HDI 2522 Manuale utente

HDI 2522 IECEX/ATEX POSITION

INDICATOR GAUGE

User’s Manual Rev A

HDI 2522 Position Indicator Gauge

IECEX/ATEX User’s Manual – HDI 2522, Rev A | November,2019

Table of Contents

Section 1 – Introduction .............................................................................................................................................. 4

1.A General Information ................................................................................................................................... 4

1.B Unpacking and Inspection ....................................................................................................................... 4

1.C Cautionary Information ............................................................................................................................ 5

Section 2 – HDI 2522 Series Position Indicating Gauge Systems Overview ...................................... 6

2.A System Overview .......................................................................................................................................... 6

2.B Accuracy ........................................................................................................................................................... 7

2.C Control Head................................................................................................................................................... 7

2.D Potentiometers .............................................................................................................................................. 7

2.E Cable ................................................................................................................................................................... 8

2.F System Options ............................................................................................................................................. 8

2.G Certification .................................................................................................................................................... 9

Section 3 – Installation ................................................................................................................................................ 9

3.A Control Head 2522........................................................................................................................................... 9

3.B Cables and Routing ................................................................................................................................... 10

Section 4 – Gauge Functions .................................................................................................................................. 10

4.A Overview ....................................................................................................................................................... 10

4.B Gauge Head Features ............................................................................................................................... 11

4.C Engineering Units Display .................................................................................................................... 11

4.D Main Display ................................................................................................................................................ 11

4.E Bar Graph Display ..................................................................................................................................... 11

4.F Membrane Panel ........................................................................................................................................ 11

4.G Power Off / On Button ........................................................................................................................... 11

4.H Mode (M) Button Calibration Only ................................................................................................... 11

4.I Up () Button ............................................................................................................................................. 12

4.J Down () Button ...................................................................................................................................... 12

4.K Enter (E) Button ........................................................................................................................................ 12

Section 5 – Gauge Operation .................................................................................................................................. 12

5.A Gauge Operation Overview .................................................................................................................. 12

5.B Run Mode ...................................................................................................................................................... 12

Section 6 – Maintenance .......................................................................................................................................... 14

6.A Cleaning ......................................................................................................................................................... 14

HDI 2522 Position Indicator Gauge

IECEX/ATEX User’s Manual – HDI 2522, Rev A | November,2019

6.B Power Pack ................................................................................................................................................... 14

6.C Processor Boards ...................................................................................................................................... 15

6.D Potentiometers ........................................................................................................................................... 15

Section 7 – Troubleshooting .................................................................................................................................. 15

7.A Battery Voltage ........................................................................................................................................... 15

7.B Additional Troubleshooting ................................................................................................................. 15

Section 8 - Installation Configurations .............................................................................................................. 16

Section 9 - Cable Connection Drawing .............................................................................................................. 22

Section 10 - Gauge Mounting Diagram .............................................................................................................. 23

Section 11 – Potentiometer Configurations ................................................................................................... 24

Section 12 - Certification Markings .................................................................................................................... 27

Section 13 - IECEX Certificate ................................................................................................................................ 28

Section 14 - ATEX Certificate ................................................................................................................................. 31

Section 15 - Warranty ............................................................................................................................................... 34

HDI 2522 Position Indicator Gauge

IECEX/ATEX User’s Manual – HDI 2522, Rev A | November,2019

Section 1 – Introduction

1.A General Information

The HDI 2522 is an industrial position indicator gauge designed for use in explosive atmospheres. The

2522 is a 4-inch panel mounted gauge with remote sensor connections. The 2522 gauge system is

various configurations for user feedback and connection to other indicator gauges. See section 8 HDI

installation configuration drawings.

This manual describes the installation, operation, and maintenance of the HDI 2522 gauge system. This

manual will provide the user with all the necessary information to properly inspect, install, operate and

perform routine maintenance and troubleshooting for onsite repairs.

The HDI 2522 has three key elements: the control head, a sensor assembly specified by the end client,

and the cable assembly connecting the control head to the sensor assembly. These items will be

discussed at greater detail in Section 2.

1.B Unpacking and Inspection

Upon receipt of the equipment, it is critical to confirm all the necessary items are accounted for as some

items can settle to the bottom of the box. In the past, some items have inadvertently been removed from

packaging by freight forwarders or third party (Custom agents) during transit. The customer should

compare the packing list against items located within the packaging. If a discrepancy exists, the

customer is advised to first contact their shipping agent and then HDI if the items have not been located.

