-WD.6
24685033_CC
24685033_CC
2-WD.7
2-WD.8
24685033_CC
3a

Contents
Page No.
3a.1
GENERAL DESCRIPTION.................................................................... 3a-3
3a.2
INSTALLATION .................................................................................... 3a-3

3a.2.1
3a.2.2
3a.2.3
3a.3
RELAY BOARD CONFIGURATION ..................................................... 3a-6

3a.3.1
3a.3.2
24685033_CC
STORAGE & PRE-INSTALLATION INSPECTION ..............................3a-3

3a.2.1.1 Storage Area .........................................................................3a-3
3a.2.1.2 Pre-Installation Inspection .....................................................3a-3
MECHANICAL INSTALLATION............................................................3a-4
3a.2.2.1 Fitting the Nylon Spacers to the Relay Output Board ...........3a-4
3a.2.2.2 Mounting the Relay Output Board on to the Input Board ......3a-4
ELECTRICAL INSTALLATION .............................................................3a-5
3a.2.3.1 PCB Interconnections............................................................3a-5
3a.2.3.2 Relay Output Connections ....................................................3a-5
RELAY OUTPUT BOARD ....................................................................3a-7

3a.3.1.1 Configuring the Relay Output Board .....................................3a-7
3a.3.1.2 Electrode/Relay Selection (Relays RL1, RL2, RL3 & RL4)
- SW1 to SW4........................................................................3a-7
3a.3.1.3 Relay Energisation (In Steam or In Water) - SW5 .............3a-8
3a.3.1.4 Electrode/Alarm Operation (RL1 function only) - SW6 .........3a-8
3a.3.1.5 System Fault Output..............................................................3a-9
ALARM AND TRIPPING FACILITIES.................................................3a-10
3a.3.2.1 Philosophy ...........................................................................3a-10
3a.3.2.2 Relay Interconnections for Alarm/Tripping Systems ...........3a-10
3a.3.2.3 Single Power Supply System ..............................................3a-11
3a.3.2.4 Dual Power Supply System.................................................3a-13
3a-1
3a.4
COMPONENT REPLACEMENT .......................................................................3a-19

3a.4.1 REPLACEMENT OF NYLON SPACERS ...........................................3a-19
3a.4.2 PARTS LIST - RELAY OUTPUT BOARD 24680504 .........................3a-19
3a.5
SPECIFICATION................................................................................................3a-20
Illustrations
Figure 3a.1 - View of relay output board showing switch positions and output pin details ...... 6
Tables
Table 3a.1 - Electrode selections for relays RL1 to RL4 .....................................................3a-7
3a-2
24685033_CC
Relay Output Board Option
3A.1 GENERAL DESCRIPTION

The Relay Output Board (PCB 24680504) has four relays and is designed to be 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 input board and PL1 on the relay output board).
A second relay output board may be mounted on top of the first on nylon spacers. Holes
have been drilled on all relay output boards to receive the 3 nylon spacers. The top board is
offset towards the centre of the unit improving the cable layout from the relay output boards.
The nylon spacer fixing holes and mounting holes are illustrated in Figure 3a.1.
Each of the 4 relays can be energised by any one of up to 16 electrodes, with an individual
choice of being energised when its selected electrode is in steam or is in water.
Furthermore, relay RL1 can be used to monitor an electrode state or to register an ALARM
condition. When set to register the ALARM state, the relay is energised in the system
normal state and de-energises when an ALARM condition exists.
This option comes complete with the nylon spacers and two 8-way output sockets.
3A.2 INSTALLATION
This sub-section deals with the mechanical and electrical installation of the Relay Output
Board (PCB 24680504) option. In the rest of this chapter the relay output board title is
shortened to relay board.
3A.2.1 STORAGE & PRE-INSTALLATION INSPECTION

3a.2.1.1 Storage Area
The storage area must be dry, dust-free and kept at a reasonable temperature. The storage
area should allow for access and inspection of all items of equipment.
3a.2.1.2 Pre-Installation Inspection

Open the option package and inspect the contents for signs of damage. Check contents for
completeness.
24685033_CC
3a-3
3A.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
interconnection (PL1/SK1) and input board-mounted spacers and pressed home on to the
spacers.
When two output boards are required to be mounted on an input board, the second output
board is mounted on three nylon spacers fitted on the first mounted output board.
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.
1. Fit the nylon spacers into their prepared holes on the output
board and lock in position using the nylon washer and M4 nut,
see inset diagram.
2. Fit the output board on to the spacers and check for correct
alignment and adjust if necessary.
3a.2.2.2 Mounting the Relay Output Board on to the Input Board

WARNING

This task can be performed on a mounted 2468 electronic enclosure or the enclosure can be
removed to a bench for the installation. Here it is assumed that the enclosure is in its normal
working location. The procedure for mounting the relay output board is as follows:
1.
Isolate the power supply from the 2468 electronic enclosure and open the instrument
front cover.
2.
If two output boards are to be fitted, make sure that the first output board to be fitted has
had its nylon spacers fitted before installation. Also ensure the first output board is fully
configured before fitting the second output board.
3.
Ease the pins of the Berg plug PL1 of the output board into the Berg socket SK1 on the
input board, checking that the mounting holes on the output board (the holes which are
not contained in white bordered areas) are aligned over the fitted spacers and gently
press the output board home until the spring-loaded spigot on each spacer is locked
firmly on to the output board.
Note:
When fitting a second output board, use the same procedure described in operation
3 but refer to the components, etc., on the mounted output board.
This concludes the mechanical installation of the output board(s) and should be followed by
the electrical installation. If the latter is not to be carried out in the immediate future then the
power supply can be reconnected.
3a-4
24685033_CC
3A.2.3 ELECTRICAL INSTALLATION

This sub-section deals with the output of the states of the four relays. Two 8-way sockets
are provided with each output board through which the relay outputs are delivered to their
external destinations.
3a.2.3.1 PCB Interconnections

Signal interconnection between the input board (PCB1) and the output board (PCB4) is
direct via the SK1/PL1 12-way Berg connectors. When two output boards are fitted, the top
boards plug PL1 engages in the lower boards SK1.
3a.2.3.2 Relay Output Connections

The relay outputs can be taken out of the enclosure via the gland plate or along with the
other cables in suitable trunking. One or more cables can be used at the discretion of the
user, however the cables must be screened and the screens terminated at the gland plate.
Since the output board is mounted on top of the input board, the routing of the relay cabling
should take the same kind of formation as the electrode cabling, but separated from it as far
as practical. The cable should be arranged such that the cables do not lie across any of the
PCBs. The layout and plug pin details of the two plugs on the relay board is given in the
diagram on the right, with the relay contacts shown in their de-energised state.
When two output boards are fitted, the output terminals of the uppermost output board are
offset towards the centre of the input board.
View illustrating mounted positions of

dual relay output boards
24685033_CC
Relay output PCB connectors
3a-5
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 RL1 - RL4 to be energised in steam or in water.
Figure 3a.1 provides a view of the output board layout to highlight the positions of the various
configuration switches.
Figure 3a.1 - View of relay output board showing switch positions and output pin details
3a-6
24685033_CC
3A.3.1 RELAY OUTPUT BOARD

3a.3.1.1 Configuring the Relay Output Board
WARNING

1. Isolate the 2468 electronics enclosure from its power supplies.

2. Gain access to the relay output PCB and set the relevant switches for the required
function.
3a.3.1.2 Electrode/Relay Selection (Relays RL1, RL2, RL3 & RL4) - SW1 To SW4
Four identical switches are provided on the relay board for electrode selection. Any of the
electrodes, connected to the input board on which the relay board is mounted, can be
selected as the input for any of the relays.
With one input board installed, any electrode connected to the system can be used as the
source for any of the four relays. With two input boards installed, the relay board mounted
on the input board connected to the odd numbered electrodes, accepts inputs from the odd
numbered electrodes. Similarly, the relay board mounted on the input board connected to
the even numbered electrodes, accepts inputs from even numbered electrodes. Table 3a.1
details switch selection.
Switch SW1, SW2, SW3 or SW4
Settings for RL1 to RL4 respectively
Switch Contacts
Electrode Selection
One Input
Two Input Cards
Card
Odd I/P Card
Even I/P Card
On
Off
On
Off
On
Off
On
Off
On
Off
On
Off
On
Off
On
Off
On
On
Off
Off
On
On
Off
Off
On
On
Off
Off
On
On
Off
Off
On
On
On
On
Off
Off
Off
Off
On
On
On
On
Off
Off
Off
Off
On
On
On
On
On
On
On
On
Off
Off
Off
Off
Off
Off
Off
Off
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
1
3
5
7
9
11
13
15
17
19
21
23
25
27
29
31
2
4
6
8
10
12
14
16
18
20
22
24
26
28
30
32
Table 3a.1 - Electrode selections for relays RL1 to RL4

Example:
24685033_CC
Single Input Board - Electrode 13 selected

Dual Input Boards: Odd input board - Electrode 25 selected
Even input board - Electrode 26 selected
OFF
3a-7
3a.3.1.3 Relay Energisation (In Steam or In Water) - SW5

This is a four-channel switch, one channel allocated per relay. The switch selects whether
the relay is energised when the selected electrode is in water or is in steam. This switch is
highlighted in Figure 3a.1 to provide additional information on channel identity and the switch
electrode state.
3a.3.1.4 Electrode/Alarm Operation (RL1 Function Only) - SW6

Relay 1 can be configured to receive either an electrode input or it can be used as the
system fault relay (see Figure 3a.1). When configured as the system fault relay, the normal
state of the relay is energised, a fault state will de-energise the relay. See the next section
for contact output details.
3a-8
24685033_CC
3a.3.1.5 System Fault Output

Relay 1 on each relay board can be configured to be used as a system fault relay by setting
SW6. When used as a system fault relay the normal state of the relay is energised and a
fault state will de-energise the relay.
The relay will only output faults detected by the input board onto which it is installed. With a
dual power supply Hydrastep unit, this means it is necessary to used two relay boards (one
on each input board) to create a system fault output.
Single Power Supply System

(Relays shown in de-energised state)
RL 1
RL 2
RL 1
PL 2
To alarm
annunciator
PL 2
To alarm
annunciator
RL 2
Alarm off when contacts closed
Alarm off when contacts open

(Switch SW6 set for fault signal operation)
Dual Power Supply System

RL 1
PL 2
PL 2
To alarm annunciator
4
Odd fault relay
(RH input board)
4
Even fault relay
(LH input board)
RL 1
PL 2
PL 2
RL 1
1
2
Odd fault relay

(RH input board)
RL 1
3
Even fault relay

(LH input board)
Note:
24685033_CC
An opto-isolated system fault is available from the display board.
3a-9
3A.3.2 ALARM AND TRIPPING FACILITIES

The relay boards provide high 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.
3a.3.2.1 Philosophy
A requirement in regulations concerning steam raising plant is the provision of an automatic
low water level shut-down or trip device. In the 2468 Hydrastep the relay output board
provides the required output signals for such devices.
In practical applications of shut-down systems two factors must be considered, the
consequences of spurious trips and the non-availability of a trip when required, due to
protection system faults.
The following relay output circuits are specific to the 2468 Hydrastep Electronic Gauging
Systems.
3a.3.2.2 Relay Interconnections for Alarm/Tripping Systems

It is necessary to open the Hydrastep 2468 Electronic Enclosure to carry out any wiring,
therefore care must be taken when working inside the unit.
WARNING
Note:
3a-10

Before any relay interconnections are made it is necessary to fulfil any safety
regulations governing the plant shut-down procedures.
24685033_CC
3a.3.2.3 Single Power Supply System

Here any relay can be operated by any of the electrodes used in the system. The relays can
be configured to be normally energised and therefore register an alarm should the power
supply fail. The following configurations can be implemented.
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 energisation
in water EW or energisation in steam ES.
Case 1a - Relays normally energised, de-energise either one to trip

RL 1
PL 2
RL 1
2
3
4
PL 2
2
3
To alarm
annunciator
or tripping
device
To alarm
annunciator
or tripping
device
5
RL 2
5
RL 2
(Switch SW5 is set to EW for low-level alarms and set to ES for high-level alarms)
Case 1b - Relays normally de-energised, energise either one to trip

RL 1
PL 2
RL 1
2
3
4
To alarm
annunciator
or tripping
device
To alarm
annunciator
or tripping
device
5
RL 2
PL 2
5
RL 2
(Switch SW5 is set to ES for low-level alarms and set to EW for high-level alarms)
24685033_CC
3a-11
Single Power Supply System (Contd.)

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 2a - Relays normally energised, de-energise both to trip

RL 1
PL 2
RL 1
PL 2
2
To alarm
annunciator
or tripping
device
3
4
To alarm
annunciator
or tripping
device
5
RL 2
5
RL 2
Case 2b - Relays normally de-energised, energise both to trip

RL 1
PL 2
RL 1
2
3
4
To alarm
annunciator
or tripping
device
To alarm
annunciator
or tripping
device
5
RL 2
PL 2
5
RL 2
3a-12
24685033_CC
3a.3.2.4 Dual Power Supply System

Since one input board receive inputs from the odd numbered electrodes and the other input
board receives inputs from the even numbered electrodes, interconnections between odd
and even relay boards will be required. The following are examples of relay configurations
used.

Case 3a - Relays normally energised, de-energise either one to trip

RL 1
PL 2
PL 2
Odd electrodes
(RH input board)
Even electrodes
(LH input board)

RL 1
PL 2
PL 2
RL 1
Odd electrodes
(RH input board)
RL 1
Even electrodes
(LH input board)

(Switch SW5 is set to EW for low level alarms and set to ES for high level alarms)
Case 3b - Relays normally de-energised, energise either one to trip

RL 1
PL 2
PL 2
1
2
2
3
4
Odd electrodes
(RH input board)
Even electrodes
(LH input board)

RL 1
RL 1
PL 2
PL 2
Odd electrodes
(RH input board)
RL 1
Even electrodes
(LH input board)
(Switch SW5 is set to ES for low level alarms and set to EW for high level alarms)
24685033_CC
3a-13
Dual Power Supply System (contd.)

