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Section: R100 Bulletin: R100.50A Date: 10/31/00 Supersedes: R100.50

ELECTRO EYE-HYE BOILER CONTROL SYSTEMS

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ELECTRO EYE-HYE STANDARD

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ELECTRO EYE-HYE 2000

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THE ELECTROLEV (PROBE) COLUMN

WIRING LEADS CONNECTIONS

Connections may be flanged, socket welded, butt welded or screw type. High temperature, Teflon® insulated leads extend 30 inches beyond the chamber to facilitate installation. Optional longer leads available.

STANDARD CONNECTIONS HOUSING REMOVED HIGH WATER LEVEL

ITEMS TO CONSIDER WHEN SPECIFYING

· Vessel connection centers · Probe locations ­ 1" (25mm) minimum centers · Type of vessel connections A) Flanged ­ size and type B) Female socket-weld-size C) Special drain connections ­ extended pipe (male) 1/2" or 3/4" ­ flange (size & type) · Extended high temperature probe wires (30" extending from unit is standard) · Integrally mounted (NEMA 4) weatherproof pre-wired junction box · Flexpak insulation jacket designed for easy access to accommodate maintenance

1" PIPE PROJECTION

CHAMBER

The Electrolev body is constructed of ASTM A106 seamless steel pipe.

INSTALL SHUTOFF VALVES BETWEEN DRUM AND ELECTROLEV

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Water Level Variation

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NORMAL WATER LEVEL

6 5 4 3

Steam & Water Centers Overall

PROBE NUMBER HOUSING

Stainless steel housing protects probes and wiring. 2

OPTIONAL FLEXPAK® JACKET

For maximum system accuracy and personnel safety, the Electrolev should be insulated with the optional FLEXPAK jacket. The jacket provides a 2-inch thick insulation that is easily removed for routine inspections. The jacket is suitable for outdoor service and will withstand contact with surfaces as hot as 650°F.

TABLE A

Model Number EL450-10 EL450-12 EL450-20 EL1000-10 EL1000-12 EL1000-20 EL1800-10 EL1800-12 EL1800-20 PSIG 450 450 450 1000 1000 1000 1800 1800 1800 3000 3000 3000 BarG 31 31 31 69 69 69 124.1 124.1 124.1 206.9 206.9 206.9

LOW WATER LEVEL

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BLOWDOWN CONNECTION FACILITATES CLEANING

Figure 8

1 /2" SOCKET WELD DRAIN CONNECTION

(standard)

MINIMUM 1" SPACING BETWEEN PROBES

Figure 9

STANDARD ELECTROLEVS CONTAIN 10, 12 OR 20 PROBES

TYPICAL ARRANGEMENT AND DIMENSIONS FOR 10-PROBE ELECTROLEV

MODEL NUMBERS EL450-10, EL1000-10, EL1800-10, ELF3000-10 EL450-12, EL1000-12, EL1800-12, ELF3000-12 EL450-20, EL1000-20, EL1800-20, ELF3000-20

(See Table A, to the right)

PROBES 10 12 20

ELECTROLEVS

Max. Temp. °F 456 456 456 545 545 545 621 621 621 695 695 695 °C (236) (236) (236) (285) (285) (285) (327) (327) (327) (368) (368) (368) Kg/cm2 31.6 31.6 31.6 70.3 70.3 70.3 126.5 126.5 126.5 210.8 210.8 210.8 No. of Probes 10 12 20 10 12 20 10 12 20 10 12 20

Max. System WSP

SPECIFICATION OPTIONS · Extra Electrolev Length Beyond 36" · Weatherproof Electrolev · Flanged Steam & Water Connections · Special Drain Connection · Female Socket Weld Steam & Water Connections · Electrode Lead Wire Longer Than 30" · Special Drain Connection Contact your Clark-Reliance representative for additional specification information.

MODEL NO.: EL

· WP for weatherproof installations · 10 12 20 - other consult factory · 450 1000 1800 3000 · F (3000PSI only)

ELF3000-10 ELF3000-12 ELF3000-20

TABLE B

Part Number T020 V020 ZG020* FG031* PSIG 450 1000 1800 3000 BarG 31 69 124.1 206.9

PROBES

Replacement Probe Part No.

