Tyco 12B User Manual
Section: 8000
I.O.M.: 8906
Issued: 05/06
Replaces: 12/02
PENBERTHY
Installation, Operation and Maintenance
for Penberthy Electronic Water Level
Gauge
Model 12B
Serial No.
Part No.:
Enclosure Type :
Input Power :
Electrode Output :
Alarm & Trip Relay Contact Rating:
Display Outputs :
02
*Optional Door Mount Display shown *Standard Electronics Enclosure
with example probe spacing
Installation, Operation and Maintenance
Instructions
TABLE OF CONTENTS
Product Warranty . . . . . . . . . ii
1.0 Description . . . . . . . . . 1
2.0 Supply & Installation . . . . . . . . 1
2.1 Packing . . . . . . . . . 1
2.2 Wiring Requirements . . . . . . . 1
2.3 Location of Electronics . . . . . . . 2
2.4 Water Column . . . . . . . . 2
2.5 Probes . . . . . . . . . 3
2.6 Wiring . . . . . . . . . 4
2.6.1 At The Probes . . . . . . . 4
2.6.2 At the Electronic Module . . . . . 5
2.6.3 Display Panel . . . . . . . 6
2.6.3.1 Flash Programming . . . . . 7
2.6.4 Control Output . . . . . . . 7
2.6.5 Electronic Fault Output . . . . . . 7
2.6.6 Level Fault Output . . . . . . 7
2.6.7 Probe Wiring . . . . . . . 8
2.6.7.1 Systems without continuity . . . . 8
2.6.7.2 Systems with Open / Short Circuitry . . . 8
3.0 Startup And Operation . . . . . . . . 8
3.1 Water Column . . . . . . . . 8
3.2 Electronic Module Sensitivity Control . . . . . 9
3.3 System Monitor . . . . . . . . 9
3.3.1 Power Supply Fault . . . . . . 10
3.3.2 Clock Fault . . . . . . . 10
3.3.3 Continuity Monitoring . . . . . . 11
3.4 Probe Installation . . . . . . . . 11
3.5 Probe Removal . . . . . . . . 11
4.0 Detection Circuitry . . . . . . . . 12
5.0 Maintenance . . . . . . . . . 13
5.1 Water Column . . . . . . . . 13
5.2 Probes. . . . . . . . . . 13
5.3 Electronic Modules and Display(s) . . . . . 14
6.0 Spare Parts . . . . . . . . . 15
7.0 Model 12B Specifications . . . . . . . . 15
8.0 Troubleshooting . . . . . . . . . 17
9.0 Disposal at End of Useful Life . . . . . . . 17
10.0 Telephone Assistance / Factory Repair . . . . . . 18
Table of Figures
Figure # 1 – Probe Assembly . . . . . . . . 3
Figure # 2 – Standard Enclosure (up to 12 probes) . . . . . 19
Figure # 3 – Standard Enclosure (13-24 probes) . . . . . 20
Figure # 4 – Wiring Diagram (up to 12 probes) . . . . . 21
Figure # 5 – Wiring Diagram (13-24 probes) . . . . . . 22
Figure # 6 – Motherboard Layout . . . . . . . 23
Figure # 7 – Full-Size Panel Mount Display (up to 12 probes) . . . 24
Figure # 8 – Full-Size Display in NEMA 4X Enclosure (up to 12 probes) . . 25
Figure # 9 – Mini Display in NEMA 4X Enclosure (up to 12 probes) . . . 26
Figure # 10 – Mini Panel Mount Display (up to 12 probes) . . . . 27
Figure # 11 – Full-Size Panel Mount Display (13-24 probes) . . . 28
Figure # 12 – Mini Panel Mount Display (13-24 probes) . . . . 29
Declaration of Conformity . . . . . . . . 30
i
PENBERTHY PRODUCT WARRANTY
Tyco Valves & Controls Prophetstown warrants its Penberthy products as
designed and manufactured by TV&C Prophetstown to be free of defects in
the material and workmanship for a period of one year after the date of
installation or eighteen months after the date of manufacture whichever is
earliest. TV&C Prophetstown will, at its option, replace or repair any
products which fail during the warranty period due to defective material or
workmanship.
Prior to submitting any claim for warranty service, the owner must submit
proof of purchase to TV&C Prophetstown and obtain written authorization
to return the product. Thereafter, the product shall be returned to TV&C in
Prophetstown, Illinois, with freight paid.
