GESTRA LRG 16-60 Installation & Operating Manual Download Page 13 | Manualshive

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13

LRG 1x-6x - Installation & Operating Manual -

819878-00

Functional safety, safety integrity level (SIL)

In combination with the URS 60/URS 61 safety control unit, LRG 16-60/LRG 16-61/LRG 17-60
conductivity electrodes are suitable for use with safety functions up to SIL 2.
They are each elements of a safety circuit up to a rating of SIL 2 as per EN 61508 in the SPECTORc

onnect system, and

can transmit alarm notifications.
Combining them with accessories produces a type B subsystem. The following information on the techni-
cal and safety characteristics in Fig. 4 are based solely on LRG 1x-6x conductivity electrodes.

Breakdown of safety function failure rates (safety shutoff)

LRG 1x-6x

LRG 1x-6x

Mechanical

LRG 1x-6x

Electronic

CANopen

URS 60,

URS 61

Safety circuit

Fig. 3

The CANopen interface
is a “Black Channel”

be ignored during calculation due to
the low failure rate of < 1FIT.

type, and can

Check the safety function regularly

The functioning of the conductivity electrode must be monitored once a year by triggering the test func-
tion (T1 = 1 year). The test function can be triggered on site via the integrated rotary knob of the terminal
box; see page 52.
Furthermore, it is possible to trigger the test function remotely from URS 60/URS 61 or the external oper-
ating units URB 60 or SPECTOR

control system.

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Summary of Contents for LRG 16-60

Page 1: ...Original Installation Operating Manual Conductivity Electrodes LRG 16 60 LRG 16 61 LRG 17 60 819878 00 E N English ...

Page 2: ...t liability 12 Functional safety safety integrity level SIL 13 Check the safety function regularly 13 Reliability data as per EN 61508 14 Function 15 Technical data 18 Name plate Identification 21 Factory settings 23 Overall view 24 LRG 16 60 24 LRG 16 61 24 LRG 17 60 24 Dimensions of LRG 16 60 26 Dimensions of LRG 17 60 27 Dimensions of LRG 16 61 28 Installation 29 Additional installation notes 3...

Page 3: ... the CAL function 45 Using the FiLt function 46 Changing the scaling of 4 20 mA actual output at LRR 1 60 46 Changing the unit of the display value µS cm or ppm 47 Triggering a display test manually 47 Comparing the measured value with the reference measurement of a reliable sample 48 Checking the alarm limit value Al Hi by triggering a test function 48 Lockout function 48 Start operation alarm an...

Page 4: ...Copyright All rights reserved Any misuse particularly reproduction and dissemination to third parties is not permitted The General Terms Conditions of GESTRA AG apply Scope of delivery Product package 1 x Conductivity electrode LRG 1x 6x 1 x Sealing ring D 33 x 39 form D DIN 7603 2 4068 bright annealed 1 x Installation Operating Manual Accessories 1 x M12 CAN bus connector 5 pole A coded with 120 ...

Page 5: ... in full and follow all instructions Please also read the instructions for use of any accessories The Installation Operating Manual is part of the equipment package Keep it in an easily accessible location Availability of this Installation Operating Manual Make sure this Installation Operating Manual is always available to the operator If you pass on or sell the equipment to a third party please a...

Page 6: ...tuation that results in death or serious injury WARNING Warning of a dangerous situation that may possibly result in death or serious injury CAUTION Warning of a situation that may result in minor or moderate injury ATTENTION Warning of a situation that results in damage to property or the environment ...

Page 7: ...y integrity level Safety integrity levels SIL 1 to 4 are used to quantify risk reduction SIL 4 is the highest level of risk reduction International standard IEC 61508 forms the basis for establishing testing and operating technical safety systems CAN Controller Area Network bus Data transmission standard and interface for connecting electronic equipment sensors and control systems Data can be sent...

Page 8: ... LRG 17 60 conductivity electrodes have been tested and approved for use in the area governed by the following directives and standards Directives Directive 2014 68 EU EU Pressure Equipment Directive Directive 2014 35 EU Low Voltage Directive Directive 2014 30 EU EMC Directive Directive 2011 65 EU RoHS II Directive Standards EN 12953 09 Shell boilers requirements for limiting devices EN 12952 11 W...