Max. System WSP

Type Electrolev Kg/cm2 Insulator Model 31.6 70.3 126.5 210.8 TFE TFE Zirc. Ox. EL450 EL1000 EL1800

T0202RK V020K ZG020K

Zirc. Ox. ELF3000 FG031RK

*Probes - Factory Renew Service Available

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ELECTRO EYE-HYE 2000 CONTROL UNIT

FEATURES OF THE ELECTRO EYE-HYE 2000

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· Modular design of microprocessor based components permits easy field installation of options at any time, with high reliability. · Internal redundant power supplies for each microprocessor operate from either 120 or 240 VAC. · Designed to accept 120 or 240 VAC from two power sources. · Optional relay contact, rated at 10 Amps each.

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· 4 wire communication/power bus designed to provide the link to relays, keypads, remote panel indicator(s). Two sets of bus lines are designed for independent control functions. One set for the 4-20 mA output and relay communication, and one set for communication with remote indicators and keypads. · Microprocessor, relay, 4-20 mA, keypad, and indicator boards are designed with watchdog timers for reliability.

· MICROPROCESSOR BASED DESIGN · FIELD PROGRAMMABLE FUNCTIONS · 4 WIRE SERIAL BUS FOR PANEL INDICATORS AND ACCESSORIES · FULLY REDUNDANT CIRCUITRY · COMPACT DESIGN MODEL ECM

· Blowdown circuitry provides testing without activating false alarms or trips. · This control unit design will operate up to 32 probe levels. · The redundant microprocessor board is completely isolated from the primary processor board, to provide the utmost input and output reliability. · The control unit measures the conductivity of each probe circuit for comparison to detect probe fatigue or contamination.

GENERAL SYSTEM SPECIFICATIONS

INPUT POWER SOURCE: 120/240 50/60 Hz (Full range: 90-264 VAC, 47-63 Hz) with over voltage protection circuitry, dual input sources, and redundant internal power supplies. PROBE INPUTS: 2-32 probe sensing levels with one wire per probe plus a common, up to 1000 feet distance capability from control to probes, and all probe circuits are intrinsically safe. MICROPROCESSOR: internal watchdog timer, out of sequence and fault detection, password protected to restrict unauthorized access, optional fully redundant isolated processor. RELAY BOARDS: 4 relays per board rated @ 10 Amps. @ 250 VAC., with epoxy sealed contacts, connected via 4 wire bus, relay boards can be remotely located for user convenience, field programmable (for delay, fault detection mode, pump control, and reverse logic), detachable terminal blocks (up to 12 Ga. wire) for easy field wiring, internal watchdog timer, wired to dedicated serial bus for relays and optional 4-20 mA. KEYPAD WITH DISPLAY: 16 keys, 4 line - 40 character back lit display, with 4 wire serial bus connection for local or remote installation, internal watchdog timer, provides access to modify all Electro Eye-Hye 2000 options. Portable keypad and LCD display, available on request, for programming capability of multiple systems: specify ECM-KD.

MODEL NUMBERS FOR THE EYE-HYE 2000 TO BE IN ACCORDANCE WITH THE FOLLOWING: ECM X X X X X

· 1 = up to 16 probes, 2 = 17 to 32 probes · 4-20 mA option (0 - NO, 1 - YES) · Relay output option, 4 alarm contacts per board (0 - NONE, 1-8) · Backup power supply & micro control boards (0 - NO, 1 - YES) · 0 ­ without keypad and LCD display 1 ­ with keypad and LCD display 2 ­ with sub-miniature bi-color display and no keypad or LCD display 3 ­ with sub-miniature bi-color display, keypad and LCD display · Electro Eye-Hye base unit in NEMA 4x enclosure with one microprocessor, designed for 120 or 240 VAC supply

SUGGESTED MODELS FOR UNITS UP TO 16 PROBES:

MODEL NO. ECM-00001 ECM-00101 ECM-00011 ECM-00111 FEATURES Base unit (no options) Base unit with one relay board Base unit with 4-20 mA output board Base unit with one relay board and 4-20 mA output board ECM-11111 Base unit with one relay board, 4-20 mA output board, redundant power supply & microprocessor, and keypad with LCD display

Note: Each relay card provides 4 independent switches

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ELECTRO EYE-HYE STANDARD LOW VOLT CONTROL UNIT

ITEMS TO CONSIDER WHEN SPECIFYING

· SELF-DIAGNOSTICS · Door mounted indicators · Types of enclosures · 220V Supply (115 VAC - 50/60 Hz Standard) · 18 AWG multi-conductor cable · Dead band relays · Back-up DC power supply · 4-20 mA. output signal · Time delay relays for alarm or trip circuits · Portable system exerciser switch for system diagnosis · Voting logic (2 out of 3) circuitry for alarm or trip

Contact your Clark-Reliance representative for additional information.