Case 4a - Relays normally energised, de-energise both to trip

RL 1
PL 2
PL 2
RL 1
Odd electrodes
(RH input board)
Even electrodes
(LH input board)

RL 1
PL 2
PL 2
3
RL 1
Odd electrodes
(RH input board)
Even electrodes
(LH input board)

Case 4b - Relays normally de-energised, energise both to trip

RL 1
PL 2
PL 2
Odd electrodes
(RH input board)
Even electrodes
(LH input board)

RL 1
1
2
Odd electrodes
(RH input board)
PL 2
RL 1
PL 2
RL 1
Even electrodes
(LH input board)
3a-14
24685033_CC

Two out of Four Relay Alarm System
In the following diagrams (5A & 5B) cdef indicate the electrode channel selected for
each relay. A fully functioning system (NO FAULTS) will perform a low level trip at electrode
level 3. For a high level trip, using electrode channels 11, 12, 9 and 10 respectively and
switch SW5 set for ES, a healthy system would trip at level 10.
Case 5a - Relays normally energised, de-energise one in each pair to trip

RL 1
PL 2
RL 1
2
3
PL 2
2
4
To alarm
annunciator
or tripping
device
5
RL 2
5
RL 2
6
7
6
7
2
8
Even electrodes
(LH input board)
Odd electrodes
(RH input board)

Case 5b - Relays normally energised, de-energise one pair to trip

RL 1
PL 2
RL 1
2
3
3
4
5
RL 2
6
7
PL 2
RL 2
To alarm
annunciator
or tripping
device
6
7
2
8
Odd electrodes
(RH input board)
Even electrodes
(LH input board)

24685033_CC
3a-15

Two out of Four Relay Alarm System (contd.)
level 2. For a high level trip, using electrode channels 9,10, 11 and 12 respectively and
Case 6a - Relays normally energised, de-energise one in each pair to trip

RL 1
PL 2
RL 1
2
3
PL 2
2
4
To alarm
annunciator
or tripping
device
5
RL 2
5
RL 2
6
7
6
7
2
8
Even electrodes
(LH input board)
Odd electrodes
(RH input board)

Case 6b - Relays normally de-energised, energise one in each pair to trip

RL 1
PL 2
RL 1
2
3
3
4
5
RL 2
6
7
PL 2
RL 2
To alarm
annunciator
or tripping
device
6
7
2
8
Odd electrodes
(RH input board)
Even electrodes
(LH input board)

3a-16
24685033_CC

Two out of Three Relay Alarm System
In the following diagrams (7A & 7B) cde indicate the electrode channel selected for each
relay. A fully functioning system (NO FAULTS) will cause a low level trip at electrode level
2. Using high level electrode channels and SW5 set to ES, the circuit can perform a high
level trip.
Note: Inputs from electrodes 1 & 2 are applied to two separate relays on their respective
boards.
Case 7a - Relays normally energised, de-energise two to trip

RL 1
PL 2
RL 1
2
3
PL 2
2
2
5
RL 2
5
RL 2
6
7
To alarm
annunciator
or tripping
device
6
7
RL 3
Even electrodes
(LH input board)
1
2
Odd electrodes
(RH input board)
4
PL 3
24685033_CC
3a-17
Case 7b - Relays normally de-energised, energise two to trip

RL 1
PL 2
RL 1
2
3
PL 2
2
2
5
RL 2
5
RL 2
6
7
To alarm
annunciator
or tripping
device
6
7
Even electrodes
(LH input board)
RL 3
1
2
3
4
Odd electrodes
(RH input board)
PL 3
3a-18
24685033_CC
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 which can be replaced is the nylon
spacer.
3A.4.1 REPLACEMENT OF NYLON SPACERS

The replacement of nylon spacers fitted to the output board requires access to the noncomponent side of the PCB.
Note: Spacers will only be fitted on the output board if a second output board is to be fitted
or has been fitted.
The spacers are secured in their holes by nut and nylon washer. To carry out a spacer
replacement, the output board has to be removed from the input board. The procedure
adopted is:
WARNING

1. Isolate the 2468 electronic enclosure from the power supply.

1. Gain access to the PCBs and undo sufficient connections for the removal of the output
board containing the defective spacer.
2. Remove the output board(s) by applying pressure to the
upper spring-loaded spigots and easing the output board off
its spacers and out of its Berg plug/socket connection.
3. Undo the nut and washer securing the faulty spacer and
extract it from its hole, see inset diagram.
4. Fit the new spacer in position, align correctly on the board
and secure firmly using the M4 nut and nylon washer.
5. Refit the PCB(s) into the enclosure, re-connect the PCB(s) as
required and close the enclosure cover. Re-apply power.
3A.4.2 PARTS LIST - RELAY OUTPUT BOARD 24680504

The following list items are available as spare parts:
Item Description
Electrical:
Relay PCB assembly:
24685033_CC
Solartron
Mobrey Part
Number
Item Description
24680504C
Mechanical:
Spacer, nylon 15.9 LG
Washer, nylon
Nut, M4
Socket 5K2 free (8-way)
351508100
Socket 5k3 free (8-way)
351503100
Solartron
Mobrey Part
Number
412012080
411999910
410031020
3a-19
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
65W
25W
Type N safety
( 30V)
( 60V)
( 125V)
5A at 12Vdc
100mA at 30Vdc
20mA at 125Vdc
Maximum initial contact resistance: 30m
3a-20
24685033_CC
3b
Contents
Page No.
3b.1
GENERAL DESCRIPTION.................................................................... 3b-3
3b.2
INSTALLATION .................................................................................... 3b-3

3b.2.1
3b.2.2
3b.2.3
3b.3
DELAY RELAY BOARD CONFIGURATION .........................................3b-6

3b.3.1
3b.3.2
24685033_CD
STORAGE & PRE-INSTALLATION INSPECTION .............................. 3b-3

3b.2.1.1 Storage Area ......................................................................... 3b-3
3b.2.1.2 Pre-Installation Inspection ..................................................... 3b-3
MECHANICAL INSTALLATION............................................................ 3b-4
3b.2.2.1 Fitting the Nylon Spacers to the Delay Relay Output Board . 3b-4
3b.2.2.2 Mounting the Delay Relay Output Board on to the Input
Board ..................................................................................... 3b-4
ELECTRICAL INSTALLATION ............................................................. 3b-5
3b.2.3.1 PCB Interconnections............................................................ 3b-5
3b.2.3.2 Relay Output Connections .................................................... 3b-5
DELAY RELAY OUTPUT BOARD........................................................ 3b-7

3b.3.1.1 Configuring the Delay Relay Output Board ........................... 3b-7
3b.3.1.2 Electrode/Relay Selection (Relays RL1, RL2, RL3 & RL4)
- SW1 to SW4........................................................................ 3b-7
3b.3.1.3 Relay Energisation (In Steam or In Water) - SW5 ............. 3b-8
3b.3.1.4 Electrode/Alarm Operation (RL1 Function Only) - SW6 ....... 3b-8
3b.3.1.5 System Fault Output.............................................................. 3b-9
3b.3.1.6 Delay Circuit Configuration.................................................. 3b-10
3b.3.1.7 Configuring the Delay Circuit Split Pads ............................. 3b-11
ALARM AND TRIPPING FACILITIES................................................. 3b-12
3b.3.2.1 Philosophy ........................................................................... 3b-12
3b.3.2.2 Relay Interconnections for Alarm/Tripping Systems ........... 3b-12
3b.3.2.3 Single Power Supply System .............................................. 3b-13
3b.3.2.4 Dual Power Supplies System .............................................. 3b-15
3b-1
3b.4
COMPONENT REPLACEMENT ..........................................................3b-21

3b.4.1
3b.4.2
3b.5
REPLACEMENT OF NYLON SPACERS ........................................... 3b-21

PARTS LIST - DELAY RELAY OUTPUT BOARD 24680509 ............ 3b-21
SPECIFICATION..................................................................................3b-22
Illustrations
Figure 3b.1 - View of relay output board showing switch positions and output pin details .......6
Figure 3b.2 - View of delay relay output board showing split pad positions............................11
Tables
Table 3b.1 - Electrode selections for relays RL1 to RL4 ...........................................................7
Table 3b.2 - Split pad functions on relay delay circuits ...........................................................10
3b-2
24685033_CD
3B.1 GENERAL DESCRIPTION

The Delay Relay Output Board (PCB 24680509) is designed to be 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 input board and PL1 on the delay relay output board).
A second delay relay output board may be mounted on top of the first on nylon spacers.
Holes have been drilled on all delay relay output boards to receive the 3 nylon spacers. The
top output board is offset towards the centre of the unit improving the cable layout from the
delay relay output boards. The nylon spacer fixing holes and mounting holes are illustrated
in Figure 3b.1 on page 3b-6.
Each of the four delay relays can be energised by any one of up to 16 electrodes, with an
individual choice of being energised when its selected electrode is in steam or is in water.
Furthermore, relay RL1 can be used to monitor an electrode state or to register an ALARM
condition. When set to register the ALARM state, the relay is energised in the system
normal state and de-energises when an ALARM condition exists.
Each relay channel also contains a delay circuit where set delays of between 0 and 23
seconds can be provided using one of four split pad links. Provision is also made by split
pad links, to bypass each delay circuit. The split pad linkage is fully covered in section 3b.3
of this Chapter.
3B.2 INSTALLATION
This sub-section deals with the mechanical and electrical installation of the Delay Relay
Output Board (PCB 24680504) option. In the rest of this chapter, the delay relay output
board title is shortened to output board.
3B.2.1 STORAGE & PRE-INSTALLATION INSPECTION

3b.2.1.1 Storage Area
3b.2.1.2 Pre-Installation Inspection

completeness.
24685033_CD
3b-3
3B.2.2 MECHANICAL INSTALLATION

interconnection (PL1/SK1) and input board-mounted spacers and pressed home on to the
spacers.
When two output boards are required to be mounted on an input board, the second output
board is mounted on three nylon spacers fitted on the first mounted output board.
3b.2.2.1 Fitting the Nylon Spacers to the Delay Relay Output Board
The spacers fit into the holes within the white bordered areas on
the output board, see Figure 3b.1 on page 3b-6.
board and lock in position using the nylon washer and M4
nut,
see inset diagram.
3b.2.2.2 Mounting the Delay Relay Output Board on to the Input

Board
WARNING

working location. The procedure for mounting the delay relay output board is as follows:
1. Isolate the power supply from the 2468 electronic enclosure and open the instrument
front cover.
2. If two output boards are to be fitted, make sure that the first output board to be fitted has
3. Ease the pins of the Berg plug PL1 of the output board into the Berg socket SK1 on the
firmly on to the output board.
Note:
3b-4
24685033_CD
3B.2.3 ELECTRICAL INSTALLATION

This sub-section deals with the output of the states of the four relays. Two 8-way sockets are
provided with each output board through which the relay outputs are delivered to their
external destinations.
3b.2.3.1 PCB Interconnections

Signal interconnection between the input board (PCB1) and the output board (PCB 9) is
direct via the SK1/PL1 12-way Berg connectors. When two output boards are fitted, the top
boards plug PL1 engages in the lower boards SK1.
3b.2.3.2 Relay Output Connections

The relay outputs can be taken out of the enclosure via the gland plate (if used) or along with
the other cables in suitable trunking. One or more cables can be used at the discretion of the
user, however the cables must be screened and the screens terminated at the gland plate.
Since the output board is mounted on top of the input board, the routing of the relay cabling
should take the same kind of formation as the electrode cabling, but separated from it as far
as practical. The cable should be arranged such that the cables do not lie across any of the
PCBs. The layout and plug pin details of the two affected plugs on the relay board is given in
the diagram on the right, with the relay contacts shown in their de-energised state.
offset towards the centre of the input board.
View illustrating mounted positions of

dual delay relay output boards
24685033_CD
Relay output PCB connectors
3b-5
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 for RL1.
SW1 - SW4: Selects individual electrode for relays RL1 to RL4.
SW5: Selects RL1 - RL4 to be energised in steam or in water.
Figure 3b.1 provides a view of the output board layout to highlight the positions of the various
Figure 3b.1 - View of relay output board showing switch positions and output pin details
3b-6
24685033_CD
3B.3.1 DELAY RELAY OUTPUT BOARD

3b.3.1.1 Configuring the Delay Relay Output Board
WARNING


2. Gain access to the delay relay output PCB and set the relevant switches for the required
function.
3b.3.1.2 Electrode/Relay Selection (Relays RL1, RL2, RL3 & RL4) - SW1 to SW4
Four identical switches are provided, one for each relay (but see SW6) each having four sets
of contacts. This allows coded selection for one of 16 electrodes for each switch and
therefore for each relay in the case of the single input card. When dual input cards are fitted,
odd numbered electrodes feed into one input card with the even numbered electrodes being
fed into the other input card. Each input card then offers any mounted relay output card the
choice from its electrode inputs, with the resultant selectivity as shown in Table 3b.1.
Electrode Selection
Switch SW1, 5W2, 5W3 or 5W4 Settings for

RL1 to RL4 respectively
Switch Contacts
One Input
Two Input Cards
Card
Odd I/P Card
Even I/P Card
On
Off
On
Off
On
Off
On
Off
On
Off
On
Off
On
Off
On
Off
On
On
Off
Off
On
On
Off
Off
On
On
Off
Off
On
On
Off
Off
On
On
On
On
Off
Off
Off
Off
On
On
On
On
Off
Off
Off
Off
On
On
On
On
On
On
On
On
Off
Off
Off
Off
Off
Off
Off
Off
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
1
3
5
7
9
Ii
13
15
17
19
21
23
25
27
29
31
2
4
6
8
10
12
14
16
18
20
22
24
26
28
30
32
Table 3b.1 - Electrode selections for relays RL1 to RL4

1
Example:
24685033_CD

OFF
3b-7
3b.3.1.3 Relay Energisation (In Steam or In Water) - SW5

This is a four-channel switch, one channel allocated per relay. The choice presented by
each channel switch is whether the relay is energised when the particular electrode is in
water or energised when that electrode is in steam. This switch is highlighted in Figure 3b.1
(on page 3b-6) to provide additional information on channel identity and the switch electrode
state.
3b.3.1.4 Electrode/Alarm Operation (RL1 function only) - SW6

Relay 1 can be configured to receive either an electrode input or it can be used as the
system fault relay. The two positions are detailed in Figure 3b.1 on page 3b-6. When
configured as the system fault relay, the normal (non-fault) state of the relay is energised.
The system fault output connections are shown in the next section.
3b-8
24685033_CD
3b.3.1.5 System Fault Output

Relay 1 on each delay relay board can be configured to be used as a system fault relay by
setting SW6. When used as a system fault relay the normal state of the relay is energised
and a fault state will de-energise the relay.
The relay will only output faults detected by the input board onto which it is installed. With a
dual power supply Hydrastep unit, this means it is necessary to use two delay relay boards
(one on each input board) to create a system fault output.