Page 9: ...wdown controller limit indicator or automatic intermittent blowdown Operating unit SIL 2 as per EN 61508 LRG 16 60 LRG 17 60 LRG 16 61 URS 60 URS 61 URB 60 SPECTOR control without safety level in line with EN 61508 LRG 16 60 LRG 17 60 LRG 16 61 LRR 1 60 URB 60 SPECTOR control Fig 1 Key to Fig 1 LRG Conductivity electrode URS Safety control unit URB Visual display and operating unit LRR Conductivit...

Page 10: ... due to explosion if the equipment is used in potentially explo sive atmospheres Do not use the equipment in potentially explosive atmospheres Do not bring any equipment into service that does not have its own specific name plate The name plate indicates the technical features of the equipment ...

Page 11: ...e voltage to the system before performing connection work Check that the system is not carrying live voltage before commencing work Danger to life from faulty LRG 1x 6x conductivity electrodes due to the sudden escape of hot steam or hot water Impacts or knocks during transportation or installation can cause the 1x 6x conductivity elec trodes to become damaged whereby hot steam or hot water can es...

Page 12: ...Maintenance work Specialist staff Maintenance and modifications may only be performed by authorised staff who have undergone specific training Modifications Specialist staff Persons trained by the plant operator to work with pressure and temperature Fig 2 Notes on product liability We the manufacturer cannot accept any liability for damages resulting from improper use of the equip ment Basic safet...

Page 13: ...re based solely on LRG 1x 6x conductivity electrodes Breakdown of safety function failure rates safety shutoff LRG 1x 6x LRG 1x 6x Mechanical LRG 1x 6x Electronic CANopen URS 60 URS 61 Safety circuit Fig 3 The CANopen interface is a Black Channel be ignored during calculation due to the low failure rate of 1FIT type and can Check the safety function regularly The functioning of the conductivity el...

Page 14: ...5 0 Test interval T1 1 year T1 1 year Probability of dangerous failure on demand PFD 100 10 5 PFD 160 10 5 Diagnostic coverage Percentage of dangerous failures detected by a test DC 95 0 DC 91 0 Mean time to dangerous failure MTTFd 30 a MTTFd 30 a Diagnostic interval T2 1 hour T2 1 hour Performance level as per ISO 13849 PL d PL d Probability of dangerous failure per hour PFH 20 10 8 1 h PFH 35 10...

Page 15: ...re In order to base the measured values on a reference temperature an integrated resistance thermometer therefore measures the medium s temperature The electrical conductivity is calculated from the measuring current and the measuring voltage and is based on the reference temperature of 25 C through temperature compensation Compensation process The measured value of the conductivity is corrected l...

Page 16: ... the URS 60 or URS 61 safety control unit via CAN data telegram Once the time delay has elapsed the alarm signal triggers the safety shutoff in the safety control unit The URS 60 or URS 61 safety control unit does not lock automatically for this The LEDs 1 and 4 signal the corresponding MAX alarm case see page 51 The safety circuit is interrupted without a delay if the following faults occur Fault...

Page 17: ...0 The device combination will then behave as if a normal alarm had been triggered The tables from page 49 clearly show the relationship between the equipment status the display and the alarm LEDs Parametrising or changing the factory settings If necessary you can adapt the conductivity electrode to the system conditions on site You can set the parameters or change the factory settings by means of ...

Page 18: ...in body Measuring tube measuring screw LRG 16 60 LRG 17 60 1 4571 X6CrNiMoTi17 12 2 Spacer LRG 16 60 LRG 16 61 LRG 17 60 PEEK Deliverable installation lengths of the electrodes cannot be shortened LRG 16 60 LRG 17 60 200 300 400 500 600 800 1000 mm LRG 16 61 180 300 380 500 600 800 1000 mm Temperature sensor Resistance thermometer Pt 1000 Measuring range for the temperature of the medium 0 to 280 ...

