GESTRA LRGT 16-3 Installation & Operating Manual Download | Manualshive

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LRGT 1x-x - Installation & Operating Manual -

819877-00

Installation

ATTENTION

Incorrect installation can lead to malfunctions in the system or the conductivity

electrode.

■

■

Inspect the sealing surfaces of tank threaded couplings or flange covers to ensure they are
perfectly machined, see Fig. 10.

■

■

Take care not to bend the electrode rods during installation!

■

■

Do not subject measuring electrodes to hard impacts during installation.

■

■

Do

not

install the body

A

or sheath

E

of the measuring electrode in the boiler thermal

insulation!

■

■

Pay attention to the mounting dimensions of the conductivity electrode, see installation
examples on pages 31 to 34.

■

■

Check the boiler connection and flange during the preliminary boiler inspection.

■

■

Tighten to the specified torques.

Additional notes for installation

ATTENTION

If the electrode is not fully immersed in the fluid, measurement results may be false

and there is a risk to plant safety.

■

■

Install the conductivity electrode in such a way that the measuring electrodes are always
fully immersed in the fluid.

■

■

As far as possible, always install the conductivity electrode below the admissible LW mark.

Ground points (metal objects) between the boiler wall and the electrode have

an adverse effect on measurement. False measurement results are a risk to plant safety.

Therefore, always adhere to the distances stated below.

LRGT 16-3, LRGT 17-3

■

■

Provide spacing of approx. 30 mm between the lower end of the measuring tube and the
boiler wall, the smoke tubes and any other metallic fittings, and the low water level (LW).

■

■

Do not shorten the measuring electrode or measuring tube.

LRGT 16-4

■

■

Provide spacing of approx. 60 mm between the lower end of the measuring tube and the
boiler wall, the smoke tubes and any other metallic fittings, and the low water level (LW).

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Summary of Contents for LRGT 16-3

Page 1: ...Original Installation Operating Manual Conductivity Transmitter LRGT 16 3 LRGT 16 4 LRGT 17 3 819877 00 E N English ...

Page 2: ...duct liability 11 Functional safety safety integrity level SIL 12 Check the secure current output regularly 12 Reliability data to EN 61508 13 Function 14 Technical data 16 Name plate Identification 19 Factory settings 21 Overall view 22 LRGT 16 3 22 LRGT 16 4 22 LRGT 17 3 22 Overall view 23 Dimensions of the LRGT 16 3 24 Dimensions of the LRGT 16 4 25 Dimensions of the LRGT 17 3 26 Installation 2...

Page 3: ...tion 41 Using the FiLt feature 42 Changing the scale of the 4 20 mA actual value output 42 Changing the display unit µS cm or ppm 43 Manually initiating a display test 43 Comparing the reading with the reference reading from a reliable sample 44 Starting operation and testing 45 System malfunctions 48 Causes 48 Indication of system malfunctions using fault codes 49 Faults that do not provoke a shu...

Page 4: ...eserved 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 transmitter LRGT 1x x 1 x sealing ring D 33 x 39 form D DIN 7603 2 4068 bright annealed 1 x Installation Operating Manual Required accessories for LRGT 16 3 LRGT 17 3 and LRGT 16 4 when installing for the...

Page 5: ...ual in full and follow all instructions Please also read the instructions for use of any accessories The Installation Operating Manual is part of the product 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 ...

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: ...al standard IEC 61508 forms the basis for establishing testing and operating technical safety systems LRGT LRR URS URB SRL etc Equipment and type designations of GESTRA AG SELV Safety Extra Low Voltage Operating point of the system The operating point describes the operating parameters at which a plant or boiler is operated in the nominal range In a pressurised steam plant for example these parame...

Page 8: ...icable directives and standards LRGT 16 3 LRGT 16 4 and LRGT 17 3 conductivity transmitters have been tested and approved for use in the scope 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 60730 1 Auto...

