Mobrey Hydrastep and Hydratect ® Water/Steam Monitoring Systems
Product Data Sheet
August 2015
BP2468, Rev EA
Mobrey® Hydrastep and Hydratect
Water/Steam Monitoring Systems

High clarity electronic gauging system for steam drums with options of local and remote indication

4–20 mA output proportional to water/steam interface level

High reliability, low water level shutdown system

Superior quality electrodes manufactured for long life and reliability

Each system custom designed for your application to ensure minimum installation costs

“Sole gauge” and ASME compliance with International approvals

Hydratect for use as a Turbine Water Ingress Protection (TWIP) system
August 2015
Hydrastep and Hydratect
Hydrastep 2468 Electronic Gauging System
Failure to detect low water levels in steam-raising plant can have
costly and potentially disastrous consequences. Reliable water
level detection is vital to prevent damage to plant and
personnel.
The Hydrastep electronic gauging system is the ideal ‘fit and
forget’ solution to overcome the problems associated with
unreliable and maintenance- intensive gauge glasses.
Designed for totally reliable operation, Hydrastep is both
fail-safe and fault tolerant.
Modern boilers are designed to provide clean, dry steam.
Detection of incorrect water level in the drum is essential:
Hydrastep Electronic Measuring Unit
The Hydrastep system consists of a water column fitted
with up to 32 electrodes, an electronic measuring unit,
local and remote displays, and connecting cables.

Too high a level can give wet steam, leading to turbine blade
erosion, and

If the level is too low, the boiler tubes can overheat, with the
danger of explosion.
All national legislatures require indication of water level in steam
generating plant and drum level indication in the control room is
absolutely necessary. Conversely however, false alarms leading
to plant shutdown and loss of revenue are also highly
undesirable.
Hydrastep offers exceptional levels of security. All
measurements are interpreted as water, steam or
contamination. Both short and open circuit conditions are
detected and indicated as faults.
An independent report by Factory Mutual Research concluded
that the probability of Hydrastep missing a trip condition is less
than 1 in 300 million and that nuisance trips will be less than 1 in
10 million. Hydrastep combines optimum safety indication with
virtually no risk of false alarms.
Contents
Hydrastep Ordering Information . . . . . . . . . . . . . . . page 4
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 7
Hydratect Ordering Information . . . . . . . . . . . . . . . page 6
Dimensional Drawings . . . . . . . . . . . . . . . . . . . . . . . page 10
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Hydrastep and Hydratect
August 2015
Hydratect 2462 Steam / Water Detection System
The Hydratect electronic water detection system is designed as
an electronic alternative to conventional water level switches on
steam raising plant.
It can be used in a wide variety of situations wherever the
detection of water or steam is vital for safe and efficient
operation.
The Hydratect 2462 system consists of electrodes, an electronic
unit and a manifold or water column. Alternatively, inserts can
be provided so that the electrodes can be fitted directly into
existing pipework.
Designed to use the same water or steam detection system as
Hydrastep, Hydratect provides much higher levels of reliability
than conventional devices, and can be used in conjunction with
Hydrastep level detection for ultimate protection. Hydratect
provides local indication and configurable alarm / trip outputs.
Hydratect Electronic Unit
The 2462 Hydratect is designed for:

Fault tolerance

Fail-safe operation

Fully validated trips

Detection of electrode contamination

Detection of open circuit electrode connections

Detection of fault ground connections
HYDRATECT
Typical Hydratect Application
The 2462:

Makes routine testing unnecessary

Conforms to all existing standards and legislation

Continuously verifies measurement integrity

Is the most economical solution for all installations
Electrodes
3
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August 2015
Hydrastep and Hydratect
Hydrastep Ordering Information
A Hydrastep electronic steam/water gauging system comprises:
Control unit (see Table 1)

Water column (see Table 2)

Electrodes (see Table 3 on page 5)

Electrode cables (see Table 4 on page 5)

