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Reference Manual

24625020, Rev AA

Installing the Electronics Control Unit

March 2017

Installing the Electronics Control Unit

Figure 3-13. 'Two-out-of-two' Configuration Using Normally-open Contacts (Hydratect 2462 A and C)

A. To trip device.
B. Relays shown in de-energized state (see

page 9

C. To alarm annunciator.

3.5.3

Preparing the fault and status relay cables
(for the Hydratect 2462E)

The Hydratect 2462 Electronics Control Unit (“Control Unit”) uses normally-open and
normally-closed switch outputs for fault and status indication.

The outputs are available on a pair of 14-way Klippon connectors: PL204 and PL404.

Procedure for making connections to the switched outputs

Remove the front panel from the Control Unit case and store it in a safe place.

(This is described in detail on

“Fitting cable glands” on page 22

. The panel has

mounted on it all the electronic circuitry and must be protected against adverse
conditions such as heat, dust, and static electricity).

Route the fault/status cable from the external equipment to the Control Unit
through suitable ducting (conduit).

Assemble the cable gland and fit it to the underside of the Control Unit.

Screened cables must be used. Ensure there is a good annular (ring-shaped)
contact between the cable screen and cable gland. Allow for cable conductors of
length 300 mm inside the Control Unit, and twist the power pairs together.

PL204 (Channel 1)

PL404 (Channel 2)

N. O.
Status

N. O.
Fault

N. O.
Status

N. O.
Fault

Summary of Contents for Mobrey Hydratect 2462

Page 1: ...Reference Manual 24625020 Rev AA March 2017 Mobrey Hydratect 2462 Steam Water Detection System ...

Page 2: ......

Page 3: ...d before control or signal leads are connected The ground earth connections must have a current rating of 25 A Avoid using unsafe equipment The equipment may be unsafe if any of the following statements apply Equipment shows visible damage Equipment has failed to perform an intended operation Equipment has been stored in unfavorable conditions Equipment has been subjected to severe physical stress...

Page 4: ...he electronics unit to be isolated from the ac supply the supply must be routed through a switch or circuit breaker The switch or circuit breaker must be within easy reach of the operator and must be clearly identified as the means of supply isolation The maximum current drawn from the supply must be limited by a fuse or trip to a maximum of 13 A Fuses Before switching on the equipment check that ...

Page 5: ...trode 8 1 6 3 LED and relay states for electrodes 9 2Section 2 Installing the electrodes 2 1 Electrode installation methods 11 2 2 Mounting an electrode to an insert 11 2 2 1 Welding the electrode insert to a pipe 12 2 2 2 Fitting the electrode insert cover part one 13 2 2 3 Fitting the electrode 15 2 2 4 Fitting the electrode insert cover part two 16 2 3 Mounting electrodes on a manifold 18 2 4 C...

Page 6: ...5Section 5 Electrodes Servicing 5 1 Service summary 47 5 1 1 Safety precautions 47 5 2 Periodic check 47 5 3 Repairing an electrode 48 5 4 Periodic system overhaul 50 5 5 Electrode replacement parts 50 6Section 6 Electronics Servicing 6 1 Fault diagnosis 51 6 2 Correcting a fault 52 6 2 1 Correcting a power loss fault 52 6 2 2 Correcting electrode connection faults 53 6 3 Electrode contamination 5...

Page 7: ...ics control unit Section A Specifications and Data contains specifications and other reference data including dimensional drawings 1 2 Product recycling disposal Recycling of equipment and packaging should be taken into consideration and disposed of in accordance with local and national legislation regulations 1 3 What the Hydratect 2462 does The Hydratect 2462 system is the electronic alternative...

Page 8: ...ect 2462 Electronics Control Unit A Wall mounting brackets lugs C Alarm and trip signal output B M6 earthing grounding stud Front view of electronics control unit B A Example of Hydratect 2462 system with the electronics control unit and horizontal pipe run with mounted electrodes and covers C ...

Page 9: ...nation detection To prevent a build up of contamination causing a false indication a contamination detection circuit operates in parallel with the steam water detection An error threshold for the contamination detection circuit can be set for high sensitivity or low sensitivity by using jumpers on a PCB The circuit can be switched off if not required See Setting the printed circuit board PCB jumpe...

Page 10: ... High water level detection in a drain pot Figure 1 2 on page 5 shows a system for detecting a high water level in a drain pot attached to a superheat steam line In this system example a Mobrey In line Manifold with two electrodes are used to detect the same level The electrode outputs of both Hydratect channels 1 and 2 are connected in a one out of two configuration inside the electronics control...