Page 9: ...l is dictated by the lowest SIL rating of a participant in the event chain as a whole Systems without SIL rating In systems without a SIL rating any controller display unit or diagnostic tester with an input for a standard 4 20 mA signal can be connected To ensure the proper use of equipment during all types of use please also read the Installation Operating Manuals for the system components used ...

Page 10: ...nt before performing connection work Check that the plant is not carrying live voltage before commencing work Danger to life from a faulty LRGT 1x x conductivity electrode due to the sudden escape of hot steam or hot water Shocks and impacts during transport or installation can result in damage to or leaks in the con ductivity electrode causing pressurised hot steam or hot water to escape through ...

Page 11: ...d conversions may only be performed by authorised staff who have undergone specific training Refits Specialist staff Persons trained by the plant operator to work with pressure and temperature Fig 1 Notes on product liability We the manufacturer cannot accept any liability for damages resulting from improper use of the equipment Basic safety information A lack of proper maintenance and cleaning ca...

Page 12: ...ystem can be operated at this safety integrity level When combined with the accessories you will have a type B subsystem The technical and safety characteristics in Fig 2 below are based solely on LRGT 16 3 LRGT 16 4 and LRGT 17 3 conductivity transmitters Check the secure current output regularly Once a year check that conductivity transmitters are functioning correctly by initiating the test fun...

Page 13: ...tion SFF 95 0 SFF 90 0 Test interval T1 1 year T1 1 year Probability of failure on demand PFD 50 10 4 PFD 50 10 4 Diagnostic coverage Percentage of dangerous failures detected by a test DC 90 0 DC 85 0 Mean time to failure MTTFd 30 a MTTFd 30 a Diagnostic interval T2 1 hour T2 1 hour Performance level to ISO 13849 PL d PL d Probability of failure per hour PFH 50 10 8 1 h PFH 50 10 8 1 h Ambient te...

Page 14: ...ductivity changes as a function of the temperature In order to base the readings on a reference temperature an integrated resistance thermometer measures the temperature of the fluid The electrical conductivity is calculated from the measuring current and measuring voltage and then based on the reference temperature of 25 C through temperature compensation Compensation process Based on a set tempe...

Page 15: ...ions The error state or malfunction is shown on the display by a fault code e g E 005 For more on fault codes see page 49 50 Every time there is a fault 0 mA is output via the current output Electrode faults cannot be acknowledged When the fault is corrected the message also disappears from the display of the conductivity transmitter and the LRGT 16 3 LRGT 17 3 or LRGT 16 4 returns to normal opera...

Page 16: ...insulation PTFE Screw in body Measuring tube screw of LRGT 16 3 LRGT 17 3 1 4571 X6CrNiMoTi17 12 2 Spacer disc of LRGT 16 3 LRGT 16 4 LRGT 17 3 PEEK Available electrode lengths do not shorten LRGT 16 3 LRGT 17 3 200 300 400 500 600 800 1000 mm LRGT 16 4 180 300 380 500 600 800 1000 mm Temperature sensor Resistance thermometer Pt 1000 Fluid temperature measuring range 0 to 280 C Conductivity range ...

Page 17: ...3 2000 µS 50000 µS 2 1 Resolution for internal processing based on 15 bits with plus or minus sign 16 bits The above figures refer to the uncompensated conductivity Time constant T measured using the two bath process Temperature Conductivity LRGT 16 3 LRGT 17 3 9 seconds 14 seconds LRGT 16 4 11 seconds 19 seconds Temperature compensation The temperature compensation process is linear and set via p...

Page 18: ...formation 1 x red LED for indicating an error state 3 x green LEDs for indicating the unit μS cm ppm and OK status 1 x rotary knob IP65 with button for menu navigation and test function Protection class III Safety Extra Low Voltage SELV IP rating to EN 60529 IP 65 Admissible ambient conditions Service temperature 0 C 70 C Storage temperature 40 C 80 C Transport temperature 40 C 80 C Air humidity 1...

Page 19: ... 32 bar 464psi 238 C 460 F 7 VA 0 5 6000µS cm 0 25 3000ppm OUT 4 20 mA 500 V 20 24 IP rating Supply voltage CE marking Appointed authority Disposal information Protection class Fig 3 The date of production quarter and year is stamped on the screw in body of each conductivity transmitter Power consumption Safety note Equipment designation Equipment function Nominal pressure rating connection thread...