HDI 2522 Position Indicator Gauge

IECEX/ATEX User’s Manual – HDI 2522, Rev A | November,2019

1.C Cautionary Information

1.C.1 Power

This system is powered by an internal power pack HDI part number HDIBATT-E608-DOT-AA. The 2522

gauge will be damaged if connected to a 12 or 24VDC system. Note that the battery should only be

replaced while in a non-hazardous area.

1.C.2 Exposed Electronics

CAUTION: Do not leave the equipment exposed to outside elements without being properly

connected as this may expose the connector leads to moisture and outside elements damaging the

electronics.

1.C.3 Cleaning

CAUTION: The customer should use caution when cleaning the Gauge (LCD) Head to prevent any

static discharge. From time to time the customer will need to use a damp cloth to clean the LCD overlay

or the gauge case. HDI suggests that the customer use a soft cloth to prevent accidental damage

(scratching) to the protective lens.

1.C.4 Returns

HDI requires that inbound returns should have a Return Material Authorization (RMA) control number

issued from the HDI website. The customer will find this by visiting the website:

http://hdigauges.com/quality/repairs/ and complete the required fields to identify basic contact details.

HDI will then provide the customer repair return quotation and will contact the customer for additional

clarity if necessary. The customer may return multiple units on one RMA submittal request. HDI will

use the inbound notification email for all related correspondence. Proper protection of the equipment

should be a top priority when returning the equipment back to HDI or an authorized agent for repair.

Additionally, it is the shipper’s responsibility to ensure equipment clears all customs as different agencies

may hold equipment without notifying HDI.

HDI 2522 Position Indicator Gauge

IECEX/ATEX User’s Manual – HDI 2522, Rev A | November,2019

1.C.5 Personnel Qualifications

CAUTION: Anyone testing the equipment should have basic electrical understanding, knowledge of

circuitry, and use of a multi-meter. The customer should read the entire manual prior to opening the

display or testing. Any modifications to the HDI 2522 system will void the one year warranty and

jeopardize the IECEX certifications.

Section 2 – HDI 2522 Series Position Indicating Gauge Systems

Overview

2.A System Overview

The HDI 2522 position indicator gauge is a standalone and intrinsically safe electronic indicator gauge

system powered with the HDI field replaceable internal 3.6 Vdc power pack. This battery provides the

power to run the internal circuitry of the gauge assembly, including its display and microcontroller. The

internal battery does not provide the power to drive the 4-20 mA loop (if equipped). The indicator gauge

system requires minimal power during normal operation. The gauge is designed for continuous

operation but can be turned off by the user if desired. The gauge will retain its calibration information

even when powered down. The battery life is guaranteed for one year of continuous operation.

All HDI position indicator gauge Displays are comprised of a liquid crystal display (LCD) display that

includes both a numeric (5 digit) representation (for accuracy) and a bar-graph representation (for trend)

and low battery alarm indicator.

The 2522 gauge system will enable the user to have either a 4-20mA output signal (as an added option)

for chart recording or PLC integration or with the ability to have a slave gauge display to repeat the same

position reading at a different location. The HDI 2522 is configured to allow for a maximum of two slave

gauge displays in addition to the master.

The 2522 gauge systems are shipped as matched and calibrated systems, comprised of the gauge

head and potentiometer assembly. The potentiometer assembly is matched to the head appropriately

and both serialized. Once calibrated, are a matched set.

HDI 2522 Position Indicator Gauge

IECEX/ATEX User’s Manual – HDI 2522, Rev A | November,2019

2.B Accuracy

HDI 2522 gauges are factory calibrated to measure and display the exact position of the item that is

being monitored to a tolerance of 1 percent full scale (FS) Each gauge system is shipped with the signed

and witnessed factory calibration test sheets.

2.C Control Head

The HDI 2522 gauge has a 4-inch diameter LCD face providing a bar graph and is supplied with numeric

digits at the bottom of the LCD for quick glance reading. Some adjustments may be necessary

depending upon location and mounting methods to take into account deck lighting and overhead

sunlight conditions. See Section 10 for mounting dimensions.

When preparing or deciding upon a location for mounting, the customer should consider the

interconnecting cable and the access route to attach or remove the cable from the gauge. HDI

recommends having a minimum of four inches of clearance for cable bend allowance from the bottom

edge of the case. See Section 10 for cable clearance details. Alternatively, the customer may request

custom specific cables (in increments of 5 feet) with 90 degree mating connectors if spacing is limited.

These would face directly to the rear of the gauge. For enclosed control panel applications, HDI

suggests a bulkhead access plate on the side so the interconnect cables to the gauges can be pre-

routed. This would allow for plug and play installation with the inline cable coming from the sensors.