Page 11: ...en water is detected at both the high and the high high water level electrodes Further information is in Section 3 Installing the Electronics Control Unit The illustrated Hydratect 2462 system uses a sidearm manifold for detecting intermediate water levels between high and low Connection information for the manifold pipework is in Figure 1 4 on page 6 Note the following points The connecting pipew...

Page 12: ... signal output from Control Unit C Low level electrode D Low low level electrode Figure 1 4 Manifold Connection Details A Steam connection D Drain connection B Water connection E Cover mounting blocks four positions C Hanger for suspending the manifold in position F Pipe insulation shown by dashed outline Pipe run slope gradient 1 in 50 minimum Installation should follow national and station pract...

Page 13: ...2 Electronics Control Unit the resistance forms the lower half of a potential divider across which an alternating driving signal is applied The signal amplitude of the potential divider output is high for steam 6 V and low for water 3 V Two conductivity values 0 6 S cm for high sensitivity and 1 6 S cm for low sensitivity are selectable to suit the operating conditions and the purity of the boiler...

Page 14: ... 2 k and 100 k for typical boiler water and a resistance greater than 10 M for steam Each electrode connection is terminated individually through a crimped nickel terminal ring to enable the Hydratect 2462 Electronics Control Unit to detect an open circuit Details for the correct connections are given in Section 3 Installing the Electronics Control Unit To avoid electrolytic action the electrode i...

Page 15: ...zed Energized Connection in electrode sense element is broken On Off On De energized Energized Connection in electrode ground is broken On Off On De energized Energized Connection to ground sense is broken electrode in water On Off On De energized Energized Connection to ground sense is broken electrode in steam On On Off De energized De energized System state Front panel LEDs Relays Steam Water F...

Page 16: ...10 Reference Manual 24625020 Rev AA Introduction March 2017 Introduction ...

Page 17: ... the pipe or manifold or 1 5 in 38 mm if on opposite sides Table 2 1 Available Electrodes 2 2 Mounting an electrode to an insert Mounting an electrode on an insert involves four steps 1 Welding the insert to the pipe see Welding the electrode insert to a pipe on page 12 2 Fitting the base plate of an electrode insert cover see Fitting the electrode insert cover part one on page 13 3 Fitting the el...

Page 18: ...nsert part number 24673540B Any debris must be removed from the pipe work before testing the system 2 Fit the electrode insert into the prepared aperture ensuring that the orientation slot is pointing downwards 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 90 5 1 06 in 27 mm 0 04 in 1 mm nomin...

Page 19: ...nsert if required Electrodes should be spaced apart by a minimum of 3 in 76 mm 2 2 2 Fitting the electrode insert cover part one Part one of the cover fitting procedure 1 Dismantle the electrode insert cover assembly part number 24670118A into its component parts see Figure 2 1 on page 14 2 Screw the base plate to the electrode insert and tighten it with a strap wrench see Figure 2 2 on page 14 Af...

Page 20: ...ing complete with cable gland C Base plate complete with two pairs of earthing grounding screws and washers Figure 2 2 Base Plate Fitting A Base plate complete with two pairs of earthing grounding screws and washers B Electrode insert with orientation slot pointing downwards welded to a pipe run C Horizontal pipe run D Vertical pipe run The base plate is screwed into the insert on the same thread ...

Page 21: ...n sales office 2 To minimize thread seizure problems lightly coat the insert thread with anti seize compound part number 830007220 3 Ease the electrode into the insert and then turn the electrode fixing nut clockwise with your fingers to engage the threads Figure 2 4 on page 16 4 Use a long reach 25 mm AF socket spanner to gradually tighten the electrode fixing nut until the electrode does not rot...

Page 22: ...rocedure Part two of the cover fitting procedure 1 Fit the cylindrical housing positioning the cable gland downwards for horizontal pipes and as close as possible to downwards for vertical pipes see Figure 2 5 on page 17 2 Fit the top plate and two stud bolts and secure the plate with the two knurled nuts and washers see Figure 2 5 on page 17 Even if the electrode cable is soon to be connected it ...

Page 23: ...trodes March 2017 Installing the electrodes 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 C D A B ...

Page 24: ...Install electrodes in the manifold ports The fitting procedure is described in Fitting the electrode on page 15 5 Replace the electrode covers and secure them 2 4 Customized manifolds Figure 2 6 on page 19 show details of two and four port customized manifolds These manifolds can be made to order to customer requirements They are side coupled to the connecting pipework and vertically mounted Separ...