Remote display (optional, see Table 5 on page 5)
Water column,
electrodes, and
electrode cables
Control
unit
Specification and selection of product materials, options, or
components must be made by the purchaser of the equipment.
See page 7 for more information on Material Selection.
Remote
display
Table 1. Hydrastep Control Unit Ordering Information
The starred options (★ ) represent the most common options and should be selected for best delivery. The non-starred offerings are subject to
additional delivery lead time.
Model
Product Description
2468
Hydrastep Control Unit
Power Supply Input Boards
CA
16 point EGS, single power supply (ac mains)
★
CB
32 point EGS, dual power supplies (2 x ac mains)
★
CC
16 point EGS, single power supply (24 Vdc)
★
CD
32 point EGS, dual power supplies (2 x 24 Vdc)
★
CE
32 point EGS, dual power supplies (1 x ac, 1 x dc)
★
Optional Output Boards
AD
No output boards
★
BD
1 Relay output board (4 relays)
★
CD
2 Relay output boards (8 relays)
★
DD
4 Relay output boards (16 relays)
★
ED
1 Relay output board with time delay (4 relays)
FD
2 Relay output boards with time delay (8 relays)
GD
4 Relay output boards with time delay (16 relays)
HD
1 Opto isolated output board (4 outputs)
JD
2 Opto isolated output boards (8 outputs)
KD
4 Opto isolated output boards (16 outputs)
Typical Model Number:
2468 CB CD
Table 2. Hydrastep Water Column Ordering Information
The starred options (★ ) represent the most common options and should be selected for best delivery. The non-starred offerings are subject to
additional delivery lead time.
Model
Product Description
(1)
120
Low pressure (up to 1740 psi / 120 bar) water column (schedule 80 process connections) – see Table 9 on page 8
★
210(1)
High pressure (up to 3045 psi / 210 bar) water column (schedule 160 process connections) – see Table 9 on page 8
★
300(1)(2)
Super critical (up to 4350 psi / 300 bar) water column (schedule XXS process connections) – See Table 9 on page 8
In-line Design
L(3)
No Code
(3)(4)
In-line design (top-and-bottom process connections)
★
Side-arm design (side-and-side process connections with hanger)
★
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Hydrastep and Hydratect
August 2015
Table 2. Hydrastep Water Column Ordering Information
The starred options (★ ) represent the most common options and should be selected for best delivery. The non-starred offerings are subject to
additional delivery lead time.
Distance Between Top and Bottom Tappings
TTTT(5)
TTTT = Distance between top and bottom tappings (mm or inches)
★
SSSS = Distance between top and bottom electrodes (mm or inches)
★
Site Range
SSSS(6)
Number Of Electrodes
XX
★
Number of electrode ports – specify an even number ranging from 08 up to a maximum of 32)
Typical Model Numbers:
120-1250-900-24 (Low Pressure Water Column, Side-and-side, 1250 mm Process Connection Centers)
210-L-43-37-16 (High Pressure Water Column, Top-and-bottom, 37 in. Process Connection Centers)
(1) See Table 9 on page 8 for details of the water column.
(2) Available to special order only.
(3) Specify the process connection size (25, 32, 38, or 50 mm) on the column design sheet, which is available from your local sales office.
(4) Water column with hanger design has side arm/side-and-side process connections. Specify the drain connection size (20 or 25 mm) on the column design sheet,
which is available from your local sales office.
(5) Maximum tap-to-tap distance is 138 in. (3500 mm).
(6) Refer to water column design sheet available from your local sales office.
Table 3. Hydrastep Electrodes Ordering Information
The starred options (★ ) represent the most common options and should be selected for best delivery. The non-starred offerings are subject to
additional delivery lead time.
Model
Product Description
459600602(1)
Low pressure threaded electrode – Zirconia insulator
459600802(1)
Low pressure threaded electrode – PTFE insulator
246781ZA(1)
High pressure union electrode (Series III), Zirconia insulator
246782AC(1)
High pressure union electrode (Series III), PTFE insulator
246785A(1)
Super critical union electrode (Series lll), ZTA insulator, 1-in. fitting
Max Pressure
PSI (Bar)
Max Temp.
°F (°C)
ph
Range
1740 (120)
698 (370)
7 to 11
★
725 (50)
500 (260)
7 to 13.5
★
3045 (210)
698 (370)
7 to 11
★
725 (50)
500 (260)
7 to 13.5
★
4350 (300)
1040 (560)
7 to 11
★
(1) Do not mix electrode types in the same water column.
Table 4. Hydrastep Electrode Cables Ordering Information
The starred options (★ ) represent the most common options and should be selected for best delivery. The non-starred offerings are subject to
additional delivery lead time.
Model
Product Description
24680204A(1)
10 ft (3m) multicore electrode cable (for up to 8 electrodes)
★
24680205A(1)
33 ft. (10 m) multicore electrode cable (for up to 8 electrodes)
★
(1)
60 ft. (18 m) multicore electrode cable (for up to 8 electrodes)
★
24680207A(1)
98 ft. (30 m) multicore electrode cable (for up to 8 electrodes)
★
24680206A
(1) Select one or more cables according to the number of electrodes. For example, select two cables if there are 16 electrodes in the column.
Table 5. Hydrastep Accessories Ordering Information
The starred options (★ ) represent the most common options and should be selected for best delivery. The non-starred offerings are subject to
additional delivery lead time.
Model
Product Description
24683C
32 point remote display, large panel mount
★
24683D
32 point remote display, IP65 wall mount (Type NEMA 4)
★
24683BB
32 point remote display, DIN panel mount
5
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August 2015
Hydrastep and Hydratect
Hydratect Ordering Information
A Hydratect steam/water detection system comprises:
Control unit (see Table 6)