Page 19: ...ge 3 2000 µS 50000 µS 2 1 Triggering internal processing based on 15 bit with sign before 16 bit The aforementioned values are related to uncompensated conductivity Time constant T measured using the two bath process Temperature Conductivity LRG 16 60 LRG 17 60 9 seconds 14 seconds LRG 16 61 11 seconds 19 seconds Temperature compensation The temperature compensation process is linear and is adjust...

Page 20: ...lues and status information 1 x red LED for indicating an alarm state 3 x green LED for indicated the unit μS cm ppm and the OK state 1 x rotary knob IP65 with button for menu navigation and test function Protection class III Safety Extra Low Voltage SELV IP rating as per EN 60529 IP 65 Admissible ambient conditions Service temperature 0 C 70 C Storage temperature 40 C 80 C Transport temperature 4...

Page 21: ... is stamped in at the screw in body of each conduc tivity electrode Admissible operating pressure admissible temperature Admissible ambient temperature Measuring range Safety integrity level Data interface Betriebsanleitung beachten See installation instructions Voir instructions de montage 0525 GESTRA AG Münchener Str 77 28215 Bremen GERMANY TÜV XXX XX XXX IEC 61508 SIL 2 LRG 16 60 Leitfähigkeits...

Page 22: ...uctibilitè 70 C 158 F T Pmax Pmax Tmax Tmax PN40 G1 1 4571 IP65 32 bar 464psi 238 C 460 F 7 VA 50 10000µS cm 25 5000ppm IN OUT CAN Bus V 20 24 Betriebsanleitung beachten See installation instructions Voir instructions de montage 0525 GESTRA AG Münchener Str 77 28215 Bremen GERMANY TÜV XXX XX XXX IEC 61508 SIL 2 LRG 17 60 Leitfähigkeitselektrode Conductivity electrode Electrode de mesure de conduct...

Page 23: ...ay in menu Unit Parameter values LRG 16 60 LRG 17 60 LRG 16 61 Limiter ID Id Hi OFF Controller group GrP 0001 Baud rate bd rt kBit s 0050 Alarm limit value AL Hi µS cm 3000 5000 Cell constant CF 0 210 Temperature coefficient tC C 002 1 Filter constant damping FiLt Seconds 0025 Scale of current output LRR 1 60 Sout µS 0500 7000 Display unit Unit µS Fig 7 ...

Page 24: ...24 LRG 1x 6x Installation Operating Manual 819878 00 OK Overall view Fig 8 OK A B C D E G K LRG 16 60 LRG 16 61 J H F I L LRG 17 60 OK ...

Page 25: ...ge 49 C Cover screws M4 x 16 mm D M12 CAN bus socket 5 pole A coded E M12 CAN bus connector 5 pole A coded F Sheath G Seal seat for sealing ring H Sealing ring D 33 x 39 form D DIN 7603 2 4068 bright annealed I Electrode thread J Threaded pin M2 5 mm LRG 16 60 LRG 17 60 K Measuring tube with measuring electrode LRG 16 60 LRG 17 60 measuring electrodes LRG 16 61 L Spacer ...

Page 26: ...s of LRG 16 60 Fig 9 All lengths and diameters in mm OK G 1 Size 41 0 Nm 50 70 90 110 120 100 80 60 41 140 175 338 x b 70 x available installation lengths 200 mm 300 mm 400 mm 500 mm 600 mm 800 mm 1000 mm Thermal insulation provided at the site of installation 20 ...

Page 27: ...ions of LRG 17 60 140 175 338 x x available installation lengths 200 mm 300 mm 400 mm 500 mm 600 mm 800 mm 1000 mm Size 41 G 1 All lengths and diameters in mm Fig 10 b 70 0 Nm 50 70 90 110 120 100 80 60 41 Thermal insulation provided at the site of installation 20 ...

Page 28: ...sions of LRG 16 61 140 175 338 x x available installation lengths 180 mm 300 mm 380 mm 500 mm 600 mm 800 mm 1000 mm b 70 Size 41 G 1 Fig 11 All lengths and diameters in mm 0 Nm 50 70 90 110 120 100 80 60 41 Thermal insulation provided at the site of installation 20 ...

Page 29: ...e connecting cable Take further measures to protect the equipment from lightning insects and animals and salty air You will need the following tools Torque wrench with size 41 open ended spanner attachment see pages 26 to 28 and page 32 DANGER Danger to life from scalding caused by sudden escape of hot steam Hot steam or hot water can escape suddenly if conductivity electrodes are unscrewed under ...