RL 1
PL 2
1
RL 1
To alarm
annunciator
RL 2
PL 2
1
To alarm
annunciator
RL 2


RL 1
PL 2
PL 2
RL 1
1
2
Odd fault relay

(RH input board)
Even fault relay

(LH input board)

RL 1
PL 2
PL 2
3
4
RL 1
3
Odd fault relay

(RH input board)
Even fault relay

(LH input board)
Note:
24685033_CD
An opto-isolated system fault is available from the display board.
3b-9
3b.3.1.6 Delay Circuit Configuration

By means of split pad links incorporated in each of the relay delay circuits, delays can be
introduced or bypassed and the following delays are made available (see also Figure 3b.2 on
page 3b-11):
Table 3b.2 - Split pad functions on relay delay circuits
3b-10
24685033_CD
3b.3.1.7 Configuring the Delay Circuit Split Pads

WARNING


2. Split pad bridging may be carried out in-situ, however it may be easier to remove the
board from the unit. Gain access to the delay relay output PCB and bridge the required
split pads (see Table 3b.2 and Figure 3b.2) with solder, ensuring that the remaining split
pads are open-circuit and clean.
Note: When two output boards are fitted, the upper board will have to be removed
temporarily to give access to the split pads of the lower output board.
3. Carry out any necessary re-assembly on the output board(s) and test that the required
delay on the relay operations is being achieved.
4. If no further work is required inside the enclosure, close and secure the enclosure lid.
Figure 3b.2 - View of delay relay output board showing split pad positions
Note: The following split pads
must be set as follows:
For Delayed Operation of the
Nominated Relay:
RL1
SP21 bridged with solder

SP15 open-circuited
RL2

SP20 open-circuited
RL3

SP1 open-circuited
RL4

SP6 open-circuited
For No Delayed Operation of

the Nominated Relay:
24685033_CD
RL1

SP21 open-circuited
RL2

SP22 open-circuited
RL3

SP23 open-circuited
RL4

SP24 open-circuited
3b-11
3B.3.2 ALARM AND TRIPPING FACILITIES

The relay boards provide high 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.
3b.3.2.1 Philosophy
low water level shut-down or trip device. In the 2468 Hydrastep the relay output board
provides the required output signals for such devices.
The following relay output circuits are specific to the 2468 Hydrastep Level Indicator
versions.
3b.3.2.2 Relay Interconnections for Alarm/Tripping Systems

WARNING
Note:
3b-12

Before any relay interconnections are made it is necessary to fulfil any safety
regulations governing the plant shut-down procedures.
24685033_CD
3b.3.2.3 Single Power Supply System

Here any relay can be operated by any of the electrodes used in the system. The relays can
be configured to be normally energised and therefore register an alarm should the power
supply fail. The following configurations can be implemented.
Case 1A - Relays normally energised, de-energise either one to trip

RL 1
PL 2
RL 1
To alarm
annunciator
or tripping
device
To alarm
annunciator
or tripping
device
5
RL 2
PL 2
5
RL 2
Case 1B - Relays normally de-energised, energise either one to trip

RL 1
PL 2
RL 1
2
3
4
To alarm
annunciator
or tripping
device
To alarm
annunciator
or tripping
device
5
RL 2
PL 2
5
RL 2
24685033_CD
3b-13
Single Power Supply System (contd.)

Case 2A - Relays normally energised, de-energise both to trip

RL 1
PL 2
RL 1
2
To alarm
annunciator
or tripping
device
3
4
To alarm
annunciator
or tripping
device
5
RL 2
PL 2
5
RL 2
Case 2B - Relays normally de-energised, energise both to trip

RL 1
PL 2
RL 1
2
3
4
To alarm
annunciator
or tripping
device
To alarm
annunciator
or tripping
device
5
RL 2
PL 2
5
RL 2
3b-14
24685033_CD
3b.3.2.4 Dual Power Supplies System

Since one input board receives inputs from the odd numbered electrodes and the other input
and even relay boards will be required. The following are examples of relay configurations
used.
Case 3A - Relays normally energised, de-energise either one to trip

RL 1
PL 2
PL 2
RL 1
1
2
Odd electrodes
(RH input board)
Even electrodes
(LH input board)

RL 1
PL 2
PL 2
Odd electrodes
(RH input board)
RL 1
Even electrodes
(LH input board)

Case 3B - Relays normally de-energised, energise either one to trip

RL 1
PL 2
PL 2
RL 1
Odd electrodes
(RH input board)
Even electrodes
(LH input board)
RL 1
Odd electrodes
(RH input board)
PL 2
PL 2
RL 1
Even electrodes
(LH input board)
24685033_CD
3b-15
Dual Power Supplies System (contd.)

Case 4A - Relays normally energised, de-energise both to trip

RL 1
PL 2
PL 2
Odd electrodes
(RH input board)
RL 1
Even electrodes
(LH input board)
PL 2
PL 2
RL 1
3
4
Odd electrodes
(RH input board)
RL 1
4
Even electrodes
(LH input board)

Case 4B - Relays normally de-energised, energise both to trip

RL 1
PL 2
4
Odd electrodes
(RH input board)
RL 1
PL 2
Even electrodes
(LH input board)
1
2
PL 2
RL 1
PL 2
RL 1
Odd electrodes
(RH input board)
Even electrodes
(LH input board)
3b-16
24685033_CD

Two out of Four Relay Alarm System
Case 5A - Relays normally energised, de-energise one in each pair to trip

RL 1
PL 2
RL 1
2
3
2
4
To alarm
annunciator
or tripping
device
5
RL 2
PL 2
5
RL 2
6
7
6
7
2
8
Even electrodes
(LH input board)
Odd electrodes
(RH input board)

Case 5B - Relays normally energised, de-energise one pair to trip

RL 1
PL 2
RL 1
2
3
3
4
5
RL 2
6
7
PL 2
RL 2
To alarm
annunciator
or tripping
device
6
7
2
8
Odd electrodes
(RH input board)
Even electrodes
(LH input board)

24685033_CD
3b-17

Two out of Four Relay Alarm System (contd.)
Case 6A - Relays normally energised, de-energise one in each pair to trip

RL 1
PL 2
RL 1
2
3
PL 2
2
4
To alarm
annunciator
or tripping
device
5
RL 2
5
RL 2
6
7
6
7
2
8
Even electrodes
(LH input board)
Odd electrodes
(RH input board)

Case 6B - Relays normally de-energised, energise one in each pair to trip

RL 1
PL 2
RL 1
2
3
3
4
5
RL 2
6
7
PL 2
RL 2
To alarm
annunciator
or tripping
device
6
7
2
8
Odd electrodes
(RH input board)
Even electrodes
(LH input board)

3b-18
24685033_CD

Two out of Three Relay Alarm System
relay. A fully functioning system (NO FAULTS) will cause a low level trip at electrode level
2. Using high level electrode channels and SW5 set to ES, the circuit can perform a high
level trip.
Note: Inputs from electrodes 1 & 2 are applied to two separate relays on their respective
boards.
Case 7A - Relays normally energised, de-energise two to trip

RL 1
PL 2
RL 1
2
3
PL 2
2
2
5
RL 2
5
RL 2
6
7
To alarm
annunciator
or tripping
device
6
7
RL 3
Even electrodes
(LH input board)
1
2
Odd electrodes
(RH input board)
4
PL 3
24685033_CD
3b-19
Case 7B - Relays normally energised, de-energise two to trip

RL 1
PL 2
RL 1
2
3
PL 2
2
2
5
RL 2
5
RL 2
6
7
To alarm
annunciator
or tripping
device
6
7
Even electrodes
(LH input board)
RL 3
1
2
3
4
Odd electrodes
(RH input board)
PL 3
3b-20
24685033_CD
3B.4 COMPONENT REPLACEMENT

The delay relay board contains no replaceable circuit components, failure of the board
requires replacement of the entire board. The only component which can be replaced is the
nylon spacers.
3B.4.1 REPLACEMENT OF NYLON SPACERS

Note:
Spacers will only be fitted on the output board if a second output board is to be fitted
or has been fitted.
adopted is:
WARNING


1. Gain access to the PCBs and undo sufficient connections for the removal of the output
board containing the defective spacer.
2. Remove the output board(s) by applying pressure to
the upper spring-loaded spigots and easing the output
board off its spacers a out of its Berg plug/socket
connection.
3. Undo the nut and washer securing the faulty spacer
and extract it from its hole, see inset diagram.
4. Fit the new spacer in position, align correctly on the
board and secure firmly using the M4 nut and nylon
washer.
5. Refit the PCB(s) into the enclosure, re-connect the
PCB(s) as required and close the enclosure cover. Re-apply power if required.
3B.4.2 PARTS LIST - DELAY RELAY OUTPUT BOARD 24680509

Item Description
Solartron
Mobrey Part
Number
Electrical:
Delay relay PCB assembly:
24680509B
351508100
351503100
24685033_CD
Item Description
Mechanical:
Washer, nylon
Nut, M4
Solartron
Mobrey Part
Number
412012080
411999910
410031020
3b-21
3B.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
65W
25W
Type N safety
( 30V)
( 60V)
( 125V)
5A at 12Vdc
100mA at 30Vdc
20mA at 125Vdc
Maximum initial contact resistance: 30m

Time Delay:
3b-22
Disabled or 0.8s 0.8s to 24.2s 0.8s
24685033_CD
3c
Contents
Page No.
3c.1
GENERAL DESCRIPTION........................................................... 3c-3
3c.2
INSTALLATION ........................................................................... 3c-3

3c.2.1
3c.2.2
3c.2.3
3c.3
OPTO-ISOLATED OUTPUT BOARD CONFIGURATION ........... 3c-6

3c.3.1
3c.3.2
24685033_CC
STORAGE & PRE-INSTALLATION INSPECTION ...............................3c-3

3c.2.1.1 Storage Area ..........................................................................3c-3
3c.2.1.2 Pre-Installation Inspection ......................................................3c-3
MECHANICAL INSTALLATION.............................................................3c-4
3c.2.2.1 Fitting Nylon Spacers to the Opto-Isolated Output Board ......3c-4
3c.2.2.2 Mounting the Opto-Isolated Output Board on to the Input
Board ......................................................................................3c-4
ELECTRICAL INSTALLATION ..............................................................3c-5
3c.2.3.1 PCB Interconnections.............................................................3c-5
3c.2.3.2 Opto-Isolated Output Connections .........................................3c-5
CONFIGURING THE OPTO-ISOLATED OUTPUT BOARD .................3c-7

3c.3.1.1 Electrode/Opto-Output Selection (Opto-1, Opto-2, Opto-3
& Opto-4 Outputs) - SW1 To SW4 .........................................3c-7
3c.3.1.2 Electrode/Alarm Operation (Output 1 Function Only) - SW6 .3c-8
3c.3.1.3 Opto-Isolated Output Activation (In Steam or In Water)
- SW5......................................................................................3c-8
3c.3.1.4 System Fault Output...............................................................3c-9
ALARM AND TRIPPING FACILITIES..................................................3c-10
3c.3.2.1 Philosophy ............................................................................3c-10
3c.3.2.2 Opto-Output Interconnections for Alarm/Tripping Systems .3c-10
3c.3.2.3 Single Power Supply System ...............................................3c-11
3c.3.2.4 Dual Power Supplies System ...............................................3c-13
3c-1
Opto-isolated Output Board Option
3c.4
COMPONENT REPLACEMENT ................................................ 3c-18

3c.4.1
3c.4.2
3c.5
REPLACEMENT OF NYLON SPACERS ............................................3c-18

PARTS LIST - OPTO-ISOLATED OUTPUT BOARD 24680505.........3c-18
SPECIFICATION ........................................................................ 3c-19

Illustrations
Figure 3c.1 - View of opto-isolated board showing switch positions and output
pin details ......................................................................................................3c-6
Tables
Table 3c.1
3c-2
- Electrode selections for opto-isolated outputs Opto 1 to Opto 4...................3c-7
24685033_CC
3C.1 GENERAL DESCRIPTION

The Opto-isolated Output Board (PCB 24680505) has four opto-isolated outputs and is
designed to be 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 input board and PL1
on the opto-isolated output board).
A second opto-isolated output board may be mounted on top of the first output board, on
spacers. Holes have been drilled on all opto-isolated output boards to receive the 3 nylon
spacers. The top output board is offset towards the centre of the unit improving the cable
layout from the opto-isolated output boards. The spacer fixing holes and mounting holes are
illustrated in Figure 3c.1 on page 3c.6.
Note:
The term energised is used to describe the ON (low resistance) state of the optoisolated output.
Each of the opto-isolated outputs can be energised by any one of up to 16 electrodes, with
an individual choice of being energised when its selected electrode is in steam or is in
water. Furthermore, opto-isolated output 1 can be used to monitor an electrode state or to
register an ALARM condition. When set to register the ALARM state, the opto-isolated
output is energised in the system normal state and de-energised when an ALARM
condition exists.
3C.2 INSTALLATION
This sub-section deals with the mechanical and electrical installation of the Opto-isolated
Output Board (PCB 24680505) option. In the rest of this chapter the opto-isolated output
board title is shortened to output board.
3C.2.1 STORAGE & PRE-INSTALLATION INSPECTION

3c.2.1.1 Storage Area
3c.2.1.2 Pre-installation Inspection

completeness.
24685033_CC
3c-3
3C.2.2 MECHANICAL INSTALLATION

interconnection (PL1/SK1) and input board-mounted spacers and pressed home onto the
spacers.
3c.2.2.1 Fitting Nylon Spacers to the Opto-Isolated Output Board

The spacers lit into the holes within the white bordered areas on
the output board, see Figure 3c.1 on page 3c.6.
board and lock in position using the nylon washer and M4 nut,
see inset diagram.
3c.2.2.2 Mounting the Opto-Isolated Output Board on to the Input Board

WARNING

working location. The procedure for mounting the output board is as follows:
1. Isolate the power supply from the 2468 electronic enclosure and open the instrument
front cover.
2. If two output boards are to be fitted, make sure that the first output board to be fitted has
3. Ease the pins of the Berg plug PL1 of the output board into the Berg socket SK1 on the
firmly onto the output board.
Note:
3c-4
24685033_CC
3C.2.3 ELECTRICAL INSTALLATION