Two electrodes, two shrouded inserts, and two covers (see Table 7)

Two electrode cables (see Table 8)

Manifold, if user is not mounting electrodes in own manifold or pipework (see Table 8)
Specification and selection of product materials, options, or components must be made by the purchaser of the equipment.
See page 7 for more information on Material Selection.
Table 6. Hydratect Control Unit Ordering Information
The starred options (★ ) represent the most common options and should be selected for best delivery. The non-starred offerings are subject to
additional delivery lead time.
Model
Product Description
2462
Hydratect Electronic Level Switch
Power Supply and Input Boards
A
2 point level switch, ac mains, single pole single throw relay outputs
★
E
2 point level switch, ac mains, two pole changeover relay outputs
★
C
2 point level switch, 24 Vdc, single pole single throw relay outputs
Typical Model Number:
2462 A
Table 7. Hydratect Electrodes, Shrouded Inserts, and Covers Ordering information
The starred options (★ ) represent the most common options and should be selected for best delivery. The non-starred offerings are subject to
additional delivery lead time.
Model
Product Description
Max Pressure
PSI (Bar)
Electrodes(1)
Max Temp.
°F (°C)
ph
Range
246785Z
Hydratect union electrode (Series III), Zirconia insulator, 1-in. fitting
3045 (210)
698 (370)
7 to 11
★
246785A
Hydratect union electrode (Series III), ZTA insulator, 1 in. fitting
4350 (300)
1040 (560)
7 to 11
★
Shrouded Inserts(2)(3)
24673540B
Series lll Insert, stainless steel (300 bar, 560 °C)
★
Cover(4)
24670118A Series III cover
Note: Manifolds (up to 4 ports) available for in-line/side-arm applications to special order – ask a local sales office for a manifold design sheet
★
(1) Two electrodes of the same type are required for a Hydratect system. Do not mix electrode types.
(2) Two shrouded inserts of the same type are required for a Hydratect system.
(3) Minimum pipe internal diameter for installation of insert is 1.65 in. (42 mm).
(4) Two covers are required for a Hydratect system.
Table 8. Hydratect Electrode Cables Ordering Information
The starred options (★ ) represent the most common options and should be selected for best delivery. The non-starred offerings are subject to
additional delivery lead time.
Model
Product Description
(1)
10 ft. (3 m) multicore electrode cable
★
24620205A(1)
33 ft. (10 m) multicore electrode cable
★
24620206A(1)
60 ft. (18 m) multicore electrode cable
★
(1)
98 ft. (30 m) multicore electrode cable
★
24620204A
24620207A
(1) One cable is required for each electrode.
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Hydrastep and Hydratect
August 2015
Specifications
Material selection
Emerson provides a variety of products with various product options and configurations including materials of construction that can
be expected to perform well in a wide range of applications. The product information presented is intended as a guide for the