2.D Potentiometers

The HDI 2522 gauge comes with several different sensor housings to be compatible to various mount

styles to reduce onsite customization and to simplify installation after removing the existing pneumatic

sensors. This device is specifically matched to the gauge’s control head and is tracked with

corresponding serial numbers that allows HDI to track repair history and specific configuration

requirements. It is important for the customer to properly retain their serial number records for more

efficient support by HDI. The 2522 gauge can be supplied with various potentiometer housing options:

See related connection types in Section 11. General dimensional drawings or photos are also available

upon request to ensure compatibility.

HDI 2522 Position Indicator Gauge

IECEX/ATEX User’s Manual – HDI 2522, Rev A | November,2019

CAUTION:

 Use of non-HDI approved potentiometers could severely damage the instrument and voids the

standard HDI one year warranty.

 Replacement or substitution of the potentiometer will require the user to recalibrate the gauge

to the new sensor based on the indication required range. Customer to review calibration

procedures in Section 5.C.2 or may visit: http://hdigauges.com for more details.

2.E Cable

To better serve HDI’s clients, interconnect cables are ordered in 5-foot increments only. In the event the

customer receives their specified interconnect cable only to find that it is too short, the customer can

order an additional inline cable. This is basically an extension cable with corresponding Male / Female

connectors for a plug and play installation.

2.F System Options

HDI offers various options as listed in the following subsections. The customer must use the installation

drawings listed in Section 8 to connect the HDI 2522 gauge from a hazardous to a non-hazardous zone.

Any deviations from the drawings will void the applicable certifications.

2.F.1 4-20 mA Output

A current loop providing a 4-20 mA output is added as an option to the 2522 gauge system. This may

be used for chart recorder inputs, data logging or PLC interface. This option requires that the 4-20 mA

current loop be externally powered via customer supplied 12 or 24 Vdc. This is a factory installed option

and does not require field calibration. Please refer to Section 8 for the connection diagram and for any

applicable zone barrier requirements.

2.F.2 0-1 Vdc Output

HDI offers as an option a 0-1 Vdc remote output that may be used for chart recorder inputs, slave

configuration, or data logging. This is a factory installed option and does not require field calibration.

Please refer to Section 8 for the connection diagram and for any applicable zone barrier requirements.

HDI 2522 Position Indicator Gauge

IECEX/ATEX User’s Manual – HDI 2522, Rev A | November,2019

2.F.3 Remote/Slave Gauge Display

The remote (“slave”) function utilizes the 0-1 Vdc output signal from the master 2522 gauge display.

The slave gauge provides repeated gauge readout as displayed on the master unit. This is done utilizing

only one potentiometer. The slave can be installed at any desired location and may also be installed

with the 4-20 mA output option if required.

2.G Certification

HDI currently offers the HDI 2522 with the below certifications.

1. IECEX/ATEX. See Section’s 12, 13, and 14 for IECEX/ATEX certification details.

Intrinsically Safe for Class 1, Div 1 Groups A-D.

Changing inline cable length does not require re-calibration of the HDI 2522.

The customer may verify which certifications are applicable to their system by locating the data

plate on the back side of the gauge head.

Section 3 – Installation

3.A Control Head 2522

The control head can be mounted using the 3 bolt (120 degree) or 4 bolt (45 degree) mounting pattern.

The gauge comes with applicable screws by default for the 120 degree bolt pattern and utilizes lock

nuts for securing the gauge. See drawing Section 10 for installation details. The lock nuts need to be

removed from the back before removing the screws from the case.

CAUTION: The customer will need to take caution to not over tighten the bolts since cracking the

front case ring is possible.

HDI 2522 Position Indicator Gauge

IECEX/ATEX User’s Manual – HDI 2522, Rev A | November,2019

3.B Cables and Routing

See Section 9 for cable connections. Cable assemblies are built with an instrument grade cable with

user defined cable lengths with preinstalled connectors allowing for simple plug and play installation for

most applications. HDI may provide an open lead cable for output options or for location junction box

termination for common cable runs of multiple pair cables, etc. Changing inline cable length does not

require re-calibration of the HDI 2522.

CAUTION: It is extremely important to pay close attention to cable routing as to avoid noise sources

that may impact gauge operation. HDI signal cable must be routed at least 6 inches from high voltage

cable, 110 Volts and above.

Section 4 – Gauge Functions

4.A Overview

The following illustration will be used for general reference in explaining operation of the 2522

gauge. There are two primary modes utilized with the 2522 gauge: run mode and configuration

mode. Configuration mode will be utilized for setting the calibration of the unit but also contains all

gauge settings.

Indice

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