3c.2.3.1 PCB Interconnections
Signal interconnection between the input board (PCB 1) and the output board (PCB 5) is
direct via the SK1/PL1 12-way Berg connectors. Similarly, interconnection between the dualmounted output boards uses the same type connectors but the top boards plug PL1
engages in the first output boards socket SK1.
This sub-section deals with the four opto-isolated outputs. Two 8-way sockets are provided
with each output board through which the opto-isolated outputs are presented to their
external destinations via transistors TRs 2, 4, 6 and 8.
3c.2.3.2 Opto-Isolated Output Connections

The opto-isolated output states can be taken out of the enclosure via the gland plate (if used)
or along with the other cables in suitable trunking. One or more cables can be used at the
discretion of the user, however the cables must be screened and the screens terminated at
the gland plate.
Since the output board is mounted on top of the input board, the routing of the output board
cabling should take the same kind of formation as the electrode cabling, but separated from it
as far as is practical. The cable should be arranged such that the cables do not lie across
any PCBs. The layout and plug pin details of the two affected plugs on the output board is
given in the diagram on the right, with the required opto-coupler output terminal polarities
shown.
offset towards the centre of the unit.
Opto-isolated output PCB connectors
View illustrating mounted positions of dual opto-isolated boards
24685033_CC
3c-5
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 electrode for opto-outputs I to 4.
SW5:
Selects Opto-outputs 1 - 4 to be energised when electrodes in

steam or in water.
Figure 3c.1 provides a view of the output board layout to highlight the positions of the various
Figure 3c.1 - View of opto-isolated board showing switch positions and output pin details
3c-6
24685033_CC
3C.3.1 CONFIGURING THE OPTO-ISOLATED OUTPUT BOARD

WARNING

Gain access to the printed circuit board assemblies inside the Hydrastep 2468 enclosure as
follows:
2. Gain access to the output PCB and set the relevant switches for the required function.
3c.3.1.1 Electrode/Opto-Output Selection (Opto-1, Opto-2, Opto-3 & Opto-4 Outputs) SW1 to SW4
Four identical switches are provided, one for each output (but see SW6) each having four
sets of contacts. This allows coded selection of any one of 16 electrodes for each switch in
the case of the single input card. When dual input cards are fitted, odd numbered electrodes
feed into one input card with the even numbered electrodes being fed into the other input
card. Each input card then offers any mounted output card the choice from its electrode
inputs, with the resultant selectivity as shown in Table 3c.1.
Switch SW1, SW2, SW3 or SW4 Settings for
Opto 1 to Opto 4 respectively
Switch Contacts
Electrode Selection
One Input
Two Input Cards
Card
Odd I/P Card
Even I/P Card
On
On
On
On
Off
On
On
On
On
Off
On
On
Off
Off
On
On
On
On
Off
On
10
Off
On
Off
On
11
12
On
Off
Off
On
13
14
Off
Off
Off
On
15
16
On
On
On
Off
17
18
Off
On
On
Off
10
19
20
On
Off
On
Off
11
21
22
Off
Off
On
Off
12
23
24
On
On
Off
Off
13
25
26
Off
On
Off
Off
14
27
28
On
Off
Off
Off
15
29
30
Off
Off
Off
Off
16
31
32
Table 3c.1 - Electrode selections for opto-isolated outputs Opto 1 to Opto 4
Example:
24685033_CC

OFF
3c-7
3c.3.1.2 Electrode/Alarm Operation (output 1 function only) - SW6

The opto-isolated output from TR2 can be configured to receive either an electrode input or it
can be used as the system fault output. The two positions are detailed in Figure 3c.1 on
page 3c.6. When configured as the system fault output, the opto-isolated output is
energised (low resistance) in the normal (non-fault) state and is de-energised (high
resistance) for a fault condition.
The system fault output connections are shown in the next section.
3c.3.1.3 Opto-Isolated Output Activation (In Steam or In Water) - SW5

SW5 is a four-channel switch, one channel allocated per opto-isolated output. The choice
presented by each channel switch is whether the output device is energised (low resistance)
when the particular electrode is in water (W) or when that electrode is in steam (S). Switch
SW5 is highlighted in Figure 3c.1 (on page 3c.6) to provide additional information on channel
identity and the switch electrode state.
3c-8
24685033_CC
3c.3.1.4 System Fault Output

Opto 1 on each opto-isolated board can be configured to be used as a system fault optoisolated output by setting SW6. When used as a system fault opto-isolated output the
normal state of Opto 1 is low resistance and a fault state will cause Opto 1 to go into its
high resistance state.
Opto 1 will only output faults detected by the input board onto which it is installed. With a
dual power supply Hydrastep unit, this means it is necessary to used two opto-isolated output
boards (one on each input board) to create a system fault output.

PL 2
TR2
1
- VE
2
3
Opto-output 1
TR4
To alarm
annunciator
+ VE
Note:
External power must

be applied as shown.
See specification for
power requirements
6
7
Opto-output 2
(Switch SW6 set for Fault Signal operation)

To alarm annunciator or
tripping device
TR2
Opto-output 1
Odd Electrodes
(RH Input Board)
PL 2
+ VE
- VE
PL 2
Note:
External power must

power requirements
TR4
Opto-output 2
Even Electrodes
(LH Input Board)
(Switch SW6 set for Fault Signal operation)
Note: Systems with a local display have an opto-isolated system fault available from the
display board.
24685033_CC
3c-9
3C.3.2 ALARM AND TRIPPING FACILITIES

The output boards provide high and low water level alarm and trip facilities for the 2468
Hydrastep system. Four to eight opto-isolated outputs can be made available for each input
board fitted.
3c.3.2.1 Philosophy
low water level shut-down or trip device. In the 2468 Hydrastep the opto-isolated output
board provides the required output signals for such devices.
The following opto-isolated output (for brevity this output title will be shortened to optooutput) circuits are specific to the 2468 Hydrastep Level Indicator versions.
3c.3.2.2 Opto-Output Interconnections for Alarm/Tripping Systems

WARNING
Note:
3c-10

Before any opto-output interconnections are made it is necessary to fulfil any safety
regulations governing the plant shutdown procedures.
24685033_CC
3c.3.2.3 Single Power Supply System

Here any opto-output can be operated by any of the electrodes used in the system. The
opto-outputs are normally open circuit and are switched into a conducting mode (short circuit)
when their dedicated electrode detects its allotted water/steam state to signal an alarm. The
following configurations can be implemented.
One out of Two Opto-output Alarm System
Either of the opto-outputs involved can signal an alarm when their assigned electrode detects
a water/steam interface change. The alarm condition is selected by switch SW5 to provide
an opto-output in conducting mode in water W or in a conducting mode in steam S.
Case 1A - Opto-output circuit normally open circuit, short circuit either one to trip
PL 2
TR2
1
- VE
2
3
Opto-output 1
TR4
+ VE
Note:
6
7
Opto-output 2
To alarm
annunciator
or tripping
device
External power must
power requirements
(Switch SW5 is set to S for low level alarms and set to W for high level alarms)
Case 1B - Opto-output circuit normally short circuit, open circuit either one to trip
PL 2
TR2
- VE
To alarm
annunciator
or tripping
device
3
Opto-output 1
TR4
5
6
7
Opto-output 2
+ VE
Note:
External power must

power requirements
(Switch SW5 is set to W for low level alarms and set to S for high level alarms)
24685033_CC
3c-11
Single Power Supply System (contd.)

Two out of Two Opto-output Alarm System
This system requires both opto-outputs to operate to cause an alarm when their assigned
Case 2A - Opto-output circuit normally open circuit, short circuit both to trip
PL 2
TR2
- VE
To alarm
annunciator
or tripping
device
3
Opto-output 1
TR4
+ VE
Note:
6
7
Opto-output 2
External power must

power requirements
Case 2B - Opto-output circuit normally short circuit, open circuit both to trip
PL 2
TR2
1
2
- VE
3
Opto-output 1
TR4
5
6
7
Opto-output 2
+ VE
Note:
To alarm
annunciator
or tripping
device
External power must
power requirements
3c-12
24685033_CC
3c.3.2.4 Dual Power Supplies System

Since one input board receives inputs from the odd numbered electrodes and the other input
and even opto-isolated output boards will be required. The opto-outputs are normally open
circuit and are switched into a conducting mode (short circuit) when their dedicated electrode
detects its allotted water/steam state to signal an alarm. The following are examples of optooutput configurations used.
One out of Two Opto-output Alarm System
Either of the opto-outputs involved can signal an alarm when their assigned electrode detects
a water/steam interface change. The alarm condition is selected by switch SW5 to provide
an opto-output in conducting mode in water W or in a conducting mode in steam S.
Case 3A - Opto-output circuit normally open circuit, short circuit either one to trip
tripping device
TR2
Opto-output 1
+ VE
PL 2
- VE
PL 2
Odd Electrodes
(RH Input Board)
Note:
TR2
Opto-output 1
Even Electrodes
(LH Input Board)
External power must

power requirements
Case 3B - Opto-output circuit normally short circuit, open circuit either one to trip
tripping device
TR2
Opto-output 1
Odd Electrodes
(RH Input Board)
PL 2
+ VE
- VE
PL 2
Note:
External power must

power requirements
TR2
Opto-output 1
Even Electrodes
(LH Input Board)
24685033_CC
3c-13

Two out of Two Opto-output Alarm System
This system requires both opto-outputs to operate to cause an alarm when their assigned
Case 4A - Opto-output circuit normally open circuit, short circuit both to trip
tripping device
TR2
Opto-output 1
+ VE
PL 2
- VE
PL 2
Odd Electrodes
(RH Input Board)
Note:
TR2
Opto-output 1
Even Electrodes
(LH Input Board)
External power must

power requirements
Case 4B - Opto-output circuit normally short circuit, open circuit both to trip
tripping device
TR2
Opto-output 1
Odd Electrodes
(RH Input Board)
PL 2
+ VE
- VE
PL 2
Note:
External power must

power requirements
TR2
Opto-output 1
Even Electrodes
(LH Input Board)
3c-14
24685033_CC

Two out of Four Opto-output Alarm System
each opto-output. A fully functioning system (NO FAULTS) will perform a low level trip at
electrode level 3. For a high level trip, using electrode channels 11, 12, 9 and 10
respectively and switch SW5 set for W, a healthy system would trip at level 10.
Case 5A - Opto-output circuit normally open circuit, short circuit one pair to trip
PL 2
PL 2
TR2
Opto-output 1
TR4
TR2
3
Opto-output 1
4
1
Opto-output 2
TR4
Odd Electrodes
(RH Input Board)
To alarm
annunciator
or tripping
device
5
6
Opto-output 2
External power must

power requirements
+ VE
Note:
- VE
Even Electrodes
(LH Input Board)
Case 5B - Opto-output circuit normally short circuit, open circuit one in each
pair to trip
PL 2
PL 2
TR2
Opto-output 1
TR4
Opto-output 2
Odd Electrodes
(RH Input Board)
4
1
TR2
Opto-output 1
TR4
4
2
7
Opto-output 2
External power must

power requirements
+ VE
To alarm
annunciator
or tripping
device
Note:
- VE
Even Electrodes
(LH Input Board)
24685033_CC
3c-15

Two out of Three Opto-output Alarm System
opto-output. A fully functioning system (NO FAULTS) will cause a low level trip at electrode
level 2. Using high level electrode channels and SW5 set to S, the circuit can perform a high
level trip.
Note:
Inputs from electrodes 1 & 2 are applied to two separate opto-outputs on their
respective boards.
Case 6A - Opto-output circuit normally open circuit, short circuit two to trip
PL 2
PL 2
TR2
Opto-output 1
TR4
Opto-output 2
TR6
TR2
Opto-output 1
TR4
Note:
4
2
7
Opto-output 2
External power must

power requirements
+ VE
To alarm
annunciator
or tripping
device
- VE
Even Electrodes
(LH Input Board)
1
2
3
Opto-output 3
Odd Electrodes
(RH Input Board)
4
PL 3
3c-16
24685033_CC
Case 6B - Opto-output circuit normally short circuit, open circuit to trip
PL 2
PL 2
TR2
Opto-output 1
TR4
TR2
3
Opto-output 1
TR4
Note:
4
2
7
Opto-output 2
External power must

power requirements
+ VE
To alarm
annunciator
or tripping
device
Opto-output 2
TR6
- VE
Even Electrodes
(LH Input Board)
1
2
3
Opto-output 3
Odd Electrodes
(RH Input Board)
4
PL 3
24685033_CC
3c-17
3C.4 COMPONENT REPLACEMENT

The components used on the opto-isolated output board are fitted using surface mount
technology and fault remedial action is by the replacement of the whole output board. The
only components fitted to the board which the general user can replace are the nylon
spacers.
3C.4.1 REPLACEMENT OF NYLON SPACERS

Note:
Spacers will only be fitted on the output board if a second output board is to be fitted
or has been fitted.
adopted is:
WARNING


2. Gain access to the PCBs and undo sufficient
connections for the removal of the output board
containing the defective spacer.
3. Remove the output board(s) by applying pressure to the
upper spring-loaded spigots and easing the output
board oft its spacers and out of its Berg plug/socket
connection.
4. Undo the nut and washer securing the faulty spacer and
extract it from its hole, see inset diagram.
5. Fit the new spacer in position, align correctly on the
board and secure firmly using the M4 nut and nylon
washer.
6. Refit the PCB(s) into the enclosure, re-connect the PCB(s) as required and close the
enclosure cover. Re-apply power if required.
3C.4.2 PARTS LIST - OPTO-ISOLATED OUTPUT BOARD 24680505

Item Description
3c-18
Electrical:
Delay relay PCB assembly:
Solartron
Mobrey Part
Number
Item Description
Solartron
Mobrey Part
Number
24680505A
Mechanical:
412012080
351508100
Washer, nylon
411999910
351503100
Nut, M4
410031020
24685033_CC
3C.5 SPECIFICATION
Outputs:
4 x Alarm/Trip Opto-isolated outputs
Opto-Isolated Output Rating:

Maximum Open-circuit Voltage:
Maximum Short-circuit Current:
Short-circuit Voltage Drop:
Open-circuit Leakage Current:
30V dc
1A
1.1V maximum at 1A
1mA at 30V dc
24685033_CC
3c-19
3c-20
24685033_CC
Remote Display Options 24683B, C & D
4
Remote Display Options 24683B, C, & D
Contents
Page No.
4.1
REMOTE DISPLAY OPTIONS................................................................ 4-3
4.2
CONFIGURATION .................................................................................. 4-4

4.2.1
4.2.2
4.2.3
4.3
MECHANICAL INSTALLATION ............................................................. 4-6

4.3.1
4.3.2
4.4
RECONFIGURING THE 24683B REMOTE DISPLAY ............................. 4-4

RECONFIGURING THE 24683C REMOTE DISPLAY ............................. 4-5
RECONFIGURING THE 24683D REMOTE DISPLAY ............................. 4-5
INSTALLING THE 24683B AND 24683C PANEL MOUNTED UNITS ..... 4-6
INSTALLING THE 24683D WALL MOUNTED UNIT ................................ 4-6
ELECTRICAL INSTALLATION............................................................... 4-7

4.4.1
4.4.2
4.4.3
4.4.4
4.4.5
STAR AND DAISY CHAIN CONNECTIONS ............................................ 4-8

EXAMPLE OF A STAR CONNECTED SYSTEM .................................... 4-9
EXAMPLE OF A `DAISY CHAIN' SYSTEM ............................................ 4-10
CONNECTING CABLES TO THE REMOTE DISPLAY .......................... 4-11
CONNECTING THE DISPLAY CABLES TO HYDRASTEP 2468 .......... 4-11
4.5
SYSTEM OPERATION.......................................................................... 4-12
4.6
FAULT ANALYSIS AND CORRECTIVE ACTION ................................ 4-12
4.7
COMPONENT REPLACEMENT ........................................................... 4-15
4.8
SPECIFICATION................................................................................... 4-16
24685033_CC
4-1
Illustrations
Figure 4.1 - Location of link headers for selecting the display mode .................................... 4-4
Figure 4.2 - Interconnection cable for a single remote display.............................................. 4-7
Figure 4.3 - Star and daisy chain connections of remote displays........................................ 4-8
Figure 4.4 - Star connection example for two remote displays ............................................. 4-9
Figure 4.5 - Daisy chain connection example for two remote displays ............................... 4-10
Figure 4.6 - Cable connection details for the remote display .............................................. 4-11
Tables
Table 4.1 - Fault Analysis and Correction Chart ................................................................. 4-12
Table 4.2 - Remote Display Replacement Parts ................................................................. 4-15
4-2
24685033_CC
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 display operates in the same way. The only difference between them is
in their mechanical construction. The 24683B is a small LED display for panel mounting; the
24683C is a large LED display for panel mounting; and the 24683D is a large LED display for
wall mounting, contained in a splash proof box to IP65 (NEMA4X) standard.
On each type of remote display there are two columns of LEDs, a red column to indicate
steam and a green column to indicate water. This provides a clear indication of the water
level in the monitored system. The number of LEDs that may be illuminated depends on the
number of electrodes being used. To mask the unused LEDs, a blanking panel is provided:
this should be fitted on the inside of the front panel. An electrode fault, or a wiring or circuit
fault, is indicated by a yellow LED.
The 2468 will drive a maximum of six remote displays, using star or daisy chain connections.
One remote display can be powered from the 2468. All other remote displays must be
locally powered.
On each type of remote display, connection to the 2468 is made through a 20-way screw
clamp terminal block. Access to the terminal block on the 24683B and 24683C is via a cutout in the rear panel. Access to the terminal block on the 24683D is made via cable glands
on one end of the enclosure.
24685033_CC
4-3
4.2
CONFIGURATION
All remote displays can be configured for operation with 8 to 16 electrodes (two LEDs per
electrode) or 18 to 32 electrodes (one LED per electrode). Remote displays are supplied
ready for operation with 8 to 16 electrodes. If a remote display is required to operate with 18
to 32 electrodes then it must be reconfigured. The procedure for each type of remote display
is described below.
4.2.1
RECONFIGURING THE 24683B REMOTE DISPLAY

The procedure for reconfiguring the 24683B for operation with 18 to 32 electrodes is:
1.
Remove the front bezel, by pulling it off.
2.
Undo the six screws securing the side panel and remove the panel.
3.
Carefully remove the link headers from sockets LK2 and LK4 on the decoding PCB, by
easing them out with a suitable flat-bladed screwdriver. (See Figure 4.1)
4.
Fit the link headers, removed in step 3, into sockets LK1 and LK3.
5.
Refit the side panel and the front bezel.
Note: This figure shows the layout of the decoding pcb fitted to the 24683C and 24683D Remote
Displays. The layout of the decoding pcb in the 24683B Remote Display is slightly different, but the
arrangement of links LK1-LK4 is the same.
LK1
LK2
18-32
8-16
LK3
LK4
18-32
8-16
Figure 4.1 - Location of link headers for selecting the display mode
4-4
24685033_CC
4.2.2
RECONFIGURING THE 24683C REMOTE DISPLAY

The procedure for reconfiguring the 24683C for operation with 18 to 32 electrodes is:
4.2.3
1.
Undo the four screws securing the rear panel and remove the panel.
2.
Withdraw the decoding PCB from the rear of the display unit. (Some force may be
necessary, initially, to disengage the decoding PCB from the LED PCB.)
3.
easing them out with a suitable flat-bladed screwdriver. (See Figure 4.1 on page 4-4)
4.
5.
Refit the decoding PCB and the rear panel.
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.
2.
Undo the four screws securing the front panel and lay the panel carefully away from the
top of the box, still connected by the ribbon cable.
3.
easing them out with a suitable flat-bladed screwdriver. (See Figure 4.1 on page 4-4)
4.
5.
Refit the front panel and the transparent cover.
24685033_CC
4-5
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
panel and wall mounting are described below.
4.3.1
INSTALLING THE 24683B AND 24683C PANEL MOUNTED UNITS

The panel related dimensions for the 24683B and 24683C are:
Panel thickness:
24683B = 2mm to 9mm

24683C = 2mm to 20mm
Aperture:
24683B = 139mm high 67mm wide

24683C = 186mm high 92mm wide
The installation procedure is:

1.
Ensure that the panel on which the remote display is to be fitted provides easy access
to the electrical connections and is sited in a good viewing position.
2.
Cut an aperture in the panel to the dimensions given above and remove any burrs.
3.
Remove the clamps (if fitted) from the remote display unit and fit the unit into the
aperture from the front of the panel.
4.
Refit the clamps to the display unit and secure the unit to the panel.
The two clamps on the 24683B are held in place by knurled nuts. Tighten the nuts so that
the clamps press firmly against the panel to hold the unit in place.
The two clamps on the 24683C each clip onto two metal studs on the case of the unit.
Adjust the clamps from the rear of the unit with a suitable flat bladed screwdriver. Tighten
the clamps until they press firmly against the panel to hold the unit in place.
4.3.2
INSTALLING THE 24683D WALL MOUNTED UNIT

The 24683D Remote Display Unit is contained in an IP65 enclosure that can be fixed to the
wall by four mounting brackets. Cables are routed to the internal PCB through glands in the
base.
The installation procedure is:
4-6
1.
Place the unit against the surface to which it is to be fixed and mark the positions of the
fixing points. These should be positioned on centers 190mm apart horizontally and
305mm apart vertically. Install suitable fixings and secure the unit to the wall.
2.
Remove the four screws securing the clear cover of the unit and place the cover
carefully to one side.
3.
Remove the four screws securing the front panel of the unit and lay the panel, still
attached by its ribbon cable, on top of the case.
4.
Loosen the cable gland nuts, pass the cables through the glands, prepare the cable
terminations, and fit the cable to the terminal block. (See Section 4.4.4 for details.)
5.
Ensure that the cables are unstrained within the unit, tighten the cable glands, and refit
the front panel and clear cover.
24685033_CC
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
display has a dual serial data input and a dual power input. When the remote display is
powered from the main unit an eight-core cable is required to connect the two units. When a
remote display is locally powered, however, a six-core cable will suffice. See the example in
Figure 4.4: remote display unit 1 is powered from the main unit and uses an eight-core cable;
remote display unit 2 is locally powered and uses a six-core cable. All cables must be
screened to comply with the EMC directive.
For remote displays powered from the main unit the loop resistance of the power conductors
must be less than 27 ohms for an ac powered unit or 7 ohms for a dc unit. To provide for
cable runs of up to 1000 metres, without the use of heavy cables, the main unit and the
remote display unit each have internally linked multiple terminals for the power and ground
connections. This allows the power and ground lines to be doubled to reduce the loop
resistance.
Hydrastep 2468
Remote Display
Display Board
Power +ve
Odd Serial Data (two lines)
PL3
Power ve
Alternative supply
from local PSU: 20V
to 54V at 240mA
Power +ve
Even Serial Data (two lines)
PL7
Power ve
TB1
Figure 4.2 - Interconnection cable for a single remote display
24685033_CC
4-7
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 whichever way best
suits the relative locations of the 2468 unit and the remote displays. The maximum cable
length permitted between the 2468 and any remote unit is 1000 metres.
RDU 1
RDU 1
RDU 2
RDU 3
RDU 2
RDU 4
RDU 3
Star
2468
2468
Daisy
Chain
RDU 5
RDU 4
RDU 5
RDU 6
RDU 6
Figure 4.3 - Star and daisy chain connections of remote displays
4-8
24685033_CC
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 the extra unit(s).
Up to six remote displays can be supported (less their power requirements): with the full
complement of units in use, three signal carrying conductors must be connected to each
terminal.
24683BB
REMOTE DISPLAY UNIT 1
(Rear View)
TB1
1
Local display visible through

front transparent window.
HINGE
4
5
6
7
8
9
10
PL3
Signal
PL7
Power Power
0V
+ve
Signal
11
Power Power
0V
+ve
12
13
14
14
+ +
+ +
1 2 3 4 5 6 7 8 9 10
1 2 3 4 5 6 7 8 9 10
15
16
12
17
3
2
5
4
7
6
Screens terminated
at gland plate
10
9
12
11
14
13
18
19
20
Cable screens at
remote display
connected together,
but not connected to
ground.
TB1
1
System 0V
reference
3
4
5
6
7
8
9
10
11
12
13
14
15
16
13
17
Local P.S.
18
19
11
20
10
+ve
0V
24683BB
REMOTE DISPLAY UNIT 2
(Rear View)
20V - 54V dc
240mA
Figure 4.4 - Star connection example for two remote displays
24685033_CC
4-9
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).
To prevent signal reflections from corrupting the data, it may be necessary to fit termination
resistors to the last unit in the chain. The resistor values should match the characteristic
impedance of the cable (120, typical). A termination resistor is connected between pins 3 and
4, and 17 and 18, on terminal block TB1. A suitable resistor to use is a W metal film type.
24683BB
R EM O T E D ISPLAY UN IT 1
(R ear View)
TB1
Local display visible through front

transparent window.
H ING E
10
11
7
8
9
10
P L3
S ign a l
P owe r
0V
11
P L7
P owe r
+ ve
S ign a l
P owe r P owe r
0V
+ ve
+ +
+ +
1 2 3 4 5 6 7 8 9 10
1 2 3 4 5 6 7 8 9 10
3
2
Screens term inated

at gland plate
13
14
7
6
12
15
12
16
17
13
18
14
19
20
C able screens at
rem ote display
connected together,
but not connected
to ground.
term ination
resistor
TB1
1
10
System 0V
reference
3
4
5
11
6
7
8
9
10
11
12
13
14
15
16
12
17
Local P.S.
18
19
13
20
14
+ve
0V
24683BB
R EM O T E D ISPLAY UN IT 2
(R ear View)
term ination
resistor
20V - 54V dc
240m A
Figure 4.5 - Daisy chain connection example for two remote displays
4-10
24685033_CC
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
displays the terminal block is located at the rear of the unit. The terminal block of the
24683D remote display is located within the unit and must be accessed as described in
Section 4.3.2.
2.
Prepare the cable ends and fit identity sleeves to the leads.
3.
Fit the leads into the respective terminals (see Figure 4.6 for details) and tighten the
terminal screws. The interconnections for multiple remote displays are shown in the
examples in Figure 4.4 and Figure 4.5.
4.
Ensure a stress-free exit for the cable, from the panel, by providing any necessary cable
support.
Terminal
Service
1&3
Signal + VE from 2468
2&4
Signal - VE from 2468
5, 6 & 7
Power 0V from 2468 or local supply
8&9
Power + VE from 2468 or local supply
12 & 13
Power + VE from 2468 or local supply
14, 15 & 16
Power 0V from 2468 or local supply
17 & 19
Signal - VE from 2468
18 & 20
Signal + VE from 2468
10 & 11
Earth
Figure 4.6 - Cable connection details for the remote display
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 procedure is:
1.
Ensure a stress-free cable run between the remote display unit and Hydrastep 2468.
2.
Gain access to the display board in the 2468. The cable from the remote display
requires connecting to connectors PL3 and PL7 on PCB 24680515.
3.
Enter the cable through the gland port in the 2468 enclosure (if this is applicable) and
ensure a stress-free run inside the enclosure.
4.
Prepare the cable ends, fit identity sleeves on the leads and connect them to their
respective terminals. See the example in Figure 4.5 on page 4-10.
5.
Ensure that the cable screen is grounded at the gland plate.
24685033_CC
4-11
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
No display of ODD
LEDs (including
bottom half of fault
LED)
Fault
Loss of power to
remote display
unit.

Check that the wiring to connector PL1 in the remote
display unit is correct.
With a suitable meter, check that the supply voltage is
present at the remote display unit connector. Ensure that
the voltage is in the range 14V through 45Vdc.
If the unit is locally powered and no voltage is present
check the voltage at the local power source.
If the unit is powered from the 2468 electronics unit check
the voltage between pins 5 and 8 of PL3 on the display
board (24680502) of that unit. A voltage of less than 14Vdc
indicates the possibility of a short circuit in the power lines
or a fault on the display board. Disconnect connector SK3
from the display PCB in the 2468 electronics unit and recheck the voltage between pins 5 and 8 of PL3. If the
voltage is less than 18Vdc then the display board in the
2468 electronics unit may be faulty. Replace this board
with a serviceable item and check for the correct voltage
between pins 5 and 8 of PL3.
No display of EVEN
LEDs (including top
half of fault LED)
Loss of power to
remote display
unit.

