Emerson Mobrey Hydratect 2462 Reference Manual
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Emerson Mobrey Hydratect 2462 Reference Manual

Emerson Mobrey Hydratect 2462 Reference Manual

Steam/water detection system
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Reference Manual
24625020, Rev AA
March 2017
™
Mobrey
Hydratect 2462
Steam/Water Detection System

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Summary of Contents for Emerson Mobrey Hydratect 2462

  • Page 1 Reference Manual 24625020, Rev AA March 2017 ™ Mobrey Hydratect 2462 Steam/Water Detection System...
  • Page 3 Reference Manual Title Page 24625020, Rev AA March 2017 ™ Mobrey Hydratect 2462 Read this manual before working with the product. For personal and system safety, and for optimum product performance, make sure you thoroughly understand the contents before installing, using, or maintaining this product. Failure to follow these guidelines could result in death or serious injury.
  • Page 4 The products described in this document are not designed for nuclear-qualified applications. Using non-nuclear qualified products in applications that require nuclear-qualified hardware or products may cause inaccurate readings. For information on Rosemount nuclear-qualified products, contact your local Emerson Process Management Sales Representative. Title Page...

  • Page 5: Table Of Contents

    Reference Manual Table of Contents 24625020, Rev AA March 2017 Contents 1Section 1: Introduction Using this manual............1 Product recycling/disposal .
  • Page 6 Reference Manual Table of Contents 24625020, Rev AA March 2017 3.5.3 Preparing the fault and status relay cables (for the Hydratect 2462E) ........33 3.5.4 Preparing the power supply cables .

  • Page 7: Using This Manual

    Introduction Reference Manual March 2017 24625020, Rev AA Section 1 Introduction Using this manual The sections in this manual provide information on installing, operating, and maintaining ™ the Mobrey Hydratect 2462. The sections are organized as follows: contains the procedures for mounting electrodes to a Section 2: Installing the electrodes pipe or manifold.
  • Page 8 Reference Manual Introduction 24625020, Rev AA March 2017 Figure 1-1. The Hydratect 2462 Electronics Control Unit Front view of electronics control unit Example of Hydratect 2462 system with the electronics control unit, and horizontal pipe run with mounted electrodes and covers. A.

  • Page 9: Steam And Water Detection

    Reference Manual Introduction 24625020, Rev AA March 2017 1.3.1 Steam and water detection On each of the two electrically-isolated channels, the Hydratect 2462 system detects steam and water by using the differences in their resistance and conductivity (Figure 1-5 on page Detection of steam and water is indicated by the illumination of a red or green LED on the front panel of the Hydratect 2462 Electronics Control Unit...

  • Page 10: The Hydratect 2462 Variants

    Reference Manual Introduction 24625020, Rev AA March 2017 Electrode signals, status outputs (relays), and fault outputs (relays) can be validated by connecting both Hydratect channels in a 'one-out-of-two' or 'two-out-of-two' tripping scheme. Typical applications are shown in Figure 1-3 on page 6 Figure 1-2 on page Further information is in Section 3: Installing the Electronics Control...

  • Page 11: Water Level Detection In A Boiler Drum

    Reference Manual Introduction 24625020, Rev AA March 2017 Figure 1-2. High Water Level Detection in Drain Pot A. Superheat steam line. D. Drain line. B. Drain pot. E. High alarm signal. C. Isolation valve. F. In-line manifold with two electrodes (channels 1 and 2). 1.5.2 Water level detection in a boiler drum A Hydratect 2462 system for detecting high and low water levels in a boiler drum is shown...
  • Page 12 Reference Manual Introduction 24625020, Rev AA March 2017 Figure 1-3. Water Level Detection in Boiler Drum A. High-high level electrode. E. High alarm and trip signal output from Control Unit. B. High level electrode. F. Low alarm and trip signal output from Control Unit. C.

  • Page 13: How Electrodes Operate

    Reference Manual Introduction 24625020, Rev AA March 2017 How electrodes operate 1.6.1 Conductivity and resistance values of steam and water Figure 1-5 shows conductivity and resistance values of steam, pure water, and typical boiler water. The significant difference between the resistance of steam and boiler water allows the Hydratect 2462 system to differentiate between the two.