Page 20: ...bilité 70 C 158 F T Pmax Pmax Tmax Tmax P 40 G1 1 4571 IP65 N 32 bar 464psi 238 C 460 F 7 VA 50 10000µS cm 25 5000ppm OUT 4 20 mA 500 V 20 24 IEC 61508 SIL 2 Betriebsanleitung beachten See installation instructions Voir instructions de montage LRGT 17 3 0525 GESTRA AG Münchener Str 77 28215 Bremen GERMANY TÜV XXX XX XXX Leitfähigkeitstransmitter Conductivity Transmitter Transmetteur de mesure de c...

Page 21: ...des are delivered ex works with the following settings Parameter Display in menu Unit Parameter values LRGT 16 3 LRGT 17 3 LRGT 16 4 Cell constant CF 0 210 Temperature coefficient tC C 002 1 Filter constant damping FiLt seconds 0025 Scale of current output Sout µS 0500 7000 Display unit Unit µS Fig 5 ...

Page 22: ...22 LRGT 1x x Installation Operating Manual 819877 00 OK Overall view Fig 6 OK A B C D F J LRGT 16 3 LRGT 16 4 I G E H K LRGT 17 3 OK ...

Page 23: ...ary knob see page 45 C Cover screws M4 x 16 mm D M12 connector 5 pole A coded E Sheath F Seal seat for sealing ring G Sealing ring D 33 x 39 form D DIN 7603 2 4068 bright annealed H Electrode thread I Threaded pin M2 5 mm LRGT 16 3 LRGT 17 3 J Measuring tube with measuring electrode LRGT 16 3 LRGT 17 3 measuring electrodes LRGT 16 4 K Spacer disc ...

Page 24: ...imensions of the LRGT 16 3 Fig 7 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 electrode lengths 200 mm 300 mm 400 mm 500 mm 600 mm 800 mm 1000 mm Thermal insulation provided at the site 20 ...

Page 25: ...OK Dimensions of the LRGT 16 4 140 175 338 x x available electrode lengths 180 mm 300 mm 380 mm 500 mm 600 mm 800 mm 1000 mm Size 41 G 1 All lengths and diameters in mm Fig 8 b 70 0 Nm 50 70 90 110 120 100 80 60 41 Thermal insulation provided at the site 20 ...

Page 26: ...K Dimensions of the LRGT 17 3 140 175 338 x x available electrode lengths 200 mm 300 mm 400 mm 500 mm 600 mm 800 mm 1000 mm b 70 Size 41 G 1 Fig 9 All lengths and diameters in mm 0 Nm 50 70 90 110 120 100 80 60 41 Thermal insulation provided at the site 20 ...

Page 27: ...ing 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 24 to 26 and page 30 DANGER Danger to life from scalding caused by the sudden escape of hot steam Hot steam or hot water can escape suddenly if the conductivity electrode is unscrewed while und...

Page 28: ... ATTENTION If the electrode is not fully immersed in the fluid measurement results may be false and there is a risk to plant safety Install the conductivity electrode in such a way that the measuring electrodes are always fully immersed in the fluid As far as possible always install the conductivity electrode below the admissible LW mark Ground points metal objects between the boiler wall and the ...

Page 29: ...ions for LRGT 16 3 LRGT 16 4 LRGT 17 3 Fig 10 Example LRGT 16 3 F G Fig 11 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 H 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 G onto the s...

Page 30: ... to the electrode thread 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 LRGT 16 3 LRGT 16 4 LRGT 17 3 250 Nm Installation examples with dimensions see Fig 12 Fig 13 Fig 14 page 31 ff 31 ...

Page 31: ...nsions Conductivity measurement Installing conductivity transmitters via a flange on the side Key see page 34 Fig 12 400 All lengths and diameters in mm 338 250 G1 1 e g LRGT 16 3 Minimum distances R LRGT 16 3 LRGT 17 3 R 30 mm LRGT 16 4 R 60 mm Sealing ring D 33 x 39 DIN 7603 2 4068 bright annealed ...