With a suitable meter, check that the supply voltage is
present at the remote display unit connector. Ensure that
the voltage is in the range 14V through 45Vdc.
If the unit is locally powered and no voltage is present
check the voltage at the local power source.
If the unit is powered from the 2468 electronics unit check
the voltage between pins 5 and 8 of PL7 on the display
board (24680502) of that unit. A voltage of less than 14Vdc
indicates the possibility of a short circuit in the power lines
or a fault on the display board. Disconnect connector SK3
from the display PCB in the 2468 electronics unit and recheck the voltage between pins 5 and 8 of PL7. If the
voltage is less than 18Vdc then the display board in the
2468 electronics unit may be faulty. Replace this board
with a serviceable item and check for the correct voltage
between pins 5 and 8 of PL7.
Table 4.1 - Fault Analysis and Correction Chart
4-12
24685033_CC
Indication
Bottom half of
fault LED
illuminated and
ODD LEDs
flashing at 1Hz, or
ODD LEDs off.
Fault
Power present,
but loss of serial
data.

If wiring is correct, proceed as follows:
1. If a termination resistor is fitted, disconnect this from
the end of the daisy chain.
2. With an ac voltmeter, check the ac voltage between
pins 1and 5, and pins 2 and 5, on PL1.
3. An ac voltage is less than 1V indicates a fault on the
signal transmission lines. Check back to the previous
remote display in the daisy chain or to the 2468
electronics unit, as appropriate. If the correct ac
voltages are present at this location then a line break
is indicated.
4. If the ac voltages are still low then either the lines are
short-circuited or there is a board fault. Disconnect
the remote displays upstream and re-check the ac
voltages. If there is a voltage of less than 1Vac at the
2468 electronics unit (with PL3 removed) then the
display board is faulty. Remove this board and fit a
serviceable item.
Bottom half of
fault LED
illuminated and
EVEN LEDs
flashing at 1Hz, or
EVEN LEDs off.
Power present,
but loss of serial
data.

If wiring is correct, proceed as follows:
1. If a termination resistor is fitted, disconnect this from
the end of the daisy chain.
2. With an ac voltmeter, check the ac voltage between
pins 1and 5, and pins 2 and 5, on PL2.
3. An ac voltage is less than 1V indicates a fault on the
signal transmission lines. Check back to the previous
remote display in the daisy chain or to the 2468
electronics unit, as appropriate. If the correct ac
voltages are present at this location then a line break
is indicated.
4. If the ac voltages are still low then either the lines are
short-circuited or there is a board fault. Disconnect
the remote displays upstream and re-check the ac
voltages. If there is a voltage of less than 1Vac at the
2468 electronics unit (with PL7 removed) then the
display board is faulty. Remove this board and fit a
serviceable item.
Table 4.1 (cont.) - Fault Analysis and Correction Chart
24685033_CC
4-13
Indication
Flickering
Display
Fault
Corruption of
signal data

Most probably caused by bad shielding (screening) of the
remote display cabling or by bad shield connections to ground.
Check shielding and shield connections. Ensure that only one
end of the cable shield is connected to ground.
If several remote displays are daisy chained together then a
termination resistor may be required on the end display. (See
Section 4.4.3 in this chapter.)
Chequered
pattern on red
and green LED
display
Wrong setting
of Number of
Electrodes
switch on 2468
display board.
Refer to Section 2.3 in Chapter 2 and ensure that the switch is

set correctly. If the display still shows a chequered pattern
then a circuit fault exists on the 2468 display board. Remove
this board and fit a serviceable replacement.
On/off pattern on
red and green
LEDs.
Wrong setting
of Number of
Electrodes
switch on 2468
display board,
or wrong setting
of links LK1,
LK2, LK3 and
LK4 on the
24683BB
decoding pcb.
As above.
If a fault is not found, check the link setting on the 24683BB
and reset the links if necessary.
Indication not
displayed for
lower electrodes.
As above.
As above.
Each electrode
represented by
only one LED
when 16 or less
electrodes are
used.
As above.
As above.
LEDs display an
irregular
red/green
pattern.
As above.
As above.
Table 4.1 (cont.) - Fault Analysis and Correction Chart
4-14
24685033_CC
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 to be fitted in its place. A list of replacement parts is given in Table 4.2.
The procedure for replacing a PCB in a remote display is:
1.
Ensure that the Hydrastep 2468 unit is switched off.
2.
Gain access to the interior of the remote display unit. The method depends on the type
of remote display being serviced:
For a 24683B: Remove the cables from terminal block TB1 at the rear of the unit.
Remove the clamps. Withdraw the unit from the front of the mounting panel and lay on
a clean surface. Pull off the bezel from the unit front panel, unscrew and remove the
side panel, and lift off the front and rear panels, and use a suitable flat bladed
screwdriver to prise apart the PCB interconnecting edge connectors. Both PCBs can
now be removed from their securing slots in the unit case.
For a 24683C: Remove the cables from terminal block TB1 at the rear of the unit.
Remove the clamps. Withdraw the unit from the front of the mounting panel and lay on
a clean surface. Remove the front and rear panels. Both PCBs can now be removed
from the unit case.
For a 24683D: Remove the unit clear cover and the front panel. The LED display and
the decode PCB can now be accessed and it can easily be seen which screws and
connections it is necessary to remove in order to remove the faulty board(s).
3.
Fit the serviceable PCB(s), following the reverse order to that given in step 2.
Item
Solartron Mobrey
Part No.
For 24683B:
LED PCB assembly
Decode PCB assembly
Header (for 8-16, 18-32 electrode operation)
Holding bar (two off, with two knurled knobs)
24680514A
24680513B
399100390
460202260
For 24683C:
LED PCB assembly
Decode PCB assembly
24680519A
24680520A
460202260
For 24683D
LED PCB assembly
Decode PCB assembly
24680521A
24680522A
460202260
Table 4.2 - Remote Display Replacement Parts
24685033_CC
4-15
4.8
SPECIFICATION
REMOTE DISPLAY UNITS
INDICATION
Red/green 6mm3mm LEDs
CASE STYLE
24683B and 24683C: Panel mounting;

24683D: Rugged enclosure, to IP65/NEMA 4X
DIMENSIONS
24683B: 144mm72mm200mm deep (5.672.38 7.87)

24683C: 192mm96mm209mm deep (7.563.7 8.23)
24683D: 302mm186mm175mm deep (11.897.32 6.89)
PANEL CUT-OUT
24683B: 139mm67mm
24683C: 186mm92mm (7.323.62)
POWER SUPPLY
Derived from 2468 electronics unit or 20V - 54Vdc, 240mA

Absolute maximum limits at remote display terminals: 16V to 60Vdc
TERMINALS
Screw-clamp
CABLES
Note: The following cables fulfil the minimum requirements. Heavier cables may be used.
Maximum gauge accepted by connectors is 16AWG (1. 5mm2).
2
Powered from 2468 electronics

(up to 1000m from 2468 unit)
BASEEFA conformity *
1.5mm , 70.53mm individually shielded, 5-pair. Overall

shield. Galvanised steel wire armour. One cable required.
(Solartron Part No.480121230)
Unit locally powered

(up to 1000m from main unit)
22 AWG (0.324mm2, 70.25mm) individually shielded, 2-pair twisted

(Belden type No. 8723). Two cables required.
(Belden type No. 8777). One cable required.


(Alpha Wire type No. 6054C). One cable required.




* The main Hydrastep 2468 unit is approved for operation in a hazardous environment to ExN11C T4.
Compliance with this approval requires that armoured cable is used to connect a remote display to the main unit.
A remote display must not be used in a hazardous environment.
4-16
24685033_CC
Hydrastep Pressure Parts

Operating Manual
Part No:
24675030
Status:
Issue:
Authors:
Date:
J. Smith / M. Le-Fevre / RCD

October 2000
Copyright 2000
Solartron Mobrey
All rights reserved
Solartron Mobrey pursues a policy of continuous development and product improvement. The specification in this
document may therefore be changed without notice.
To the best of our knowledge, the information contained in this document is accurate and Solartron Mobrey cannot be
held responsible for any errors, omissions or other misinformation contained herein. No part of this document may be
photocopied or reproduced without prior written consent of Solartron Mobrey.
Solartron Mobrey Limited
Solartron Inc.
158 Edinburgh Avenue, Slough,

Berkshire, SL1 4UE, UK
Telephone: +44/0 1753 756600
Fax: +44/0 1753 823589
19408 Park Row, Suite 320

Houston, Texas 77084, USA
Telephone: +1 281-398-7890
Fax: +1 281-398-7891
Email: sales@solartron.com
Web: http://www.solartron.com
A Roxboro Group Company
For details of our agents in other countries, please contact our Slough, UK office.
Pt.2-2
24675030_AK
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 Hydrastep system of water level determination.
Chapter 2 describes the water column and its components. The preparation, installation of
the water column on to the boiler, acid and steam purging of the boiler system and the fitting
of the electrode sensors.
Chapter 3 details the fault repair procedures carried out on the system pressure parts and
their commissioning.
Chapter 4 provides a general description of the pressure parts used in the Hydrastep
systems.
Chapter 5 details the Pressure Parts specifications.
Appendix
Appendix A Approval Certificates contains copies of certificates complying with the
necessary safety approvals for the Hydrastep system.
CAUTION: The procedures described in this manual do not overrule any mandatory
regulations and procedures applied on site regarding the installation, testing and
safety precautions affecting the specific Hydrastep System.
The objective of this manual is to describe various procedures involved in the installation of
the water columns, their attachments and the electrodes used in determining the level of
water in the column as required by the following Hydrastep Systems.
Commissioning the water column and limited component repair procedures on the system
pipework are also covered.
24675030_AK
Pt.2-3
Pt.2-4
24675030_AK
REMINDER
ELECTRODE INSTALLATION
THREADED ELECTRODE(S), PART Nos. 4596006 & 456008
MAKE SURE THAT THE COMPRESSION GASKET IS REGISTERED IN THE
PROBE RECESS PRIOR TO TIGHTENING THE ELECTRODE. THIS CENTRES
THE GASKET TO THE PROBE.
GASKET
ELECTRODE
SEAT SURFACE
COLUMN BODY
CORRECT
24675030_AK
INCORRECT
Pt.2-5
Pt.2-6
24675030_AK
NOTICE
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 THE APPROPRIATE MANUAL SECTION FOR
PROPER DIAGNOSTIC PROCEDURES IF BLOCKAGE
PROBLEMS ARE SUSPECTED.
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Pt.2-7
Pt.2-8
24675030_AK
Part 2 - Hydrastep Pressure Parts
24675030_AK
Chapter 1
General Introduction
Chapter 2
Installation Procedures
Chapter 3
Fault Repair and Commissioning
Chapter 4
Unit Description
Chapter 5
Unit Specifications - Hydrastep
Appendix A
Approval Certificates
Pt.2-9
Pt.2-10
24675030_AK
1
1.1
PRINCIPLE OF OPERATION ..................................................................1-3
1.2
WATER LEVEL INDICATION ..................................................................1-3

Illustrations
Figure 1.1 - Schematic of high pressure resistance measuring cell and electrodes............. 1-3
Figure 1.2 - Low pressure water column (120bar, 1740psi).................................................. 1-4
Figure 1.3 - High pressure water column (210 bar, 3045psi and 300 bar, 4350psi)............. 1-5
24675030_AK
1-1
1-2
24675030_AK
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 differences in resistivities of water and steam over
the range 100C (212F) to 370C (698F). (Series 3 super-critical components are used up
to 560C, 1040F)
A vertical row of electrodes is installed in the water column which forms a side arm attached
to a boiler arid aligned, typically, such that an equal number of electrodes appear above and
below the normal water level, see Figure 1.1. The resistance measurement is made
between the insulated tip of the electrode and the wall of the column. The cell constant,
defining the actual resistance measured, is determined by the length and the diameter of the
electrode tip and the water column bore. In practice, the cell constant is chosen so that the
resistance in water is less than 100k ohms, with a consequent resistance in steam of greater
than 10M ohms.
Since the resistivities of water and steam are substantially different, the system is simple
and requires minimum setting up adjustments. It is not critical in terms of power supply
variations, ambient temperature changes, etc., resulting in a highly reliable system.
Figure 1.1 shows the resistance-measuring cell complete with installed electrode. Figure 1.2
and Figure 1.3 show examples of the Low Pressure (120bar, 1740p.s.i.) and the Series 3
and Super 3 High Pressure (210bar, 3045p.s.i. & 300bar, 4350p.s.i.) Water Columns
respectively.
1.2
WATER LEVEL INDICATION

Each electrode is connected to its own electronic measurement channel where the
resistance value measured decides which of two Light Emitting Diode (LED) drive circuits is
energised. The LEDs are presented in two columns, one column of green LEDs (illuminated
for water) and one column of red LEDs (illuminated for steam) indicating the water level.
Figure 1.1 - Schematic of high pressure resistance measuring cell and electrodes
24675030_AK
1-3
Figure 1.2 - Low pressure water column (120bar, 1740psi)
1-4
24675030_AK
Figure 1.3 - High pressure water column (210 bar, 3045psi and 300 bar, 4350psi)
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1-5
1-6
24675030_AK
2
Contents
Page No.
2.1
SCOPE OF PROCEDURES.....................................................................2-3
2.2
STORAGE................................................................................................2-3
2.2.1
2.2.2
2.2.3
2.2.4
AMBIENT CONDITIONS ........................................................................ 2-3