Page 25: ...g the electrodes Figure 2 6 Mobrey Customized Sidearm Manifolds 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 Top view E A B C D Side view ...

Page 26: ...20 Reference Manual 24625020 Rev AA Installing the electrodes March 2017 Installing the electrodes ...

Page 27: ...weight c The case must be bonded to ground earth through a suitably rated cable and grounding earthing point d Control Unit mounting and grounding earthing procedures are in the section Mounting the Hydratect 2462 Control Unit on page 23 3 Select the various Hydratect 2462 system configuration options using the jumpers plug links on the internal printed circuit board PCB See Setting the printed ci...

Page 28: ...r mounting the glands has been restricted to that shown in Figure 3 1 The only constraint within this area is that the distance between the peripheries of adjacent holes must not be less than 9 mm When only one channel is required the holes for this should be located towards the rear of the Control Unit this leaves the maximum amount of room between cables and the PCB Fitting cable glands procedur...

Page 29: ...e wall by screwing or bolting through the brackets 4 Connect the ground earth stud to a suitable grounding earthing point This connection must have a rating of 25 A 3 4 Setting the printed circuit board PCB jumpers Various configuration options on the front panel PCB can be selected by using jumpers 1 that plug into a DIL pin strip headers labeled PL203 and PL403 The configuration options are Norm...

Page 30: ...403 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 Electrode type Series III Electrode Status relay operation Relay non latching Relay latched until reset Water normal with high sensitivity Spare Series III electrode type Contamination and error detection ena...

Page 31: ...lling the Electronics Control Unit Figure 3 4 PCB Connectors and Jumper Locations A PCB jumpers for setting configuration options See Figure 3 2 and Figure 3 3 on page 24 for jumper details Hydratect Channel 2 Hydratect Channel 1 PL404 PL204 PL101 PL201 PL406 PL206 PL403 PL203 A A PL405 PL205 ...

Page 32: ...le 3 1 may affect system performance For security reasons use continuous cable runs instead of junction boxes Table 3 1 Electrode Cable Availability Connecting the cable to an electrode 1 Remove the electrode cable from its packaging being careful not to lose the bag of crimp terminations for the electronics unit end of the cable 2 Remove the top plate securing nuts from the electrode cover Figure...

Page 33: ...en wire to achieve thus The cable screen must not be connected to ground earth at the electrode end of the cable 7 Replace the top plate of the electrode cover and fit the top plate securing nuts Coat the threads with a high temperature anti seize compound 8 Tighten the cable gland Figure 3 5 Insert mounted Electrode Cover Details A Ground earth screw D Top plate securing nuts B Housing cylinder E...

Page 34: ...An effective seal against electromagnetic interference is made with good annular ring shaped contact with the RF cable gland Trim the insulation to leave about 20 mm of metal foil exposed which can be folded back over the insulation Make sure this foil cover is the part clamped by the screen of the gland when it is tightened Be careful not to damage the drain wire which can be clamped as you would...

Page 35: ...nector on electrode cable C Connector on Hydratect 2462 front panel printed circuit board PL205 Channel 1 and PL405 Channel 2 Figure 3 8 Fitting 3m Electrode Cable to 8 way Connector PL205 and PL405 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 Red Red Black Black B C A 1 2 3 ...

Page 36: ...ontact between the cable screen and cable gland Allow for cable conductors of length 300 mm inside the Control Unit and twist the power pairs together The fault and status cable should not be shared with electrode or power wires in the same cable 4 Prepare the fault status cable for fitting to the Klippon connector by stripping the end of each conductor and crimping on the pins required Remove onl...

Page 37: ... 9 B External connections see Figures 3 10 to 3 14 E PL204 Channel 1 or PL404 Channel 2 on control unit C Latch reset switch if required Figure 3 10 One out of two Configuration Using Normally closed Contacts Hydratect 2462 A and C A To trip device C Relays shown in de energized state see page 9 B To alarm annunciator C B D E N O Status N O Fault N C Status N C Fault A 10 9 8 7 6 5 4 3 2 1 C A B P...

Page 38: ...elays shown in de energized state see page 9 B To alarm annunciator Figure 3 12 Two out of two Configuration Using Normally closed Contacts Hydratect 2462 A and C A To trip device C Relays shown in de energized state see page 9 B To alarm annunciator PL204 Channel 1 PL404 Channel 2 N O Status N O Fault N O Status N O Fault C A B 8 7 4 3 8 7 4 3 C PL204 Channel 1 N C Fault N C Status N C Fault N C ...