Page 30: ...g torques Additional installation notes ATTENTION An electrode that is not fully immersed in the medium leads to incorrect measurement results and jeopardises system safety Install the conductivity electrode such that it is always fully immersed in the medium As far as possible always install the conductivity electrode below the admissible LW mark Measuring points metallic objects between the boil...

Page 31: ...for LRG 16 60 LRG 16 61 LRG 17 60 Fig 12 Example LRG 1x 60 G H Fig 13 DANGER Danger to life from escaping hot steam if incorrect or defective seals are used Only use the supplied sealing ring for sealing the electrode thread I Sealing ring D 33 x 39 DIN 7603 2 4068 bright annealed Prohibited seal materials Hemp PTFE tape Conductive paste or grease 2 Push the supplied sealing ring H onto the seal s...

Page 32: ...o the electrode thread I 4 Screw the conductivity electrode into the threaded standpipe of the tank or flange cover and tighten securely using a torque wrench with size 41 open ended spanner attachment Tightening torque when cold LRG 16 60 LRG 16 61 LRG 17 60 250 Nm Installation examples with dimensions see Fig 14 Fig 15 Fig 16 from page 33 ...

Page 33: ...mensions Conductivity measurement Installation of conductivity electrodes via a side flange Key see page 36 Fig 14 400 All lengths and diameters in mm 338 250 G1 1 e g LRG 16 60 Minimum distances R LRG 16 60 LRG 17 60 R 30 mm LRG16 61 R 60 mm Sealing ring D 33 x 39 DIN 7603 2 4068 bright annealed ...

Page 34: ...uous blow down valve Key see page 36 Minimum distances R LRG 16 60 LRG 17 60 R 30 mm LRG16 61 R 60 mm Fig 15 Installation examples with dimensions All lengths and diameters in mm NW LW NB R A OK 600 338 250 197 G1 1 2 3 Sealing ring D 33 x 39 DIN 7603 2 4068 bright annealed e g LRG 16 60 4 Distance A depending on connection flange DN 15 mm A 182 mm DN 20 mm A 184 mm DN 25 mm A 184 mm DN 40 mm A 18...

Page 35: ...nuous blowdown control via a separate measuring vessel Installation of conductivity electrode in the continuous blowdown line via a separate measuring vessel Key see page 36 M OK Outlet 3 2 DN 15 40 G1 Inlet DN 15 40 5 Sealing ring D 33 x 39 DIN 7603 2 4068 bright annealed e g LRG 16 60 All lengths and diameters in mm Fig 16 ...

Page 36: ...lowdown valve BAE 4 Connection piece in T shape 5 Measuring vessel Aligning the terminal box If necessary you can orientate the display in the desired direction by rotating the terminal box ATTENTION Rotating the terminal box 180 will damage the conductivity electrode s internal wiring Never rotate the terminal box more than 180 degrees in either direction ...

Page 37: ...00 Functional elements A Terminal box B Cover screws M4 x 16 mm C Operating panel with 4 digit LCD display alarm and status LEDs and rotary knob see page 49 D M12 CAN bus socket 5 pole A coded E M12 CAN bus connector 5 pole A coded Fig 17 OK A B C D E ...

Page 38: ... 24 V is required per sensor With 5 sensors there is therefore a voltage drop of approx 8 V per 100 m when using cables of 0 5 mm In this case the system is operating at its limits With 5 sensors or more and a cable length of 100 m the wire cross section needs to be doubled to 1 0 mm At larger distances of 100 m the 24 V DC supply can also be connected on site Connecting the CAN bus system Example...

Page 39: ...st be connected to the first and last devices between terminals CL CH Use the CAN bus connector with terminating resistor if you are using the conductivity electrode as the first or last device Only one URS 60 and one URS 61 safety control unit may be used in the CAN bus network The CAN bus network must not be interrupted during operation If it is an alarm signal is triggered Pin assignment of the...