This warranty shall not apply if the product has been disassembled,
tampered with, repaired or otherwise altered outside of TV&C
Prophetstown factory, or if it has been subject to misuse, neglect or
accident.
The responsibility of TV&C Prophetstown hereunder is limited to repairing
or replacing the product at its expense. TV&C Prophetstown shall not be
liable for loss, damage or expenses related directly or indirectly to the
installation or use of its products, or from any other cause or for
consequential damages. It is expressly understood that TV&C
Prophetstown is not responsible for damage or injury caused to other
products, buildings, personnel or property, by reason of the installation or
use of its products.
THIS IS TV&C PROPHETSTOWN’S SOLE WARRANTY AND IN LIEU OF
ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED WHICH ARE
HEREBY EXCLUDED, INCLUDING IN PARTICULAR ALL WARRANTIES
OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.
This document and the warranty contained herein may not be modified and
no other warranty, expressed or implied, shall be made by or on behalf of
TV&C Prophetstown unless made in writing and signed by the General
Manager or Director of Engineering of TV&C Prophetstown.
ii
INSTALLATION, OPERATION and MAINTENANCE MANUAL
FOR PENBERTHY Model 12B
1.0 Description
The Penberthy Model 12B is an accurate and ultra-reliable instrument for detection of
steam/water presence in subcritical pressure steam generators. The unit pr ovides up to
12 channels per unit (cascadable) for steam/water indication and is complete with
control outputs and internal system fault monitoring, Local and Remote indication and
Level Fault output. Prior to performing any work, personnel responsible for the
installation of the system should read these instructions and become familiar with the
unit. There is a patent pending on the detection and verification circuitry.
Two functional options covered by this I.O.M. may be specified. Check purchasing
documents and verify that the unit received has the options specified.
1.1 Independent Power Line Inputs (a.k.a. dual transformer option) provides
redundancy throughout the entire system.
1.2 Open/short detection
If both options are specified, the unit has at minimum either error detection or double
redundancy for its functions and complies with ANSI/ISA S84.01 – 1996 “Safety
Instrumented Systems”.
The contract drawing supplied for each installation specifies the tapping point spacing
on the water column, the number of probes and their positioning.
This I.O.M. is organized so that article 2 describes the essentials of installation and
wiring to allow initial turn-on. Articles 3 and 4, covering the same basic subjects, may
seem redundant but describe the details of operation beyond initial turn-on. They should
be perused to maximize the utility of the Model 12B.
2.0 Supply & Installation
2.1 Packing
Prior to installing this equipment clean all packing material from around the unit
and inspect for any damage that may have occurred during shipment. Any
claims for loss or damage must be filed by the purchaser with the carrier. A cop y
of the bill of lading and freight bill will be supplied on request by
TV&C – Prophetstown.
2.2 Wiring Requirements
All wiring shall be terminated in a screw type terminal block, a screwed crimp- on
terminal or a screwed lug point.
All wiring for mains in and control relays out shall be dressed away from all
probe and display wiring, bundled and tie wrapped to maintain separation.
Probes and their wiring that are in steam/vapor are essentially antennas and are
susceptible to noise pick-up. To reduce RFI/EMI pick-up, a cable with an overall
shield should be used for the probe/junction box to electronic module
connections. This is a low current line so small wire diameters are acceptable.
The maximum distance is 300’ [91M], refer to section 2.3 for other details.
Remote display wiring should be limited to 1000’ [305M]. Since I•R loss is the
distance limiter – larger wire will allow longer distances. The low level signals
used suggest that an overall shield on this cable is prudent. If the installation is
to be in an area with high electrical noise or to fully comply with EMC directives,
1
all enclosures should be specified as metallic or with a conductive coating rather
p
than the basic polymer enclosures.
Wiring shields should be terminated on both ends to the enclosures’ ground lugs
– not to circuit common.
TV&C – Prophetstown recommends that all wiring be enclosed in electrical
metallic tubing (EMI) and that drip loops are established at each enclosur e entry
point. Spiral wrap cable conduits (e.g. Greenfield, BX) should not be used.
2.3 Location of the Electronics
The section on Startup and Operation, Sensitivity Control (Section 3.2) explains
how to set the sensitivity range according to the conductivity of the water in your
application. Water with a low conductivity requires a higher sensitivity and
consequentially has greater noise susceptibility. The highest sensitivity (<1-10
μS) range limits the shielded cable distance between probe and electronic
module to 80 ft. [25m]. The intermediate sensitivity range
(10-100 μS) places an upper limit of 165 ft. [50m] for the shielded cable distance.