Page 32: ... connection Key see page 34 Minimum distances R LRGT 16 3 LRGT 17 3 R 30 mm LRGT 16 4 R 60 mm Fig 13 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 LRGT 16 3 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 189 mm ...

Page 33: ...ng and continuous blowdown control via a separate level pot Installing the conductivity transmitter in the blowdown line via a separate level pot Key see page 34 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 LRGT 16 3 All lengths and diameters in mm Fig 14 ...

Page 34: ... Continuous blowdown valve BAE 4 T type connector 5 Level pot 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 35: ...ating Manual 819877 00 Functional elements Fig 15 OK A Terminal box B Cover screws M4 x 16 mm C Operating panel with 4 digit LCD display malfunction and status LEDs and rotary knob see page 45 D M12 connector 5 pole A coded A B C D ...

Page 36: ...4 V DC A safety power supply unit that delivers a Safety Extra Low Voltage SELV and is isolated from connected loads must be used to supply the equipment with 24 V DC Connecting the actual value output 4 20 mA Please note the maximum output load of 500 W Maximum cable length 100 m Pin assignment of the M12 connector for non pre wired control cables If non pre wired control cables are used you must...

Page 37: ...ing the factory settings if necessary You will need the following tools Slotted screwdriver size 2 5 Notes for bringing into service for the first time When the equipment is brought into service for the first time the scale of the current output is set to 500 µS 20 mA for the LRGT 1x 3 and 7000 µS 20 mA for the LRGT 16 4 After installation first change the scale to suitable values for your specifi...

Page 38: ...range By pressing the knob briefly you can jump to the next digit This is a more convenient way of making large changes to values If you do not set a parameter within 10 seconds the process is aborted quit and the old parameter value is retained Bringing into service Selecting and setting a parameter 1 Using the screwdriver turn the rotary knob clockwise or anti clockwise until the desired paramet...

Page 39: ...t Its aim is to prevent the entry of an incorrect value due to undetected faulty display segments For this test the user is required to keep an eye on the display segments during the test to determine whether any segments are faulty When the first safety relevant parameter is selected the one off display test opens a 10 minute time window during which time several safety relevant parameters can be...

Page 40: ...oiler capacity in order to minimise false results due to vapour bubbles This parameter can be used to manually adjust the display value on site in line with a reference reading from a reliable sample Alternatively you can perform recalibration using the convenient CAL function see page 41 Pay attention to the setting instructions on page 38 39 and proceed as follows 1 Select the parameter CF 2 Pre...

Page 41: ...cell constant CF when the electrode gets increasingly soiled during operation Here the reference reading of a reliable sample is converted into the display value at the operating point The internal processor then automatically recalculates and corrects the cell constant CF ATTENTION If the CF cell constant value of 003 0 is exceeded the warning message CF Hi will appear The electrode urgently requ...

Page 42: ...is displayed 2 Press and hold the rotary knob until the current value flashes on the display 3 Set the desired value 4 Save your setting by pressing the rotary knob for approx 1 second Changing the scale of the 4 20 mA actual value output Pay attention to the setting instructions on page 38 39 and proceed as follows 1 Select the parameter Sout 2 Press and hold the rotary knob until the current val...

Page 43: ...r setting by pressing the rotary knob for approx 1 second Manually initiating a display test Pay attention to the setting instructions on page 38 39 and proceed as follows 1 Select the parameter diSP 2 Press and hold the rotary knob until the display test starts and shows 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...

Page 44: ...ode is brought into service or replaced proceed as follows Establish the current conductivity of the boiler water with the aid of a reference reading from a controlled sample at the desired plant operating point Compare the indicated reading with the current reference reading Never start up any plant that has not passed this check of the conductivity value If electrodes are new or have been cleane...