Page 40: ...ne after the other when you turn the rotary knob clockwise 1234 Id Hi GrP bd rt C in C Pt AL Hi CF tC CAL FiLt Sout Unit diSP Key to parameters see page 41 4 Save your set value by pressing the rotary knob for approx 1 second The message donE is shown and the parameter appears on the display again If you do not enter anything for 30 seconds the display automatically shows the actual value again 2 ...

Page 41: ...ntroller LRR 1 60 Unit Unit of display value µS or ppm diSP Trigger a display test Upstream display test for safety relevant parameters There is a display test upstream of some safety relevant parameters e g AL Hi This is intended to pre vent an incorrect value being entered due to faulty display segments that have not yet been noticed Setting example see page 43 Using the alarm limit value for th...

Page 42: ...n Operating Manual of the URB 60 visual display and operating unit or the SPECTORcontrol Changing the baud rate Note the setting instructions on page 40 and proceed as follows 1 Select the parameter bd rt 2 Press and hold the rotary knob until the current baud rate flashes on the display 3 Set the desired baud rate 50 kBit s 250 kBit s 4 Save your set value by pressing the rotary knob for approx 1...

Page 43: ...er are independent from this For this also observe the information in the relevant Installation Operating Manual Note the setting instructions on page 40 and proceed as follows 1 Select the parameter AL Hi 2 Press and hold the rotary knob until the display test starts by showing 3 The following numbers and decimal points run across the display from right to left 1 2 3 4 5 6 7 8 9 4 Check that all ...

Page 44: ...value can be correlated manually with a reference measured value from a reliable sample at the operation site Alternatively the readjustment can be performed using a convenient solution by means of the CAL function see page 45 Note the setting instructions on page 40 and proceed as follows 1 Select the parameter CF 2 Press and hold the rotary knob until the current value flashes on the display 3 S...

Page 45: ...cts it ATTENTION If the CF value cell constant 003 0 is exceeded there is a warning message CF Hi Clean the electrode as a matter of urgency see page 59 Operation continues to be possible Note the setting instructions on page 40 and proceed as follows 1 Determine a reference measured value for the current conductivity by means of a reliable sample in the operating point of the system 2 Select the ...

Page 46: ... setting instructions on page 40 and proceed as follows 1 Select the parameter FiLt After this the current value of the filter constant is shown first 2 Press and hold the rotary knob until the current value flashes on the display 3 Set the desired value 4 Save your set value by pressing the rotary knob for approx 1 second Changing the scaling of 4 20 mA actual output at LRR 1 60 Note the setting ...

Page 47: ...he rotary knob for approx 1 second Triggering a display test manually Note the setting instructions on page 40 and proceed as follows 1 Select the parameter diSP 2 Press and hold the rotary knob until the display test starts by showing 3 The following numbers and decimal points run across the display from right to left 1 2 3 4 5 6 7 8 9 4 Check that all numbers and decimal points are displayed cor...

Page 48: ...are the measured value with the actual reference measured value Never bring any system into operation without successfully checking the conductivity value For new or cleaned electrodes and identified deviations the parameter tC is to be changed until the displayed measured value corresponds with the reference measurement Also see parameter description tC on page 44 LRG 1x 6x conductivity electrode...

Page 49: ...tion and settings 1 2 3 6 4 5 Notes on the display priority of the various messages Error messages and alarms are displayed based on their priority Messages with higher priority are shown continuously before those with low priority if several messages need attention the display does not alternate between them Priority 1 Error messages according to fault code table see page 54 ff Priority 2 Conduct...

Page 50: ... tested The LEDs and display are tested Normal operation The conductivity electrode is immersed Display 1234 LED 1 is Off LED 3 or 4 lights up green Display of the current temperature compensated conductivity Display of the set unit LED 2 flashes green The equipment is performing a self test LED 2 lights up green The self test is complete the equipment is OK During the self test phase the measured...

Page 51: ...not automatically lock the safety contacts Behaviour in the event of an error fault code display The conductivity electrode is immersed or not immersed There is an error Display e g E005 LED 1 Alarm LED lights up red A fault code is permanently displayed fault code display see page 54 There is an active error LED 3 or 43 lights up green Display of the set unit LED 2 flashes green The equipment is ...