The lowest sensitivity greater than about 50 μS allows the shielded cable
distance to be up to 500 ft. [150m]. The coolest, most accessible location for
mounting the electronics is preferred, usually on an outside wall. Dimensions of
enclosures are shown in fig’s 2 and 3.
2.4 Water Column (Refer to Water Column I.O.M. for complete details)
The water column is fixed to the steam drum either by being welded directly to
the isolating valves or welded to flanges that mate with existing flanges on the
steam drum tapping points. A steam inlet line must be installed to provide a free
flow of steam to the Model 12B column. The steam line must slope down toward
the column (a slope of 2% is recommended). When globe valves are used as the
isolation valves, they must be installed with the stem horizontal. Ideally, the
return water leg should be horizontal. This leg may, however, be sloped down to
the drum, in which case it must be insulated. In no case should the steam line be
insulated.
Water Columns with three maximum pressure ratings are available –
850 [58 bar], 1800 [124 bar] and 3000 psi [206.9 bar] design. The fittings on
steam generators of lower pressure usually have a lesser rating. As a result, the
overall rating of a system is governed by the lowest rating of any of the
components.
The metal probe covers should be removed from the water column after it is fully
plumbed into the system and remain off until the system is in service and a
satisfactory inspection of all the probes and the associated wiring is completed.
! W A R N I N G !
The nature of the electronics, the harsh operating environment and the
potential hazards associated with live steam require that only qualified
personnel install and maintain this equipment. Without adequate qualifications,
an operator could allow live steam to escape which may cause property damage
or severe
ersonal injury.
2
2.5 Probes
The Model 12B is supplied with either of two probe styles. For applications below
525°F [274°C] / 850 psi [58 bar], an economical probe is available with a PTFE
wetted insulator. It can not be used if either parameter (525°F [274°C] or 850 psi
[58 bar]) is exceeded.
For all other applications, probes with the zirconium oxide (ceramic) insulators
must be used. The high pressure (HP) probes are easily recognized by the
brazing between the insulator and the body (fig 1). The two styles of probes are
not interchangeable and will not fit in a receptacle designed for the other, the LP
probe uses a threaded fitting, the HP a compression fitting. In this I.O.M., all
instructions address the HP style probe (see figure 1). Refer to the water
column I.O.M. for details on both the HP and LP probes.
Note: The probe hex nut and hex jam nut located on the post used for the
electrical connection have been pre-torqued to exact specification. If the
hex nuts are inadvertently moved, the probe must be replaced.
Figure 1 – Probe Assembly
3
2.5.1 Probes are supplied fully assembled. Probe receptacles on the water
column are ½” swaged fittings.
2.5.2 To ensure the probes remain clean, mount the receptacles so the probes
are exposed to mild fluid circulation. Do not locate the probes in high
velocity steam or water. Probes may be located horizontally or vertically
with the electrical connection up.
2.5.3 Ensure that the receptacle and probe retaining nut threads and sealing
surfaces are clean. The threads on the receptacle and probe retaining
nut should be lubricated with an anti-seize compound to prevent galling
and lower the tightening torque on the threaded parts. Recommended
compounds include:
Silver Goop (Swagelok trade name)
MP-50 Moly Paste (Jet Lube of Canada)
Never-Seez (trade name)
2.5.4 Insert the probe into the receptacle and tighten the probe retaining nut by
hand. With a wrench, further tighten the nut ¼ turn only. Subsequent
connections will be made in a similar manner.
2.6 Wiring (refer to figures 4 and 5)
! C A U T I O N !
Before making any connections, make sure that the power source to be used is
isolated by use of the appropriate circuit breakers and switches so that no work
is being performed with “live wires”, otherwise personal injury or property
damage may result.
Note: All wiring should be in accordance with applicable national
and local codes by qualified personnel.
2.6.1 At the Probes
If the column mounted junction box option is ordered, the unit is prewired from the probes to the junction box mounted on the water column.
Probe to junction box wiring must be high temperature (e.g., mineral /
glass insulated or thermocouple wire).
The cabling between the standard off-column junction box and the
Electronic Module does not require any high temperature capability. It is
recommended, however, the cable should have an overall shield, 18-24
gauge tin or silver plated wire and have a minimum rating of 221°F,
[105°C]. If the junction box is located on the water column, higher
temperature wiring may be required.