  • Page 14: The Signal Returned By The Electrode

    Reference Manual Introduction 24625020, Rev AA March 2017 1.6.2 The signal returned by the electrode Figure 1-6, the signal returned by the electrode is proportional to the resistance between the electrode tip and ground (earth). This signal is used to detect the presence of steam or water.

  • Page 15: Led And Relay States For Electrodes

    Reference Manual Introduction 24625020, Rev AA March 2017 1.6.3 LED and relay states for electrodes Table 1-2 Table 1-3 on page 9 summarizes the ways in which the LEDs and relays of Hydratect reflect the system state for electrodes. Note “Setting the printed circuit board (PCB) jumpers”...
  • Page 16 Reference Manual Introduction 24625020, Rev AA March 2017 Introduction...

  • Page 17: Electrode Installation Methods

    Electrode covers are available which offer a basic level of mechanical and environmental protection, but have not been assessed to any particular protection standards. Emerson recommend that the installer gives particular attention to the location and environment where the equipment is being installed and, if necessary, fit additional protective measures.

  • Page 18: Welding The Electrode Insert To A Pipe

    Reference Manual Installing the electrodes 24625020, Rev AA March 2017 Note “Mounting electrodes on a manifold” on page 18 for the alternative mounting method. 2.2.1 Welding the electrode insert to a pipe Take care not to damage the thread or conical seat on the Series III electrode insert. The cast/lot number on the insert must not be obscured by welding.

  • Page 19: Fitting The Electrode-Insert Cover (Part One)

    Reference Manual Installing the electrodes 24625020, Rev AA March 2017 Check that the inner edge of the circular groove around the electrode insert body is level with the bottom of the weld preparation. Horizontal pipe run Weld preparation Weld the electrode insert in place. The welding procedure must comply with the National or Regional Codes of Practice for Joining Dissimilar Metals.
  • Page 20 Reference Manual Installing the electrodes 24625020, Rev AA March 2017 Figure 2-1. Individual Electrode-insert Cover Assembly of Component Parts A. Top plate (complete with securing studs, washers, and nuts). B. Cylindrical housing (complete with cable gland). C. Base plate (complete with two pairs of earthing/grounding screws and washers). Figure 2-2.

  • Page 21: Fitting The Electrode

    If the electrode or the electrode insert seat is damaged in any way, contact your local Emerson sales office. To minimize thread seizure problems, lightly coat the insert thread with anti-seize compound (part number 830007220).

  • Page 22: Fitting The Electrode-Insert Cover (Part Two)

    Reference Manual Installing the electrodes 24625020, Rev AA March 2017 Figure 2-4. Electrode Fitting A. Mobrey Series III Electrode. C. Horizontal pipe run. B. Installed base plate of insert cover. D. Vertical pipe run. “Fitting the electrode” on page 15 for the recommended tightening procedure.
  • Page 23 Reference Manual Installing the electrodes 24625020, Rev AA March 2017 Figure 2-5. Electrode-insert Cover Fitting (Part Two) A. Cylindrical housing with cable gland positioned downwards. B. Top plate with stud bolts, fixing nuts, and washers. C. Horizontal pipe run D. Vertical pipe run. Installing the electrodes...

  • Page 24: Mounting Electrodes On A Manifold

    Reference Manual Installing the electrodes 24625020, Rev AA March 2017 Mounting electrodes on a manifold Note “Mounting an electrode to an insert” on page 11 for the alternative mounting method. Procedure Remove the electrode covers and port dust caps. Temporarily cover the manifold ports with heat-resistant material, to prevent the ingress of weld splatter and dirt.
  • Page 25 Reference Manual Installing the electrodes 24625020, Rev AA March 2017 Figure 2-6. Mobrey Customized Sidearm Manifolds Top view Side view A. Steam connection. B. Water connection. C. Vent connection or capped. D. Drain connection. F. Individual-electrode cover (cutaway to show electrode). Allow at least 210 mm (8.3 in.) for electrode removal.
  • Page 26 Reference Manual Installing the electrodes 24625020, Rev AA March 2017 Installing the electrodes...

  • Page 27: Installation Summary

    Reference Manual Installing the Electronics Control Unit 24625020, Rev AA March 2017 Section 3 Installing the Electronics Control Unit Installation summary The basic steps to installing the Hydratect 2462 Electronics Control Unit (“Control Unit”) are as follows: Fit cable glands to the bottom of the Control Unit. For this, holes need to be cut through 1.6 mm of stainless steel.