BASE SYSTEM INCLUDES:

· Independently fused relay modules for each probe level. · One dry set of form C switch contacts rated @ 5 Amp @ 240 VAC or 30 VDC for all probe levels, prewired to terminal block for field selection. MODEL ECIL

SHOWN IS A 12-LEVEL CONTROL UNIT IN A NON-METALLIC ENCLOSURE

OPTIONAL TEST SWITCH

A Test Switch can be furnished that provides rapid status of Control Unit circuitry and indicator lamps. The Test Switch may be a self-contained unit for independent mounting or contained within the Control Unit as an integral component. Specify ECTSLR or ECTSLR-2.

OPTIONAL SYSTEM EXERCISER SWITCH

Designed to plug into control unit receptacle for testing each level independently or cumulatively. Can be used to assist programming the 4-20 mA option, specify ECID-71.

OPTIONAL DEAD BAND RELAYS

Dead Band Relays are available within the Control Unit that will actuate "on" and "off" signals to electrical devices at two "high" and two "low" liquid levels.

TABLE C

Model Number SMI-10BD SMI-12BD SMI-20BD Style Sub-Min. Sub-Min. Sub-Min.

DOOR MOUNTED INDICATORS

Width Height No. of Lights Color(s) Inches mm Inches mm 10 12 20 Red/Green 1.75 Red/Green 1.75 Red/Green 1.75 44 44 44 4.50 4.50 4.50 114 114 229

OPTIONAL 4-20 mA OUTPUT

May be used to interface with computers, or to power auxiliary analog level indicators. Specify PC-27.

TABLE D

Model Number ECIL-10R ECIL-12R ECIL-20R

CONTROL UNITS

Est. Wt. Lbs. 21 27 37 Kgs. 9.5 12 17

Test Switch No. of Use With Points Electrolev Models (Optional) 10 12 20 All 10 Probe Models All 12 Probe Models All 20 Probe Models ECTSLR ECTSLR ECTSLR-2

CHOICE OF ENCLOSURES

Control Units are available in the following standard enclosures: NEMA 1: Indoor NEMA 4: Indoor/Outdoor NEMA 4X: Indoor/Outdoor NEMA 12: Indoor/Dirt, Noncorrosive Liquids

Specify stainless steel, epoxy coated steel, or non-metallic.

TABLE E

Component No. ECID-69 ECID-70 ECID-71 PC-27

CONTROL UNIT OPTIONS

Description Fault Detector - 120 VAC Supply Fault Detector - 240 VAC Supply System Exerciser Switch 4-20 mA Output Board 120 VAC Power Supply Diverter 240 VAC Power Supply Diverter Back-Up 12 VDC Supply

NEMA 7:

Explosion Proof R

· # of probes = 10, 12 & 20 standard - other, consult factory

MODEL NO.: ECIL

PSD-120 PSD-240 ECIV-13

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INDICATORS

MINIATURE RED

(only with ECIL)

STANDARD RED

(only with ECIL)

ALL INDICATORS ARE SHOWN APPROXIMATELY 1/3 ACTUAL SIZE. SEE TABLE D BELOW FOR SPECIFIC DIMENSIONS

MINIATURE BI-COLOR

SUBMINIATURE BI-COLOR

STI-SERIES

· · · · Standard Incandescent lamp Red only Lights on for water, no lights for steam STI - 10 12 20

MTI-SERIES

· Miniature LED · Red only · Lights on for water, no lights for steam MTI - 10 12 20

MTI-BI-COLOR SERIES

· Miniature LED · Green for water, red for steam MTI - 10B 12B 20B

SMI-BI-COLOR SERIES

· Subminiature LED · Green for water, red for steam SMI - 10BR 12BR 20BR

TABLE F

Model Number STI-10 Style Standard Miniature Miniature Sub-Min. Standard Miniature Miniature Sub-Min. Standard Miniature Miniature Sub-Min.