Page 39: ...nnections to the switched outputs 1 Remove the front panel from the Control Unit case and store it in a safe place This is described in detail on Fitting cable glands on page 22 The panel has mounted on it all the electronic circuitry and must be protected against adverse conditions such as heat dust and static electricity 2 Route the fault status cable from the external equipment to the Control U...

Page 40: ...e pin 5 Fit the cable to a Klippon connector by screwing in the crimped on pins Figure 3 14 on page 35 6 Repeat steps 2 to 4 for the second channel The fault and status cables are now ready for connection to the front panel of the Control Unit Remember however that it is easier to prepare all the cables before connecting them to the front panel Note In a Hydratect 2462 system the normal state of a...

Page 41: ...t and Status reset Connections Hydratect 2462E A Status Fault cable Klippon connector D Relays shown in de energized state see page 9 B Latch reset switch if required E PL204 Channel 1 or PL404 Channel 2 on control unit C External connections B C D E N O A 10 9 8 7 6 5 4 3 2 1 N C C N C N O C N O N C C N C N O C 11 12 13 14 Fault Fault Status Status ...

Page 42: ...ble from the external supply to the Control Unit through suitable ducting conduit 3 Assemble the cable gland and fit it to the underside of the Control Unit Screened cables and RF cable glands to EN61010 clause 6 10 2 2 must be used Ensure there is a good annular ring shaped contact between the cable screen and cable gland Allow for cable lengths of 300 mm inside the unit Twist the power pairs tog...

Page 43: ...procedure 1 Take the front panel and plug the cables for Hydratect channels 1 and 2 into the relevant connectors on the PCB referring to Figure 3 16 on page 38 2 Connect the ground earth bonding lead from the case to the grounding earthing point on the front panel 3 Fit the front panel of the Control Unit into the case ensuring that no cable conductors are trapped between panel and case 4 Secure t...

Page 44: ...ork where possible Use shielded screened cables for all connections making sure a good annular ring shaped contact is made with a good quality RF cable gland Do not run cables over the PCB where possible Figure 3 16 Connector Locations on Front Panel PCB A Connector for plugging in fault and status outputs and status reset input cable B Connector for plugging in power supply connection cable C Gro...

Page 45: ...depends to some extent on the ancillary equipment installed in your system You will need A resistor to simulate steam presence 10 M A resistor to simulate water presence 56 k low sensitivity or 120 k high sensitivity A resistor to simulate electrode contamination 270 low sensitivity or 820 high sensitivity A fault relay reset push button This is required only when the latched relay option is confi...

Page 46: ...taken to ensure that no hazard can result from this operation 3 Verify the Control Unit jumpers are set for the required mode of operation See Setting the printed circuit board PCB jumpers on page 23 to check this 4 Check the front panel LED states are as expected LED off STEAM LED off WATER LED on 5 Check the fault and status relays are as expected a Fault relay energized b Status relay energized...

Page 47: ...If the Status Relay Operation setting is set to latched the Control Unit must first be power cycled to set the status relay back to the energized position 10 Check the front panel LED states are as expected LED on STEAM LED off WATER LED on 11 Check on the fault and status relays are as expected a Fault relay de energized b Status relay energized 12 Remove the resistor Check that the LEDs and faul...

Page 48: ...setting is set to latched the Control Unit must be power cycled to set the status relay back to the energized position Check the front panel LEDs and fault and status relays have returned to their original states as shown in steps 4 and 5 21 Replace and secure the electrode cover 22 Remove the safety function bypass and otherwise restore normal operation 4 2 2 Suggested test for steam normal setti...

Page 49: ...xpected LED off STEAM LED off WATER LED on 6 Check the fault and status relays are as expected a Fault relay energized b Status relay de energized 7 To check system operation in steam remove the resistor 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 8 Check the front panel LED states are as expec...

Page 50: ...elay de energized b Status relay de energized 13 Remove the resistor 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 8 and 9 14 Remove a knurled nut from the electrode and disconnect the white c...

Page 51: ...ctor lead from ground by removing the screw securing it to the manifold or if using an insert by removing the electrode cover base plate 19 Check the front panel LED states are as expected LED on STEAM LED on WATER LED off 20 Check the fault and status relays are as expected a Fault relay de energized b Status relay energized 21 Reconnect the black conductor lead Check the front panel LEDs and fau...