  • Page 28: Fitting Cable Glands

    Reference Manual Installing the Electronics Control Unit 24625020, Rev AA March 2017 Fitting cable glands Cables must enter through suitably-rated cable glands to ensure the Hydratect 2462 Electronics Control Unit (“Control Unit”) interior remains sealed from moisture ingress. The type of glands used will vary according to locale and application. It is essential to use screened cables and RF glands that give a good annular (ring-shaped) connection to the cable screen (shield) to ensure EMC compliance in European installations.

  • Page 29: Mounting The Hydratect 2462 Control Unit

    Reference Manual Installing the Electronics Control Unit 24625020, Rev AA March 2017 Mounting the Hydratect 2462 Control Unit To protect the printed circuit boards (PCBs), the Hydratect 2462 Electronics Control Unit (“Control Unit”) must be mounted without the front panel fitted. Mounting procedure Note The Control Unit weight is 2.8 kg (6.2 lb).
  • Page 30 Reference Manual Installing the Electronics Control Unit 24625020, Rev AA March 2017 Figure 3-2. PCB Jumper Settings for Configuration Options (PL203 and PL403) Normal condition Steam normal Water normal Low sensitivity (1.6 s/cm) High sensitivity (0.6 s/cm) Electrode contamination Detection disabled Detection enabled Low sensitivity High sensitivity...
  • Page 31 Reference Manual Installing the Electronics Control Unit 24625020, Rev AA March 2017 Figure 3-4. PCB Connectors and Jumper Locations Hydratect Channel 2 Hydratect Channel 1 PL404 PL204 PL101 PL201 PL403 PL206 PL203 PL406 PL405 PL205 A. PCB jumpers for setting configuration options. (See Figure 3-2 Figure 3-3 on page 24 for jumper details).

  • Page 32: Connecting The Electronics

    “Preparing electrode cables for connection to the control unit” on page  Table 3-1 lists the four-core electrode cables available from Emerson. The Hydratect 2462 systems uses all four leads (conductors) of these cables. Note The use of cables that are not listed in Table 3-1 may affect system performance.
  • Page 33 Reference Manual Installing the Electronics Control Unit 24625020, Rev AA March 2017 On the electrode, secure the red and white conductors under the crinkle-washers and knurled nuts (Figure 3-6). Ensure that there is a stress-free run of cable inside the electrode cover and the cable gland is oriented correctly.
  • Page 34 Reference Manual Installing the Electronics Control Unit 24625020, Rev AA March 2017 Preparing electrode cables for connection to the control unit Note This following procedure assumes that the electrode cable has already been connected to the electrode as described in “Connecting the cable to an electrode”...
  • Page 35 Reference Manual Installing the Electronics Control Unit 24625020, Rev AA March 2017 Figure 3-7. Fitting 10/18/30 m Electrode Cable to 8-way Connector (PL205 and PL405) Black Black A. Termination screws are on this side. B. Connector on electrode cable. C. Connector on Hydratect 2462 front panel printed circuit board: PL205 (Channel 1) and PL405 (Channel 2). Figure 3-8.

  • Page 36: Preparing The Fault And Status Relay Cable (For The Hydratect 2462A And 2462C)

    Reference Manual Installing the Electronics Control Unit 24625020, Rev AA March 2017 3.5.2 Preparing the fault and status relay cable (for the Hydratect 2462A and 2462C) The Hydratect 2462 Electronics Control Unit (“Control Unit”) uses normally-open and normally-closed switched outputs for fault and status indication. The outputs are available on a pair of 10-way Klippon connectors: PL204 and PL404.
  • Page 37 Reference Manual Installing the Electronics Control Unit 24625020, Rev AA March 2017 Figure 3-9. Status, Fault and Status Reset Connections (Hydratect 2462 A and C) N. O. Status N. C. Status N. O. Fault N. C. Fault A. Status/Fault cable Klippon connector. D.
  • Page 38 Reference Manual Installing the Electronics Control Unit 24625020, Rev AA March 2017 Figure 3-11. 'One-out-of-two' Configuration Using Normally-open Contacts (Hydratect 2462 A and C) PL404 (Channel 2) PL204 (Channel 1) N. O. N. O. Status Status N. O. N. O. Fault Fault A.