Page 45: ...sh button for operation and settings OK 1 2 3 6 4 5 Notes on the priority of the various indications Fault indications are displayed based on their priority Indications with higher priority are shown continuously before those with low priority If several indications need attention the display does not alternate between them Priority of fault code display Higher priority fault codes overwrite lower...

Page 46: ... test is complete the unit is OK The reading is not updated during the selftest phase Behaviour in the event of a malfunction fault code display The measuring electrodes of the conductivity transmitter are immersed or not immersed There is a fault Display e g E005 LED 1 Alarm LED lights up red A fault code is permanently displayed fault code display see page 49 There is an active fault LED 3 or 4 ...

Page 47: ... performs a self test LED 2 lights up green Test function is active 20 mA is output at the current output of the conductivity electrode The down stream control can be checked based on the MAX alarm for example When the rotary knob is released the test ends Faulty equipment jeopardises system safety If the conductivity transmitter does not behave as described above the equipment may be faulty Perfo...

Page 48: ... of temperature vibration interference sources minimum distances etc Wiring Does the wiring conform to the wiring diagrams Does the 4 20 mA current loop have the correct polarity and is it closed Is the 4 20 mA current loop below the overall output load of 500 Ω ATTENTION An open circuit in the 4 20 mA current loop can cause a system shutdown and a malfunction is indicated Bring the system into a ...

Page 49: ...rr Pt1000 above maximum temperature or open circuit Check installation location Replace conductivity transmitter E 006 Ch1Ch2PtDiffErr Excessive difference from redundant Pt1000 measurement Replace conductivity transmitter E 007 USIGTSTErr Test signal measuring voltage outside tolerance Replace conductivity transmitter E 008 ISIGTSTErr Test signal measuring current outside tolerance Replace conduc...

Page 50: ...ltage 1 V outside tolerance Replace conductivity transmitter E 023 V12Err System voltage 12 V outside tolerance Replace conductivity transmitter E 024 CANErr Communication error not LRGT models Check the baud rate wiring and terminating resistors E 025 ESMG1Err µC error Replace conductivity transmitter E 026 BISTErr µC periphery self test error Replace conductivity transmitter E 027 OvertempErr PC...

Page 51: ...t from GESTRA AG The indicated conductivity very occasionally but repeatedly displays extreme values Possible causes if no error messages appear Remedy Electrode rods are not continuously immersed Check that the installation conforms to this manual Pay attention to the installation examples and stated minimum distances Flashing values from t 71 to t 75 appear on the display Possible causes Remedy ...

Page 52: ...st see page 47 when bringing into service and whenever the LRGT 1x x conductivity transmitter has been replaced System malfunctions in the LRGT 1x x conductivity transmitter result in an output of 0 mA at the analogue output If you require assistance please tell us the indicated fault code In the event of malfunctions or faults that cannot be remedied with the aid of this Installation Operating Ma...

Page 53: ...y remove the conductivity electrode at a boiler pressure of 0 bar WARNING The hot conductivity electrode can cause severe burns The conductivity electrode becomes extremely hot during operation Perform installation and maintenance work only when the conductivity electrode has been allowed to cool Only remove conductivity electrodes that have cooled down Proceed as follows 1 Reduce the boiler press...

Page 54: ...see page 53 LRGT 16 3 LRGT 17 3 1 Slacken the threaded pin I and manually unscrew the measuring tube J 2 Clean the electrode rod and measuring surface 3 Wipe off loose deposits with a fat free cloth Scrub off stubborn deposits using sandpaper medium grain 4 Next screw the measuring tube J back on and secure it with the threaded pin I LRGT 16 4 1 Clean the measuring electrodes J 2 Wipe off loose de...

Page 55: ...s processing will otherwise be impossible and the products will be returned to the sender at their expense Please proceed as follows 1 Let GESTRA AG know about the return beforehand by e mail or phone 2 Wait until you have received the return confirmation from GESTRA 3 Fill out the return confirmation and declaration of decontamination and send it with the products to GESTRA AG EU Declaration of C...

Page 56: ...5 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 819877 00 09 2019cm 808953 00 GESTRA AG Bremen Printed in Germany ...

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