PHYSICAL PROTECTION ..................................................................... 2-3
INSPECTION .......................................................................................... 2-3
HANDLING PRECAUTIONS .................................................................. 2-3
2.3
INSTALLATION OF WATER COLUMN...................................................2-3
2.4
INSPECTION OF MECHANICAL INSTALLATION WORK......................2-6
Illustrations
Figure 2.1 - Universal weld profile ........................................................................................ 2-5
Figure 2.2 - Typical water column installation ...................................................................... 2-7
Figure 2.3 - Typical water column suspension ..................................................................... 2-8
24675030_AK
2-1
2-2
24675030_AK
2.1
SCOPE OF PROCEDURES
The procedures apply to the Hydrastep Boiler Drum Water Level Equipment supplied by
Solartron-Mobrey, who are responsible, under their supply contract, for delivery of all items of
the above equipment listed in the delivery schedules.
Solartron-Mobrey are not responsible for handling, storage, installation and protection of
equipment on-site. However, the procedures define the requirements for these activities
which must be complied with to allow Solartron-Mobrey to meet their contractual obligations
for the efficient performance of equipment supplied by them.
The items of equipment are listed in detail on the Packing Note that is issued with the
equipment to the site.
2.2
STORAGE
2.2.1
AMBIENT CONDITIONS
The storage area must be dry, dust-free and under cover. Storage conditions should be
controlled within the temperature range of 10C to 40C (50F to 104F) with a maximum of
80% R.H.
2.2.2
PHYSICAL PROTECTION
The equipment shall be stored, where possible, in the original or robust packages to prevent
accidental mechanical damage. The equipment shall be stored on shelving or racks above
ground level as further protection from mechanical damage and to eliminate dampness.
2.2.3
INSPECTION
If the equipment is to be stored for a long period, suitable access is to be provided so that
regular inspection can take place. These inspections should check for signs of physical
deterioration, and should take place at least every three months.
2.2.4
HANDLING PRECAUTIONS
The water columns are heavy and lifting equipment suitable for hoisting up to 50kg should be
used, both for inspection and carriage. The electrodes should be handled with considerable
care, both for inspection and installation. The electronic units should be protected from
electrostatic damage, induced via signal input terminals.
2.3
INSTALLATION OF WATER COLUMN

The Water Column is delivered with all electrode ports fitted with plastic inserts. These
inserts should not be removed until the electrodes are due to be installed.
24675030_AK
2-3
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 column after all erection and electrical
work is completed and the water column is ready to be commissioned.
Caution: It is essential that the electrodes are NOT fitted until the acid and steam purging
of the boiler drum has been completed. However, if it is essential that the
Hydrastep be used to gauge the water level during acid cleaning, a sacrificial set
of electrodes must be used for this task with a new set of electrodes provided for
installation before normal operation is started. Sacrificial electrodes should be
discarded.
The water column is provided with a lifting eye at its upper end to be used for support from
the local site superstructure.
Before fitting the water column, the following points must be checked:
a) 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 the Water connections on the Drum and are
ready to have the water column welded to them. All steam isolation valves should be
fitted with their spindles horizontal.
b) Check that items of hardware required for supporting the water column are available and
that the suspension points on the superstructure have been installed.
c) Water columns are normally supplied with a lifting/support eye, but where this is not the
case, alternative support must be provided.
d) The water column and associated pipework are secured to resist sympathetic vibrations
from surrounding plant.
e) Ensure that the relevant installation diagrams, support services including that of an
approved welder, and suitable welding plant are available.
Note:
2-4
All joints in pipework must be welded, tested and inspected in accordance with
the approved welding procedure documents. Ideally, this should be to ASME B &
PVC Section IX Welding Qualifications, but Local Regulations may otherwise
apply. To minimise errors due to temperature difference between the water in the
boiler drum and the water in the Hydrastep column, the length of the pipework
between the drum and the Hydrastep column should not exceed 2 metres. Paths
should be as straight and direct as possible.
24675030_AK
45
1.5mm
For HP (210 bar)

For HP (300 bar)
For LP
Material:
Size:
Material:
Size:
Material:
Size:
SA106B
1" N.B, Sch. 160 pipe dim.
SA479 - 316
1" N.B, Sch. XXS PPE
SA106B
1" N.B, Sch. 80 pipe dim.
Figure 2.1 - Universal weld profile

The Steam and Water connections on the water column must be set to position the water
column at the correct level before they are welded in place, Figure 2.2 gives an example of
the water column installation. Normally, the water level of the drum will be between
electrodes 6 and 7 for a twelve port water column. However, due to the physical or operating
conditions, this could be offset. The steam leg must slope downwards to the water column
with a minimum gradient of 1 in 50 to ensure condensate circulation. The water leg must
slope downwards to the drum to prevent water from being trapped at the bottom of the water
column.
Caution: Care must be exercised to ensure that the pipework is not allowed to take the
unsupported weight of a standard water column. The weight of the column and
its associated pipework are fully supported - there must not be any load on the
welded pipework attachment points.
Installation should commence with the support of the column, see Figure 2.3. The water
column is attached to the supports which will carry the weight of the water column and allow
it to be accurately aligned with the drum steam and water connections before and during the
welding operation.
After the welding to the connecting pipework, valves and the fitting of the drain pipework is
complete, a further check on the level alignment must be carried out and adjustments made,
if necessary.
24675030_AK
2-5
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 (see Figure 2.2).
Lagging the water column will reduce the density error, provided that 0.5 metre minimum of
the steam leg is left unlagged.
If errors in the water level indication are observed, it may be necessary to lag the water
column, either up to NWL or for its full length, depending on the ambient conditions
prevailing at the site. Suitable lagging, part number 450601450, is available from SolartronMobrey
When the installation of the water column has been completed, precautions must be taken to
protect it against damage during the installation of adjacent plant and pipework.
Note:
Particular attention must be paid to the protection of the electrode sealing

surfaces in the column against foreign bodies or weathering. For this purpose the
following sealing plugs should be fitted as appropriate:
L.P. Sealing Plug
Part No. 24569A
Series 3 Sealing Plug
Part No. 450600880
Caution: If there is any possibility of the ambient temperature at drum level falling below
zero C for any period when the boiler is not operational, it is ESSENTIAL that the
water column is isolated, drained and vented to prevent ice-expansion damage to
the electrodes in the column. Ice-expansion damage can also affect adjacent
valves.
For instructions regarding the assembly of electrodes in the water column, see Chapter 3,
sub-section 3.1.4 (low pressure electrodes) and 3.1.5 (high pressure electrodes).
2.4
INSPECTION OF MECHANICAL INSTALLATION WORK

When the mechanical installation work has been completed, the site surveillance staff may
be required to inspect the work and the equipment, such as the installation of the electronics
unit and the installation of the water column, checking particularly the level relative to the
drum, before releasing it for electrical work and cabling.
2-6
24675030_AK
Figure 2.2 - Typical water column installation, showing optional column lagging.
24675030_AK
2-7
Figure 2.3 - Typical water column suspension
2-8
24675030_AK

Contents
Page No.
3.1
BACKGROUND .......................................................................................3-3
3.1.1
3.1.2
3.1.3
3.1.4
3.1.5
3.2
SAFETY PRECAUTIONS....................................................................... 3-3

WATER COLUMN ISOLATION .............................................................. 3-3
ELECTRODE AND ELECTRODE SEAL LEAKS ................................... 3-4
3.1.3.1 Low Pressure Electrodes ........................................................ 3-4
3.1.3.2 High Pressure Electrodes........................................................ 3-4
3.1.3.3 Tightening Procedure for High Pressure Electrode
Installation ............................................................................... 3-5
PROCEDURE FOR CHANGING THE LOW PRESSURE
ELECTRODES AND GASKETS............................................................. 3-5
PROCEDURE FOR CHANGING HIGH PRESSURE ELECTRODES ... 3-6
WATER COLUMN COMMISSIONING OR RECOMMISSIONING............3-7

3.2.1
3.2.2
3.2.3
VENT AND DRAIN VALVE REPAIRS .................................................... 3-7

WATER COLUMN TRANSIENT RESPONSE........................................ 3-7
WATER COLUMN OR PIPEWORK BLOCKAGE .................................. 3-8
Note:
THERE IS NO NEED TO BLOW WATER COLUMN DOWN WHEN COMMISSIONING.
THE SYSTEM CONTINUOUSLY FLUSHES THE WATER COLUMN.
24675030_AJ
3-1
3-2
24675030_AJ
3.1
BACKGROUND
With any steam/water detection gauge, a partial blockage or leak within the pressurised
system may result in incorrect water level indication. The Hydrastep water column design is
such that density errors in water level indication (due to the water temperature in the column
being lower than the water temperature in the boiler drum) are minimised for the
temperatures and pressures specified. This is achieved by stimulating condensate flow in
the upper part of the column by omitting lagging on the column steam pipe. The flow of
condensate maintains the temperature of the water column close to that of the boiler drum.
Caution: If a serious blow occurs, immediate attention is required. Ensure that the
column or manifold is VALVED OFF AS SOON AS POSSIBLE otherwise any
resulting electrode seat erosion may require the removal of the column or
manifold for re-machining of the ports. Site machining of the water column is
possible and satisfactory results can usually be obtained (for small leak damage).
3.1.1
3.1.2
SAFETY PRECAUTIONS
a)
Ensure that tripping, where fitted, is disabled and that the operators are briefed to
expect erroneous indications or alarms.
b)
Ensure that you know the valve positions and other procedures BEFORE working on the
water column.
c)
Allow the water column to cool before changing electrodes and check for signs of steam
at the drain to ensure complete isolation.
d)
Wear industrial gloves to change electrodes.
e)
On Low-level Tripping Schemes, either electro-mechanical interlocks or recognised

procedures MUST be applied to ensure that draining the column does not cause a
spurious trip.
f)
Refit the electrode covers before pressurising the column.
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 equalises, close the drain valve.
c)
Check for no-pressure condition of water column. A failure to cool and a re-filling of the
water column would indicate a pressure condition. Alternatively, carefully unscrew the
first electrode and look out for the presence of steam.
Warning: Great care is required during the check on the first electrode.
Where a separate atmospheric drain is used, open the drain valve and leave it open.
d)
Proceed with the work required.
24675030_AJ
3-3
3.1.3
ELECTRODE AND ELECTRODE SEAL LEAKS

The distinction between electrode/insert seal and electrode/insulator leaks is often difficult to
determine prior to removal of the electrode, unless the leak is small. Steam wisps which
appear to come from between the outside of the electrode body and the gasket indicate a
seal leak, steam appearing through the external ceramic insulator suggests that the
electrode itself is faulty. Even if the electrode is in water, the water temperature in an
operating system will cause the water to flash off to steam as atmospheric conditions are
reached.
Caution:
3.1.3.1
Do not attempt to cure a leaking seal on a low pressure electrode by

overtightening the electrode clamping nut. The most probable fault for low
pressure electrodes lies in damage to the sealing washer. The correct degree
of compression on this washer is inherent in its design. Tightening beyond this
point will only cause damage to the electrode or to the water column.
Low Pressure Electrodes

The correct procedure on low pressure electrodes for repairing either a seal or an electrode
failure is to remove the knurled nut(s) and disconnect the electrode lead(s). Next, remove
the electrode complete with its sealing washer from the column. A thorough examination of
the electrode and washer is likely to give a more positive identification of the cause of the
leak. However, unless it can be definitely established that the electrode was not at fault, it is
advisable to fit a new electrode at this stage. To assist in identifying a seal leak, this may be
caused by:
a)
Failure to remove the old washer on a previous occasion before inserting the
replacement washer and electrode.
b)
Re-using an old and already compressed washer instead of a new one.
c)
Failing to ensure that the land and the recess in the electrode port were clean and
undistorted at the last inspection.
Note: When installing low pressure electrodes, ensure that the threads in the electrode port
are free of loose particles. Lightly coat the electrode threads with anti-seize
compound (Part No. 830007220). Insert the electrode, ensuring that the new gasket
is centred in the electrode groove, and tighten the electrode with a torque wrench to
40 lbft (55Nm). After 15 minutes, re-tighten the electrode with the torque wrench set
to 40 lbft (55Nm). The maximum torque is 50 lbft (68Nm) so DO NOT OVERTIGHTEN.
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 Service Tool Part No. 24579AA.
3.1.3.2
High Pressure Electrodes

In the case of high pressure electrodes, sealing is performed by a taper form on the
electrode body. The act of tightening the electrode clamping nut compresses the taper form
into the port sealing taper, thereby effecting a pressure seal. For these electrodes, the
condition of the electrode port sealing surface is of great importance, and the tightening
procedure is given to prevent damage to the electrode or the water column electrode port.
Should a leak develop, the electrode must be removed and both the port and taper seating
surfaces examined for signs of surface deterioration.
3-4
24675030_AJ
3.1.3.3
Tightening Procedure For High Pressure Electrode Installation

a)
Ensure the electrode is clean and the electrode port bore is clean and free of debris.
b)
Lightly coat the column port thread with anti-seize compound (Part No.: 830007220).
c)
Assemble the electrode to the column port and tighten the electrode nut until the
electrode will not rotate in its seat.
d)
Finally, tighten the electrode nut a further /8 to turn to complete the procedure.
NOTE: The final /8 to turn corresponds to a torque level of between 28lbft (35Nm)
1
and 47lbft (60Nm). /8 turn is the recommended tightening condition. turn is the
maximum allowable, and the tightening torque used must be the minimum to achieve
this. Failure to comply with this limitation may cause damage to the port or to the
electrode, due to over tightening.
If necessary, where the sealing surfaces can be recovered by simple cleaning practices, the
old electrode can be refitted and tightened to within the maximum torque value given and the
system pressure tested. However, it is recommended that the best solution to minimise the
system down time is to fit a new electrode.
Where scoring or erosion of the sealing seat has occurred in the water column port, this can
be re-cut to acceptable standards using the Service Tool 246791AA.
3.1.4
PROCEDURE FOR CHANGING THE LOW PRESSURE ELECTRODES

AND GASKETS
Carry out the isolation procedure as detailed in sub-section 3.1.2. Ensure that the tripping is
disabled (see Safety Precautions, sub-section 3.1.1). There is no need to switch off the
Hydrastep electronic equipment; then:
a)
Remove the electrode cover guard, taking care to avoid knocking the electrodes.
Note: Remove only one electrode at a time (avoids risk of incorrect reconnection).
b)
Disconnect the leads, extract the electrode and the gasket carefully without damage to
the seat face.
c)
Inspect the column seat, making sure that it is free of loose particles and is not pitted or
corroded.
d)
Carefully unpack the new electrode and check that there is no damage to the ceramic
insulators or to the sealing gasket.
e)
Assemble the new electrode to the water column as detailed in sub-paragraph 3.1.3 for
low pressure electrodes, paragraph d.
f)
Refit the electrical lead(s) and guard. Recommission as detailed later in this Chapter.
24675030_AJ
3-5
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 tripping is
disabled (see Safety Precautions, sub-section 3.1.1). There is no need to switch off the
Hydrastep electronic equipment; allow system about 20 minutes to cool down, then:
a)
Remove the electrode cover guard, taking care to avoid knocking the electrodes.
Note: Remove only one electrode at a time (avoids risk of incorrect reconnection)
b)
Disconnect the leads, extract the electrode carefully without damage to the seat face.
c)
Inspect the column seat, remove any scaling or residue taking care not to damage the
seat.
d)
Carefully unpack the new electrode and check that there is no damage to the ceramic
insulators or to the seating ferrules.
e)
Lightly coat the electrode threads with anti-seize compound (Part No.: 830007220) and
assemble the new electrode to the water column as detailed in sub-section 3.1.3 for
high pressure electrodes.
Note:
f)
3-6
At the first pressure/temperature test, check for leaks and tighten electrode nut
as necessary, but not exceeding turn from the nipped electrode
condition.
Refit the electrical lead(s) and guard. Recommission as stated in section 3.2.
24675030_AJ
3.2
WATER COLUMN COMMISSIONING OR RECOMMISSIONING