  • Page 39: Preparing The Fault And Status Relay Cables

    Reference Manual Installing the Electronics Control Unit 24625020, Rev AA March 2017 Figure 3-13. 'Two-out-of-two' Configuration Using Normally-open Contacts (Hydratect 2462 A and C) PL404 (Channel 2) PL204 (Channel 1) N. O. N. O. Status Status N. O. N. O. Fault Fault A.
  • Page 40 Reference Manual Installing the Electronics Control Unit 24625020, Rev AA March 2017 The fault and status cable should not be shared with electrode or power wires in the same cable. Prepare the fault/status cable for fitting to the Klippon connector, by stripping the end of each conductor and crimping on the pins required.
  • Page 41 Reference Manual Installing the Electronics Control Unit 24625020, Rev AA March 2017 Figure 3-14. Status, Fault and Status-reset Connections (Hydratect 2462E) N. O. Fault N. C. N. C. Fault N. O. N. O. Status N. C. N. C. Status N. O. A.

  • Page 42: Preparing The Power Supply Cables

    Reference Manual Installing the Electronics Control Unit 24625020, Rev AA March 2017 3.5.4 Preparing the power supply cables Each Hydratect channel has an independent power supply input that can receive power from the following sources: 230 Vac or 115 Vac (for Hydratect 2462A and 2462E) ...

  • Page 43: Connecting The Prepared Cables To The Front Panel

    Reference Manual Installing the Electronics Control Unit 24625020, Rev AA March 2017 Figure 3-15. Power Supply Connections 20 to 60 Vdc 115 Vac 230 Vac Not connected Not connected Not connected A. Connector on printed circuit board (PCB): PL101 (Channel 1) and PL301 (Channel 2). B.
  • Page 44 Reference Manual Installing the Electronics Control Unit 24625020, Rev AA March 2017 If the installation is adversely affected by the operation of nearby equipment, then re-routing the cables to these instructions should improve performance: Avoid bundling the cables together.  Ensure that cables run against earthed (grounded) metalwork, where possible.

  • Page 45: Test Summary

    Reference Manual System Testing 24625020, Rev AA March 2017 Section 4 System Testing Test summary Section 4 contains the procedures for testing the two basic configurations of the Hydratect 2462 system: (1) water-normal and (2) steam-normal Use the procedures to check the operation of the Hydratect 2462 system after installation completion or any configuration change.

  • Page 46: Testing The Electrodes

    Reference Manual System Testing 24625020, Rev AA March 2017 Testing the electrodes 4.2.1 Suggested test for water-normal setting Note This test requires the electrode to be in its normal state (e.g. immersed in water). Inspect the accessible parts of the Control Unit and cabling for any damage, and the electrode inserts and covers for any leaks or damage.
  • Page 47 Reference Manual System Testing 24625020, Rev AA March 2017 Check the fault and status relays are as expected: Fault relay energized b. Status relay de-energized To simulate electrode contamination detection (if enabled), short the electrode sense element terminal to ground through an 820  resistor (for High Sensitivity operation) or a 270 ...

  • Page 48: Suggested Test For Steam-Normal Setting

    Reference Manual System Testing 24625020, Rev AA March 2017 Check the fault and status relays are as expected: Fault relay de-energized b. Status relay energized Reconnect the white conductor. Check the LEDs, and fault and status relays, have returned to their original states as shown in steps and 5.
  • Page 49 Reference Manual System Testing 24625020, Rev AA March 2017 To simulate the electrode in water, remove the electrode cover and short the electrode sense element terminal to ground through a 120 k resistor (when configured for High Sensitivity operation) or a 56 k resistor (when configured for Low Sensitivity operation).
  • Page 50 Reference Manual System Testing 24625020, Rev AA March 2017 To simulate electrode contamination detection (if enabled), short the electrode sense element terminal to ground through an 820  resistor (for high sensitivity operation) or a 270  resistor (for low sensitivity operation). White 820or 270...
  • Page 51 Reference Manual System Testing 24625020, Rev AA March 2017 Reconnect the white conductor. If the Status Relay Operation setting is set to latched, the Control Unit must be power cycled to set the status relay back to the energized position. Check that the LEDs, and fault and status relays, have returned to their original states as shown in steps and 9.
  • Page 52 Reference Manual System Testing 24625020, Rev AA March 2017 System Testing...