INDICATORS

Width Height No. of Indicator Lights Color(s) inches mm inches mm 10 10 10 10 12 12 12 12 20 20 20 20 Red Red Red/Green Red/Green Red Red Red/Green Red/Green Red Red Red/Green Red/Green 3.62 3.00 3.00 1.75 3.62 3.00 3.00 1.75 3.62 3.00 3.00 1.75 92 76 76 44 92 76 76 44 92 76 76 44 16.62 422 11.75 298 11.75 298 4.50 114

REMOTE INDICATORS

MODEL NO. STI-10 MTI-10 MTI-10B SMI-10BR STI-12 MTI-12 MTI-12B SMI-12BR STI-20 MTI-20 MTI-20B SMI-20BR

(See Table F, right)

MTI-10 MTI-10B* SMI-10BR* STI-12 MTI-12 MTI-12B* SMI-12BR* STI-20 MTI-20 MTI-20B* SMI-20BR*

STYLE LIGHTS Standard 10 Miniature 10 Miniature Bi-Color 10 Sub-Miniature Bi-Color 10 Standard 12 Miniature 12 Miniature Bi-Color 12 Sub-Miniature Bi-Color 12 Standard 20 Miniature 20 Miniature Bi-Color 20 Sub-Miniature Bi-Color 20

19.38 492 11.75 298 11.75 298 4.50 114

30.62 778 16.44 418 16.44 418 9.00 229

* Note: Add "E" suffix for use with ECM Control Unit

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THE PROBES:

HEART OF THE SYSTEM AND KEYS TO RELIABLE PERFORMANCE

MODEL T PROBE FOR PRESSURES TO 450 PSI (TEFLON® INSULATED)

EXCEPTIONAL PERFORMANCE

The outstanding success of the Electro Eye-Hye System followed development of reliable, long-lasting Probes. As industry's pioneer and continuing innovator in Probe technology and performance, Clark-Reliance provides Probes of the highest quality and reliability.

MODEL V PROBE FOR PRESSURES TO 1000 PSI (TEFLON® INSULATED)

MANUFACTURING PRECISION

Functioning as the heart of the system, Electro Eye-Hye Probes reflect current advanced standards in materials selection and manufacturing precision. ClarkMODEL ZG PROBE Reliance technology now provides Probes FOR PRESSURES TO 1800 PSI that allow almost pure water of ultra-low (ZIRCONIUM OXIDE INSULATED) conductivity (less than 1 micromho) to complete necessary electrical circuits. MODEL FG PROBE FOR PRESSURES TO 3000 PSI (ZIRCONIUM OXIDE INSULATED)

ge probe with high-volta Older systems upgraded with new control circuits can be tors ­ consult factory units and indica

Patented Probes: U.S. 4,507,521 Plus Others World-Wide

S.A. 83/664

U.K. 2,127,976

Canada 1,200,283

PROBE REPAIRABILITY

System economy is enhanced by the availability of off-the-shelf Probe Repair Kits. Replaceable parts include gaskets and other components that are susceptible to routine wear factors over extended periods of time. Kit model numbers appear in Table B, see page 2. (Available for ZG and FG probes).

Copper Cushion Washer, Upper Stainless Steel Compression Washer Stainless Steel Belleville Washer Stainless Steel Wiring Terminal Inconel Center Rod Stainless Steel Terminal Nut Stainless Steel Compression Nut Ceramic Standoff Insulator Monel-Silver Sealing Gasket Graphite Gaskets Zirconia Wetted Insulator Stainless Steel Flanged Body Copper Cushion Washer, Lower Ceramic Sleeve Insulator Stainless Steel Electrode Connector

DOOR MOUNTED INDICATORS FOR CONTROL UNITS

Sub-Miniature Bi-color Style Door Mounted Indicators are weather resistant and provide a wide viewing angle. The Door Mounted Indicators are retrofitable on all model ECIL**R Control Units. Optional enclosure door window kit available, for use with miniature or standard indicators.

MODEL NO. STYLE LIGHTS SMI-10BD Sub-Miniature Bi-color 10 SMI-12BD Sub-Miniature Bi-color 12 SMI-20BD Sub-Miniature Bi-color 20

For component information, or retrofit (upgrade), contact your local Clark-Reliance representative with the existing system serial number. Numbers begin with EE-__ __ __ __, located on probe housing nameplate, control unit door nameplate, and stamped directly on column. SYSTEM POWER REQUIREMENTS ECM or ECIL Systems: 120 VAC Supply 240 VAC Supply

Note: Most systems consume less than 75 watts of power. Consult factory for actual system combination power requirements, if required.

®

16633 FOLTZ INDUSTRIAL PARKWAY · STRONGSVILLE, OHIO 44149, U.S.A. TELEPHONE (440) 572-1500 · FAX (440) 238-8828 www.clark-reliance.com 6

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