The method given allows the column to fill slowly with condensate from the steam leg
through a cracked steam valve and for subsequent warming to continue at a controlled rate
as the water is forced back through the cracked water valve.
Caution: DO NOT BLOW WATER COLUMN DOWN
3.2.1
a)
Notify the unit operator of the intention to commission the column, in accordance with
recognised procedures.
b)
Check that the electrode guard is in place.
c)
Close the drain valves.
d)
Crack open the steam valve. Check with the display or the unit operator that the column
fills with condensate slowly (10 to 15 minutes).
e)
Crack open the water isolating valve. Check with the unit operator that the water level is
falling (1 to 2 minutes) to approximately normal water level and allow to stabilise and
heat up for 15 minutes.
f)
Open the water valve fully.
g)
Open the steam valve fully.
VENT AND DRAIN VALVE REPAIRS

These will usually involve replacement of the gland packing or regrinding of the seat, and
should follow the normal practice for the particular valve types concerned. If it is necessary
to replace an entire valve, ensure that the new valve is correctly orientated for its sealing
direction.
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 the rise in water level due to the condensate flow until the topmost channel
changes to a water indication. Now re-open the water isolating valve fully and quickly.
Time the fall in water level, from the change to steam at the topmost level to the change to
steam at the channel immediately above the lowest channel to indicate steam at the start of
the measurements.
The measured times should be similar to those obtained when the Hydrastep was first
commissioned, provided that the drum operating conditions are similar. The usual times are
in the region of 60 seconds for the rising levels and 5 to 15 seconds for the falling levels.
Any serious variation from these times for a standard length column suggests either a partial
blockage or the water valve failing to seal properly.
Note: A standard length column is 550mm (22 inches) sight range. Larger sight ranges will
proportionally extend the water level rise and fall times.
24675030_AJ
3-7
3.2.3
WATER COLUMN OR PIPEWORK BLOCKAGE

If a blockage, either partial or complete, is diagnosed from the response times, isolate the
column as described in Water Column Isolation, sub-section 3.1.2. With the drain valve
open, slowly open the steam isolating valve until the steam line is completely cleared. Close
the steam valve fully. Slowly open the water isolating valve until the water line is also
completely cleared. Close the water valve fully. Close the drain valve and re-check the
transient response. If the response times are still seriously in error, it is probable that the
steam or water valve is not seating or opening properly and needs re-seating.
Note:
3-8
Ensure that all valves are left correctly set and locked.
24675030_AJ
Unit Description
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.)..........................................................................4-5
4.4
WATER COLUMN (H.P.) .........................................................................4-6
4.5
WATER COLUMN (H.P. SUPERCRITICAL)............................................4-7
Illustrations
Figure 4.1 - Low pressure electrode...................................................................................... 4-3
Figure 4.2 - High pressure electrode ..................................................................................... 4-4
24675030_AK
4-1
Unit Description
4-2
24675030_AK
4.1
Unit Description
LOW PRESSURE ELECTRODES

These electrodes can be used for pressures of 50bar (725psi) for 459600802 units, and up to
120bar (1740psi) for 459600602 units - see Chapter 5 for Specifications. They are used with
the low pressure version of the Hydrastep water column shown in Figure 1.2 (in Chapter 1,
Part 2 of the manual).
Fitting instructions are supplied on the electrode package. Electrode details for this version
are shown in Figure 4.1.
Figure 4.1 - Low pressure electrode
24675030_AK
4-3
Unit Description
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 (in Chapter 1, Part 2 of the manual). The fitting
instructions for high pressure electrodes are included within the electrode package.
High pressure electrodes are supplied complete with ferrules fitted. See Figure 4.2.
Figure 4.2 - High pressure electrode
4-4
24675030_AK
4.3
Unit Description
WATER COLUMN (L.P.)

The low pressure water column is manufactured from carbon steel, extruded rectangular
hollow bar. The electrode ports are drilled and fitted with helicoil inserts to accept the
electrodes. This thread system gives greater strength than if the electrodes were mounted
directly into tapped ports. Corrosion of the threads is minimised since the helicoil inserts are
made of stainless steel.
The top cap and the drain components of the water column are manufactured from forged
carbon steel bar, the drain components being available in " and 1" sizes. A lug is machined
on the top cap to accept a vertical forked member for support of the water column when in
situ.
The steam and water connections are made from 1 N.B SCH 80 carbon steel pipe with weld
preps already machined to weld the water column to the steam system.
The electrode covers are fabricated from stainless steel 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
requirements. The materials and design are to ASME B31.1.
The completed water column undergoes pressure proof tests at 150% of duty pressure after
manufacture.
For further details on the water column dimensions, etc., refer to Figure 1.2 in Chapter 1, part
two of the manual.
24675030_AK
4-5
Unit Description
4.4
WATER COLUMN (H.P.)

The high pressure water column is manufactured from 2 NB SCH S carbon steel pipe.
The inserts used are made from high grade stainless steel and are welded into position on
the water column body.
carbon steel bar, the drain components being available in and 1 sizes. A lug is machined
situ.
The steam and water connections are made from 1 N.B SCH 160 carbon steel pipe with
weld preps already machined to weld the water column to the steam system.
manufacture.
two of the manual.
4-6
24675030_AK
4.5
Unit Description
WATER COLUMN (H.P. SUPERCRITICAL)

The high pressure water column is manufactured from 2 NB SCH S stainless steel pipe.
The inserts used are made from Inconel 625 and are welded into position on the water
column body.
carbon steel bar, the drain components being available in and 1 sizes. A lug is machined
situ.
The steam and water connections are made from 1 NB SCH S stainless steel pipe with
weld preps already machined to weld the water column to the steam system.
manufacture.
two of the manual.
24675030_AK
4-7
Unit Description
4-8
24675030_AK

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 370C (698 F)
pH range 7-11
Hydrostatically tested to 180 bar (2610 psi) at ambient temp.
Type 459600802
Complete with sealing gasket: Metaflex.

Screw in type M18x 1.5
Insulator: PTFE or Teflon
Rating 50 bar (725 psi) at 260 C (500 F)
pH range 7-13.5
Hydrostatically tested to 155 bar (2247 psi) at ambient temp.
Type 246781A:
Complete with ferrule sealing

22mm AF nut, thread x 20 tpi UNEF form (Swagelok or Parker)
Insulator: High purity alumina ceramic
Rating 300 bar (4350 psi) max. at 560C (1040 F)
pH range 7-11
Hydrostatically tested at 450 bar (6525 psi) at ambient temp.
Type 246782A:

Insulator: PTFE or Teflon
Rating 50bar (725 psi) at 260 C (500 F)
pH range 7-13.5
Hydrostatically tested at 155 bar (2247psi) at ambient temp.
Type 246784A:

Insulator: PTFE or Teflon coated ceramic
Rating 300bar (4350 psi) at 260 C (500 F)
pH range 7-13.5
Hydrostatically tested at 450 bar (6525psi) at ambient temp.
Type 246781Z:

Insulator: Zirconia ceramic
Rating 210 bar (3045 psi) at 370 C (698 F)
pH range 7-11
Hydrostatically tested at 315 bar (4568 psi) at ambient temp.
24675030_AK
5-1
5.2
5-2
Hydrastep Pressure Parts Manual
WATER COLUMNS
Type Low Pressure:
Rating 120bar (1740psi) at 343 C (650 F)
Type High Pressure:

(Series III)
Type High Pressure:

(Super III)
24675030_AK
Hydrastep 2468 Operating Manual
Appendix A: Approval Certificates
Appendix A
Approval Certificates
This appendix contains copies of the Safety and System Certificates for the Hydrastep 2468 Electronic
Gauging System and the Declarations of Conformity with EEC directives.
Safety and System Certificates
Certificate Type
Certificate
No.
Date
Issuing
Authority
No. of
Pages
Comments
Company Licence
M0941
8-Jul 97
EECS
Lists the equipment which may be

manufactured with the BASEEFA mark.
System Certificate
Ex94Y4362X
1-Nov 94
BASEEFA
Prime certificate and schedules for the

Hydrastep 2468 system.
Sys. Cert. Variation
Ex94Y4362X/1
24-Feb 95 BASEEFA
Permits the use of a ceramic fuse with a

time lag, as an alternative to a fast acting
ceramic fuse.
Ex94Y4362X/2
6-Jun 95
BASEEFA
Permits the gland plate to have up to a

maximum of twelve glands, with a
minimum of 9mm between each gland
hole.
Ex94Y4362X/3
12-Jun 96
BASEEFA
Permits the following:

1. An alternative mild steel enclosure,
with a stainless steel gland plate.
2. A modified display PCB, containing an
EMC filter.
3. A modified input PCB, containing an
EMC filter and using an alternative
make of mains transformer and
terminals.
4. Minor changes to the relay PCB,
which do not affect safety.
IMPORTANT NOTE: The System Certificate Ex94Y4362X is issued with special conditions for safe
use (indicated by the X suffix). It is essential that these conditions - given on page 5 of the certificate
- are implemented fully.
For further details, contact Solartron-Mobrey.
24675030_AH
A-1
Appendix A: Approval Certificates
Hydrastep 2468 Operating Manual
Declarations of Conformity
Directives Covered
Product
Basis of Conformity
Date
89/336/EEC Electromagnetic
Compatibility Directive, amended
by 92/31/EEC and 93/68/EEC.
2468C and 2468A

Hydrastep Level Indicators.
Technical Construction File, number

TC950907, approved by Radio
Frequency Investigations Ltd.
Oct. 2000
24683B Hydrastep Remote

Display.
Technical Construction File, number

TC950915, approved by Radio
Frequency Investigations Ltd.
Oct. 2000
As above
24683C Hydrastep Level

Indicators.
BS EN 50081-2:1994
Oct. 2000
As above
24683D Hydrastep Level

Indicators.
BS EN 50081-2:1994
73/23/EEC Low Voltage

Equipment Directive, amended
by 93/68/EEC
89/336/EEC Electromagnetic
Compatibility Directive, amended
by 92/31/EEC and 93/68/EEC.
A-2
BS EN 50082-2:1995
Oct. 2000
BS EN 50082-2:1995
24675030_AH
Solartron Mobrey Limited

158 Edinburgh Avenue Slough Berks England SL1 4UE
Tel: 01753 756600 Fax: 01753 823589
e-mail: sales@solartron.com www.solartron.com
a Roxboro Group Company
Bestobell Mobrey GmbH

Solartron Mobrey Ltd
Mobrey sp z o o
Mobrey AB
Mobrey SA
Mobrey SA-NV
Solartron Mobrey
Deutschland
China
Polska
Sverige
France
Belgium
USA
abcdef
tel: 0211/99 808-0

tel: 021 6353 5652
tel: 022 871 7865
tel: 08-725 01 00
tel: 01.34.30.28.30
tel: 02/465 3879
tel: (281) 398 7890
The right is reserved to amend details

given in this publication without notice
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process measurement solutions

Hydrastep 2468CA & 2468CC

About this manual

Part 1 - Electrical/Electronic System

Part 2 - Pressure Parts

SYMBOLS USED IN THIS MANUAL AND ON THE UNIT

Earth (ground) terminal

Protective conductor terminal

Caution (refer to accompanying documents)

DANGEROUS VOLTAGES ARE PRESENT IN

Introduction to the Hydrastep 2468 Electronic

2468CA & 2468CC Single Power Supply Version

2468 - Relay Output Board Option

Delay Relay Output Board Option

2468 Opto-isolated Output Board Option

Remote Display Options 24683B C & D

Hydrastep 2468CA and 2468CC Manual

Introduction to the Hydrastep 2468 Electronic Gauging System

Introduction to the Hydrastep 2468

WATER LEVEL MEASUREMENT .........................................................3

HYDRASTEP 2468 ELECTRONIC GAUGING SYSTEM .......................5

INPUT BOARDS ................................................................................... 5

OUTPUT BOARDS ............................................................................... 6

HYDRASTEP 2468 UPGRADE PATHS AND AVAILABLE OPTIONS ..7

Introduction to the Hydrastep 2468 Electronic Gauging System

Hydrastep 2468CA and 2468CC Manual

Hydrastep 2468CA and 2468CC Manual

Introduction to the Hydrastep 2468 Electronic Gauging System

WATER LEVEL MEASUREMENT

Figure 1.2 - Schematic of resistance measuring cell and electrodes

Introduction to the Hydrastep 2468 Electronic Gauging System

Hydrastep 2468CA and 2468CC Manual

Figure 1.3 - Typical Hydrastep 2468 System Installation

Hydrastep 2468CA and 2468CC Manual

Introduction to the Hydrastep 2468 Electronic Gauging System

HYDRASTEP 2468 ELECTRONIC GAUGING SYSTEM

A Single Power Supply System with Local Level Display

A Dual Power Supply System with Local Level Display

Introduction to the Hydrastep 2468 Electronic Gauging System

Hydrastep 2468CA and 2468CC Manual

SYSTEM FAULTS (2468CA OR 2468CC)

REMOTE DISPLAY UNITS

Hydrastep 2468CA and 2468CC Manual

Introduction to the Hydrastep 2468 Electronic Gauging System

HYDRASTEP 2468 UPGRADE PATHS AND AVAILABLE

Relay output board

Time delay relay

Provides an additional power

Provides an additional power

Relay output board

Time delay relay

Dual Power Supply.

Introduction to the Hydrastep 2468 Electronic Gauging System

Hydrastep 2468CA and 2468CC Manual

Hydrastep 2468CA and 2468CC Electronic Gauging Systems

2468CA & 2468CC Single Power Supply Version

INTRODUCTION ..................................................................................... 2-3