purchaser to make an appropriate selection for the application. It is the purchaser’s sole responsibility to make a careful analysis of all
process parameters (such as all chemical components, temperature, pressure, flow rate, abrasives, contaminants, etc.), when
specifying product, materials, options and components for the particular application. Emerson Process Management is not in a
position to evaluate or guarantee the compatibility of the process fluid or other process parameters with the product, options,
configuration or materials of construction selected.
Hydrastep specifications
General
Product
Hydrastep electronic steam/water gauging system
Electrode Channels
8 to 32, in pairs. See Table 3 on page 5 for Hydrastep electrode specifications
Water/Steam Threshold
0.6 S/cm in clean water (up to 106S/cm); 1.6S/cm in dirty water (up to 300 S/cm)
Models for highly contaminated water, up to 1600 S/cm, available to special order
Display and fault indication
Integral Display
Red/green bar graph, 32 LED segments. Display blanking from the bottom with less than 32 electrodes in
use. Channel fault indication by flashing display segment. General fault indication by amber LED
Indication same as Integral Display
Remote Display
Powered from main unit (1 display only).
Local power 20 to 54 Vdc, 240 mA required for additional remote displays
Electrical
Power Supply
Power supply (ac): 94 to 130 V or 187 to 256 V, 48Hz to 65 Hz, 60 VA max. (1)
Power supply (dc): 20 to 40V negative ground or isolated
Analog Output
Signal is proportional to the water level
Range: 0–20 mA or 4–20 mA, forward or reverse
Accuracy: ± 0.2 mA
Drive capability 600 ohms at nominal supply voltage, or 500 ohms at minimum supply voltage
Maximum of four relay boards can be fitted for alarm indication
Relay Outputs (Optional)
Relay Board:
Four independent change-over relays
Relay contact rating (ac powered):
Maximum voltage of 250 Vac
Maximum current of 8A
Maximum switching power: 1500 VA
Relay contact rating (dc powered):
Maximum voltage of 125 Vdc
Maximum current of 8 A
Maximum switching power:
40 W < 30 V, 65 W < 60 V, 25 W < 125 V
Type N safety:
5 A at 12 Vdc, 100 mA at 30 Vdc, 20 mA at 125 Vdc
Delayed Relay Board
(Specification as per Relay Board)
Delay range: 0 to 25s ±1s
Opto-coupled Board
Solid state relays: Four independent outputs
Rating: 30 Vdc, 1A
Maximum voltage drop: 1.1 V @ 1A
Maximum leakage current: 1 mA @ 30 Vdc
Remote Display Output
Drive to remote displays (maximum 6 units). 3280 ft. (1000 m) maximum distance
Opto-isolated Fault Output
Detects fault in electrode connection (open circuit and short-circuit to ground)
Environment
Operating Temperature
–4 to 158 °F (–20 to 70 °C)
Operating Pressure
See Table 9 on page 8 for the Hydrastep water column specifications
Relative Humidity
Up to 100%
7
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August 2015
Hydrastep and Hydratect
Mechanical
Weight
26.4 Ib (12 kg)
Control Unit Enclosure
Brushed stainless steel, wall mounting (four point), IP65 / NEMA4X
16.7 in. high x 12.8 in. wide x 6.4 in. deep (425 mm x 325 mm x 163 mm)