Page 52: ...46 Reference Manual 24625020 Rev AA System Testing March 2017 System Testing ...

Page 53: ...rvice Ensure that any tripping action likely to occur is inhibited Where automatic control actions could be initiated these actions must be inhibited outside the Hydratect 2462 system before starting the service Advise the operators of any unusual effects likely to occur during the service Where operator warning alarms are fitted operators must be informed which alarms will be affected and for how...

Page 54: ...xternal ceramic insulator of the electrode or from the electrode nut Steam will always tend to emanate from a leak even if the electrode is immersed in water This is due to the temperature in a pressurized system causing water to flash off to steam as it reaches ambient pressure 5 Check the electrode connections are in good condition and are tightly secured Tighten any loose connection 6 Re fit an...

Page 55: ...nd or a defective seal a Examine the seating surface of the electrode to ensure that it is clean and free from surface deterioration b If the electrode is able to perform an effective seal then it can be used again However to ensure absolute cleanliness wipe the internal insulator of the electrode with a clean cloth Alternatively if the seating surface is eroded or if there is a possibility of a l...

Page 56: ... system overhaul During a system overhaul the Hydratect 2462 system must be protected against mechanical damage Protect it using any rigid material such as packing cases that prevents impact damage When the system overhaul is complete remove the protective material and use the periodic check procedure on page 47 to verify the correct operation of the Hydratect 2462 system 5 5 Electrode replacement...

Page 57: ...tus normal Power supply loss Off Off Off De energized De energized Electrode contaminated or short circuited On Off On De energized Energized Connection to electrode sense element broken On Off On De energized Energized Connection to electrode ground broken On Off On De energized Energized Connection to ground sense broken electrode in water On Off On De energized Energized Connection to ground se...

Page 58: ...fault that is reducing the power supply card output 3 Switch off the external power supplies to the Control Unit 4 Undo the two screws securing the front panel of the Control Unit and then carefully withdraw the front panel from the case 5 Remove the connectors from the power supply and from the logic card 6 Remove the power supply card and the logic card 7 Return the power supply card and logic c...

Page 59: ...y lead that has broken off Remember that all connections to the electrode must be made individually Do not twist any two or more wires together The ground and ground sense for example must be made to separate ground screws 6 Replace the cable cover and secure Tighten the cable gland 7 Switch on the external power supplies to the Control Unit and then check the system as described in Section 4 Syst...

Page 60: ...ment procedure 1 Switch off the external power supplies to the Hydratect 2462 Electronics Control Unit Control Unit 2 Undo the two screws securing the front panel of the Control Unit and then carefully withdraw the front panel from the case 3 Remove the connectors from the power supply and from the logic card 4 Remove the power supply card and the logic card Five screws and five threaded pillars m...

Page 61: ...ement 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 24620501B 24620502A 360190350 2462C 24620511B 24620502A K9633 2462E 24620503B 24620504A 360190350 ...

Page 62: ...56 Reference Manual 24625020 Rev AA Electronics Servicing March 2017 Electronics Servicing ...

Page 63: ...t detection capabilities Broken wire to electrode and short circuit to ground Any component failure to prEN50156 Status relay output one per channel Energized for steam or water normal status Separate normally open and normally closed contacts Hydratect 2462A and 2462C 250 Vac or 125 Vdc maximum switched voltage 8 A maximum switched current 8 Adc 30 V dc 1 08 Adc 60 Vdc 0 2 Adc 125 Vdc 2000VA ac r...

Page 64: ...nal drawing Figure A 1 Hydratect 2462 Electronics Control Unit A Outline of front panel B M6 earth ground stud Dimensions are in inches mm Overall depth 100 mm case and panel 3 mm brackets 4 5 mm bolt heads and washers 9 02 229 8 46 215 7 72 196 0 98 25 3 74 95 7 48 190 7 48 190 7 72 196 ø0 3 ø8 A B 3 78 96 ...

Page 65: ......

Page 66: ...ions 6021 Innovation Blvd Shakopee MN 55379 USA 1 800 999 9307 or 1 952 906 8888 1 952 949 7001 RFQ RMD RCC Emerson com Standard Terms and Conditions of Sale can be found at www Emerson com en us Terms of Use The Emerson logo is a trademark and service mark of Emerson Electric Co Mobrey is a registered trademark of Rosemount Measurement Ltd All other marks are the property of their respective owne...

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