  • Page 53: Service Summary

    Reference Manual Electrodes Servicing 24625020, Rev AA March 2017 Section 5 Electrodes Servicing Service summary Section 5 describes the servicing procedure that must be followed to ensure continued and trouble-free operation of the Hydratect 2462 system. Electrodes should be examined periodically to ensure that each one is fully serviceable, as described in “Periodic check”...

  • Page 54: Repairing An Electrode

    Reference Manual Electrodes Servicing 24625020, Rev AA March 2017 Recommended periodic check procedure Inspect the electrode covers and cables. Any damaged item must be removed and a serviceable replacement part fitted. Standard replacement parts are listed in “Electrode replacement parts” on page Loosen the cable glands on the electrode covers.
  • Page 55 Reference Manual Electrodes Servicing 24625020, Rev AA March 2017 Repair procedure Isolate and drain the pipe on which the electrode is mounted, following the safety precautions listed in “Safety precautions” on page Loosen the electrode cable glands (if applicable) and remove the electrode cover. Disconnect conductors (leads) from the electrode, undo the electrode nut, and carefully remove the electrode from the port.

  • Page 56: Periodic System Overhaul

    Reference Manual Electrodes Servicing 24625020, Rev AA March 2017 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 from over tightening. Re-connect conductors (leads) to the electrode. Repeat steps for any other electrode in need of repair or replacement.

  • Page 57: Fault Diagnosis

    Reference Manual Electronics Servicing 24625020, Rev AA March 2017 Section 6 Electronics Servicing Fault diagnosis Electrical and electronic faults in the Hydratect 2462 system are indicated by the LEDs on the front panel and by the fault and status output. Table 6-1 Table 6-2 are lists of faults...

  • Page 58: Correcting A Fault

    Reference Manual Electronics Servicing 24625020, Rev AA March 2017 Table 6-3. Test Point Values Test points number Normal state – 6.0 V – 5.4 V 20 Hz, ±6 V PL206 (Channel 1) Status reference PL406 (Channel 2) – 5.7 V Error reference 20 Hz, ±6 V + 5.7 V...

  • Page 59: Correcting Electrode Connection Faults

    Reference Manual Electronics Servicing 24625020, Rev AA March 2017 Fit a new logic card and a new power supply card, securing these with the threaded pillars and screws removed in step 5. Re-fit the connectors to the power supply and logic cards, ensuring the connections are made correctly to each channel.

  • Page 60: Electrode Contamination

    Reference Manual Electronics Servicing 24625020, Rev AA March 2017 Remove the faulty electrode cable and connect a new one, as described in Section 3: Installing the Electronics Control Unit. Switch on the external power supplies to the electronics unit, and then check the system as described in Section 4: System Testing.

  • Page 61: Electronic Replacement Parts

    Reference Manual Electronics Servicing 24625020, Rev AA March 2017 Electronic replacement parts Table 6-4 lists the replacement parts recommended to be kept readily available on-site in the event of an electronics failure. Table 6-4. Replaceable Parts Hydratect variant PSU board Logic board Fuse 2462A...
  • Page 62 Reference Manual Electronics Servicing 24625020, Rev AA March 2017 Electronics Servicing...

  • Page 63: Specifications

    Specifications and Data Reference Manual March 2017 24625020, Rev AA Appendix A Specifications and Data A.1 Specifications Status relay output (one per channel) Energized for steam- or water-normal status  A.1.1 General Separate normally-open and normally-closed contacts  Product Hydratect 2462A and 2462C: ...

  • Page 64: Dimensional Drawing

    Specifications and Data Reference Manual March 2017 24625020, Rev AA A.2 Dimensional drawing Figure A-1. Hydratect 2462 Electronics Control Unit 9.02 (229) 8.46 (215) 7.72 (196) 3.78 (96) 7.48 (190) 7.72 0.98 (196) (25) 3.74 ø0.3 (ø8) (95) 7.48 (190) A.
  • Page 66 Standard Terms and Conditions of Sale can be found at: www.Emerson.com/en-us/Terms-of-Use +1 800 999 9307 or +1 952 906 8888 The Emerson logo is a trademark and service mark of Emerson Electric Co. +1 952 949 7001 Mobrey is a registered trademark of Rosemount Measurement Ltd.

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