Remote Display Unit Enclosure
2468 3BB (Case style: DIN Panel Mount)
Dimensions: 5.67 in. x 2.38 in. x 7.87 in. deep (144 mm x 72 mm x 200mm)
Panel cutout: 5.41 in. x 2.60 in. (137.5mm x 66mm)
2468 3C (Case style: Large Panel Mount)
Dimensions: 7.56 in. x 3.78 in. x 8.23 in. deep (192mm x 96mm x 209mm)
Panel cutout: 7.32 in. x 3.62 in. (186mm x 92mm)
2468 3D (Case style: Rugged enclosure, NEMA 4X (IP65))
Dimensions: 11.89 in. x 7.32 in. x 6.89 in. deep (302mm x 186mm x 175mm)
Approvals
ATEX
II3 G EEx nA IIC, T4 (–20 °C < ta < +70 °C)
CSA
(Canada) Ex nA [nL] nL IIC T4, (USA) CIass 1 Zone 2, AEx nA IIC
with relay output connected only to energy limited circuits
FM
Approved for boiler water-level control
LVD
EN 61010-1
Pressure Equipment Directive
Safety accessory
Electromagnetic Compatibility
EN 61326-1
(1) Dual power supply version of Hydrastep Control Unit – Table 1 on page 4 for option codes.
Table 9. Water Column Specifications
Parameter
LP Rectangular Section
HP Series 3
HP Super 3
Design Pressure
1740 psi (120 bar)
3045 psi (210 bar)
4350 psi (300 bar)
Test Pressure
2610 psi (180 bar)
4567 psi (315 bar)
6525 psi (450 bar)
Design Temp.
650 °F (343 °C)
698 °F (370 °C)
1040 °F (560 °C)
Design Code(1)
ASME B31.1 Power Piping
ASME B31.1 Power Piping
ASME B31.1 Power Piping
Maximum Length
138 in. (3500 mm)
138 in. (3500 mm)
138 in. (3500 mm)
Materials of
Construction(2)
Carbon Steel ASTM A105/A106 GR B
Carbon Steel ASTM A105/A106 GR B body
with SA 479 – 316N electrode mounts
Stainless steel ASTM A312/A182 F316
with SA 479 – 316N electrode mounts
Protective Covers
18 SWG (17 AWG) Stainless steel
18 SWG (17 AWG) Stainless steel
18 SWG (17 AWG) Stainless steel
Gross Weight(3)
26.5 Ib (12 kg)
37.5 Ib (17 kg)
37.5 Ib (17 kg)
Electrode Types
459600602 or 459600802
246781ZA or 246782AC
246785A
Blanking Plugs(4)
24569A
450600880
24673763A
(1) Manufactured and tested in accordance with ASME Boiler and Pressure Vessel Code: Section 1.
(2) Material certification: in accordance with BS EN10204 3.1 (we can also provide to BS EN10204 3.2 at additional cost and if specified by Customer, prior to order).
(3) Typical for (610 mm / 24 in.) steam/water range, 12 port, with electrodes and covers.
(4) Electrode port blanking plugs are available to order using the part numbers given in each column.
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Hydrastep and Hydratect
August 2015
Hydratect specification
General
Product
Hydratect steam/water detection system
Electrode Channels
2 (See Table 7 on page 6 for Hydratect electrode specifications)
Water/Steam Threshold
0,6 S/cm (normal) or 1,6S/cm (alternate) depending on water purity
Display
Integral Display
One Red LED for indication of steam
One Green LED for indication of water
One Amber LED for indication of fault
Electrical
Power Supply
Status Relay Output
(One Per Channel)
Power supply (ac):
94 to 130 V or 187 to 256 V, 48 Hz to 65 Hz, 2 x 10 VA maximum
Power supply (dc):
20 to 60 V, 2 x 200 mA maximum, +ve or –ve ground
Water normal: Energized in water
Steam normal: Energized in steam