The lowest probe on ALL
terminal in the Electronic Module is 1. Wire successively higher probes in
systems is numbered 1 and the corresponding
4
the same manner.
Cascaded Electronic Modules (more than 12 channels) may be installed
with probe wiring in numerical series or interleaved. If interleaving is
used, make certain that the low Electronic Module Probe 1 terminal block
location is wired to the lowest probe or the level fault logic will not work.
The wiring method used must be specified so the level fault logic can be
properly programmed at the factory.
Do not run input power through spare conductors in multi-conductor cables
used for probes and display module wiring. Input power is to be run in
separate cable runs.
2.6.2 At the Electronic Module
No wiring access holes are drilled in the enclosure. Access holes may be
placed at any convenient point during installation. Use appropriate
fittings, consider EMI and RFI, also maintain the NEMA/IP rating of the
enclosure. The access hole for the probe wiring should contain only
probe wiring. The access hole for the remote display wiring (if used)
should contain only remote display wiring. (Refer to fig 7 through 10 for
display wiring and dimensions).
It is recommended that the relay out and mains power input each have
their own access hole although this is not mandatory. Dress all mains
carrying conductors away from signal wiring.
To ease installation and wiring, the entire module may be removed from
its enclosure by removing the screws holding the metal back plate. Do
not separate the printed circuit board from the back plate.
For reliable operation, a mains power source with the following
requirements is required:
120 or 240 Vac
Single Phase, 50/60 Hz
40VA / 80VA, depending on configuration
Mains higher than 240 Vac will require the use of a stepdown
transformer. DC voltages will require use of a voltage inverter.
(refer to fig 6, loc 1 and 2)
If a standard unit was specified:
Mains power is connected to TB27 only.
For 120 Vac operation: L1 is “hot”, L2 is “neutral”. A fuse should be
installed at F1. G is for electrical ground.
For 240 Vac operation: L1 and L2 are directly wired. Fuses should be
installed at F1 and F2. G is for electrical ground.
If the dual transformer option was specified:
Mains 1 power is connected as above. Mains 2 power should be sourced
from a different mains supply. Mains 2 power is connected to TB28 only.
5
Follow the connections above for mains 1 using TB28. Fuse positions
are F3 and F4 for mains 2.
Earth bonding should be to the earthing lug on the mounting plate.
Mains power is MOV protected. Although the Model 12B uses jumper
set dual primary toroidal transformers, do not attempt to change factory
set mains voltage level unless the MOV’s are also changed to the proper
value.
If a door mounted local display or 4-20 mA loop output was specified, a
ribbon cable connects it to the connector at fig 6, loc 14. Do not use this
connector for any other purpose.
Keep-Outs (refer to fig 6, loc 5 and 16)
Note: Failure to heed these “keep-out” areas may damage the
electronics.
The terminal blocks at the upper left are for factory cascading level logic
– do not use for any purpose. Do not connect any wiring to these
terminal blocks.
The programming pins at the lower right are for the CPLD logic block –
do not use for any purpose. Do not store flash jumpers on these pins.
2.6.3 Display Panel (refer to fig 6, loc 15)
External display panel(s) are connected to the Electronic Module by a
16-20 AWG multi-conductor cable. Shielding is required if electrical
conductors other than those for the Model 12B low voltage display share
the same wiring conduit. Do not use extra cable leads for anything
except display module wiring. Use of these cables for other than what
they were intended may cause damage to the electronics.
The number of conductors required between Electronics and Display
Panel for your system can be calculated as follows:
Minimum conductors required = Number of probes x 2 + 2 (commo n) +
2 (fault LED’s).
Therefore, a twelve probe system requires (12 x 2 + 2 +2) = 28
conductors.
When several display modules are used a maximum of one local and
one remote or two remotes may be directly driven. For more than two,
the displays must be independently powered models. Each module may
be connected in parallel to the Electronic Module terminal strip or daisy
chained from the terminal strip of a preceding display module. Care must
be taken to match the corresponding terminal connections. For daisy
chained connections use heavier gage wire. A smaller remote display
(suitable for desk mounting) is also available.
Light emitting diodes (LED’s) are used on the display module. These
LED’s have an expected 20+ year life and can be replaced only on a
modular basis.