Page 52: ...ctual measured value are displayed alternately The MAX alarm is active LED 3 or 4 lights up green Display of the set unit LED 2 flashes green The equipment is performing a self test LED 2 is OFF MAX alarm occurrence The URS 60 URS 61 safety control unit or the device combination behaves as if there were a real alarm see page 51 After the test simulation has been cancelled letting go of the test bu...

Page 53: ...rm to the wiring diagrams Is the bus line polarity correct throughout Is a 120 Ω terminating resistor terminated at the terminal devices of the CAN bus line Configuration of the conductivity electrodes Is the conductivity electrode set to the correct limiter ID 1 2 3 4 5 6 7 8 Limiter IDs must not be assigned in duplicate Baud rate Is the cable length correct for the set baud rate Is the baud rate...

Page 54: ...t Pt1000 exceed ed or cable break Check installation location Replace the conductivity electrode E 006 Ch1Ch2PtDiffErr Difference of redundant Pt1000 measure ment too high Replace the conductivity electrode E 007 USIGTSTErr Measuring voltage of test signal outside limits Replace the conductivity electrode E 008 ISIGTSTErr Measuring current of test signal outside limits Replace the conductivity ele...

Page 55: ... System voltage 1 V outside limits Replace the conductivity electrode E 023 V12Err System voltage 12 V outside limits Replace the conductivity electrode E 024 CANErr Communication failure Check the baud rate wiring and terminating resistors E 025 ESMG1Err µC fault Replace the conductivity electrode E 026 BISTErr µC periphery self test fault Replace the conductivity electrode E 027 OvertempErr PCB ...

Page 56: ...dentical in construction The displayed conductivity shows rare but sporadically recurring extreme values Possible causes if no fault messages are present Remedy The electrode rods are not permanently immersed Check the executed installation using the Manual Note the installation examples and the specified mini mum distances Flashing values from t 71 to t 75 appear on the display Possible causes Re...

Page 57: ...ty electrode the displayed measured value and the set alarm limit value must be checked and an equipment test must be performed System errors in the LRG 1x 6x conductivity electrode also trigger a system error in the URS 60 URS 61 safety control unit The output contacts open without a delay and the relevant signal output is activated If you require assistance please tell us the indicated fault cod...

Page 58: ... bar WARNING Hot conductivity electrodes can cause severe burns The conductivity electrodes are extremely hot during operation Perform installation and maintenance work only on conductivity electrodes that have been allowed to cool Only remove conductivity electrodes that have cooled down Proceed as follows 1 Reduce the boiler pressure to 0 bar 2 Allow the conductivity electrode to cool to room te...

Page 59: ...electrode must be taken out of operation and removed see page 58 LRG 16 60 LRG 17 60 1 Loosen the threaded pin J and unscrew the measuring tube K by hand 2 Clean the electrode rod and the measuring surfaces 3 Then screw the measuring tube K back on and secure it with the threaded pin J LRG 16 61 1 Clean the measuring electrodes K Continue with the following points J K Key to the overall view see p...

Page 60: ...STRA AG can accept returned goods only if accompanied by a completed and signed return note and also a completed and signed decontamination declaration The return confirmation and decontamination declaration must be attached to the returned goods and be accessible from the outside Otherwise the goods cannot be dealt with and will be returned carriage unpaid Please proceed as follows 1 Let GESTRA A...

Page 61: ...es Directive 2014 68 EU EU Pressure Equipment Directive Directive 2014 35 EU Low Voltage Directive Directive 2014 30 EU EMC Directive Directive 2011 65 EU RoHS Directive Please see our Declaration of Conformity for details on the conformity of our equipment with European Directives The current Declaration of Conformity can be found on the Internet at www gestra com or requested from us ...

Page 62: ...62 LRG 1x 6x Installation Operating Manual 819878 00 For your notes ...

Page 63: ...63 LRG 1x 6x Installation Operating Manual 819878 00 ...

Page 64: ... Bremen Germany Phone 49 421 3503 0 Fax 49 421 3503 393 e mail info de gestra com Web www gestra com You can find our authorised agents around the world at www gestra com 819878 00 08 2019cm 808950 00 GESTRA AG Bremen Printed in Germany ...

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