Separate normally open and normally closed contacts:
• Maximum voltage: 250 Vac, 125 Vdc
• Maximum current: 8 A
• Maximum Switching Power (ac): 1500 VA
• Maximum Switching Power (dc): 240 W < 30 V, 65 W < 60 V, 25 W < 125 V
Opto-isolated Fault Output
Detects fault in electrode connection (open circuit and short-circuit to ground)
Output rating “off”: 30 Vdc max, leakage <1 mA
Output rating “on”: 1 A dc, voltage <1.1 V @ 1 A
Fault Relay Output
(One Per Channel)
Energized during normal operation (fail-safe).
Specification as status relay output above
Mechanical
Enclosure
Stainless steel, grade 304, wall mounting (two point)
Finish - natural
IP65 / NEMA4X
7.5 in. x 7.5 in. x 3.5 in. (190 mm x 190 mm x 90 mm)
Weight
6.2 Ib (2.8 kg)
Environment
Operating Temperature
–4 to 158 °F (–20 to 70 °C)
Operating Pressure
Manifolds are available with 1 to 4 electrode ports. Various materials depending on required pressure and
temperature rating. Design sheets are available on request.
See Table 7 on page 6 for the Hydratect electrode specifications
Relative Humidity
Up to 100%
Approvals
FM
Approved for steam-system water detection
LVD
EN 61010-1
Pressure Equipment Directive
Safety accessory
Electromagnetic Compatibility
EN 61326-1
9
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August 2015
Hydrastep and Hydratect
Dimensional Drawings
Hydrastep enclosure
Note: Dimensions are in inches (mm).
16.06 (408)
15 (381)
12.8 (325)
2 Slots
0.43 (11) Wide
16.73 (425)
12.2 (310)
1.57
(40)
2 Holes
Ø0.43 (11)
M10 Earth Stud
WeidMuller
Pt No 301859
2.16 (55)
Cable Gland Plate Usable Area:8.27 x 3.15 (210 x 80)
See Note 3
6.42 (163)
NOTES:
1. Weight: 12 kg
2. IP Rating: IP65 / NEMA4X
3. Material Thickness Between Cable Gland Holes Must Be 9 mm Minimum.
4. Enclosure: Brushed Stainless Steel
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Hydrastep and Hydratect
August 2015
Hydratect enclosure
Note: Dimensions are in mm.
229
215
196
190
196
190
25
Ø8
95
M6
Ground
Stud
Outline of front panel
Overall depth = 100 mm (case and panel) + 3 mm (bracket) + 4.5 mm (bolt heads and washers)
11
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Hydrastep and Hydratect
BP2468, Rev EA
Product Data Sheet
August 2015
United Kingdom
Emerson Process Management
Rosemount Measurement Ltd.
158 Edinburgh Avenue
Slough, Berks., SL1 4UE, UK
+44 (0) 1753 756600
+44 (0) 1753 823589
infocentral@emersonprocess.com
North America
Emerson Process Management
Rosemount Inc.
8200 Market Blvd.
Chanhassen, MN 55317, USA
+1 800 999 9307 or +1 952 906 8888
+1 952 949 7001
RMT-NA.RCCRFQ@Emerson.com
The Emerson logo is a trademark and service mark of Emerson Electric Co.
Mobrey and the Mobrey logo are registered trademarks of Rosemount
Measurement Ltd.
Rosemount is a registered trademark of Rosemount Inc.
All other marks are the property of their respective owners.
Standard Terms and Conditions of Sale can be found at
www.rosemount.com\terms_of_sale
© 2015 Rosemount Measurement Ltd. All rights reserved.
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