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2.6.3.1 Flash Programming (refer to fig 6, loc 17)
For operationally critical point indication – any green (water) or
red (steam) LED on all displays may be user programmed to
flash. As supplied all LED’s are programmed steady state.
There are two columns each three pins wide. Red LED control
is the left three pin columns; green, the right three pin colum ns.
If the shorting link is placed on the right two pins in a color
column, that LED color/channel will be steady state.
If the shorting link is moved to the left two pins in a column, that
LED color/channel will flash. Probe numbers, color and F(lash)
/ S(teady state) are silk screened on the printed circuit board as
a guide. The flash oscillator frequency may be checked with an
oscilloscope at test point #7 as a 5V ≈ 3Hz square wave.
Note: Do NOT set any of the LED’s to flash if a 4-20mA output
module is used with the system. This will interfere with the
proper operation of the 4-20mA module.
2.6.4 Control Output (water fail-safe) (refer to fig 6, loc 10)
SPDT Form-C contacts are provided for the control output of each
channel. These outputs are designated Relays “1” through “12” for
channels 1 through 12, respectively. Contact Rating:
8 A @ 28 VDC
10 A @ 120 Vac
10 A @ 250 Vac CSA and UL
5 A @ 250 Vac TÜV
Careful consideration should be given to the design of the alarm and trip
logic. Power loss or vessel blowdown could inadvertently shut down the
steam generator or leave the unit without protection. A keyed lock-out
switch, for trips, alarms, etc. is available as an option. The NC/NO/C
terminals are graphically marked at each relay. See detail on fig 4.
2.6.5 Electrical Fault Output (fail-safe)
A SPDT Form-C relay contact is provided to monitor the operation of the
Model 12B. This relay coil is normally energized. Loss of power to the
unit or detection of an internal Electrical Fault condition will cause the
relay to de-energize, opening the contacts. The electrical fault detection
circuit covers clock failure, open and short circuit detection and two
internal power supplies. This feature has variable time delay from 3 to
about 10 seconds. See fig 6, loc 12 for the adjustment potentiometer.
Turn clockwise to increase the length of delay.
2.6.6 Level Fault Output (fail-safe)
The Model 12B is also equipped with a Level Fault relay. A Level Fault
occurs whenever water is detected above steam. Probe 1 is always at
the lowest level. This feature also has variable time delay. The
adjustment potentiometer is on fig 6, loc 13. Turn clockwise to increase
the length of delay.
7
2.6.7 Probe Wiring (refer to fig 6, loc 4)
Each electronic module will support a maximum of twelve probes. Each
probe input to the module may have two wires. These are probe wire
(electrode marked “E” = minimum wiring required with all systems) and a
open/short sense wire, marked “S” (optional). Wiring at the probe is via
the crimp type eyelet supplied with each probe. If the eyelet is not used
intermittent operation may result. At least two ground wires must be
connected to the water column ground. Units with more than 12 probes
use two or more electronic modules in a larger enclosure. The num ber of
conductors required between the water column and Electronics for your
system may be calculated as follows:
2.6.7.1 Basic Systems (wired only to “E” on the terminal block)
Minimum conductors required = Number of probes + 2
(ground)
Therefore, a twelve probe system requires (12 + 2) = 14
conductors.
2.6.7.2 Systems with Open / Short Option (two wires at each
probe. One from probe to “E” on the terminal block, the
other to “S” on the terminal block.)
Minimum conductors required = Number of probes x 2 + 2
(ground)
Therefore, a twelve probe system with open/short option
requires (12 x 2 + 2) = 26 conductors.
Note: If this option was specified and is NOT
wired as described in
2.6.7 and 2.6.7.2, the electrical fault indication and relay will
continuously indicate fault.
3.0 Startup and Operation
3.1 Water Column
To place the water column in service the following procedure is recommended:
(1) Inspect the water column to ensure that all the probes are installed and the
associated wiring is correct and all connections are secure. Wiring should
be neatly routed and any contact between the high temperature water
column body or the probe cover should be avoided.
(2) Open the blowdown valve.
(3) Crack the steam block valve and warm up the water column for a period of
3 to 5 minutes with low velocity steam.
(4) At the end of the warm-up period, close the blowdown valve and then fully
open the steam valve.
(5) The water connection block valve should now be opened, or alternately, if
this valve is left closed, the vessel will fill with condensate allowing the
operating range to be verified.
(7) The water block valve must then be fully opened.
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